Birth of a Syncro

[Pickles]

I have finally decided that I have too many T3s.

I know most you will find this hard to believe but it is possible apparently.
I have a 2wd Camper, Syncro Doka and Syncro Ambulance.
I have have had lots of fun with the Syncro Doka greenlaning and off roading. But doesn't get much use. What I really needed was a Syncro Camper hence I bought the Ambulance. I was going to convert it into a camper, apparently this is not a good idea either.

So after speaking to MG who said its easy to convert a 2wd to Syncro.
I decided to convert my 2wd camper to a syncro.
I have had my camper for 17 years and is part of the family it was not really an option to sell it and buy a Syncro Westy.
I bought the 2wd drive as a panel van 30k on clock 1 owner, and converted it using a Holdsworth kit and Reimo double glazed windows. A reimo pop top was added a few years later to accomodate the kids.

A deal was done and the Doka went to a new home

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The work to convert the 2wd to syncro took 4 days.

Day 1

Work started at about 10.30 on Friday 26th June.
Me and Mike worked all day stripping the vehicle of 2wd stuff by about 5.00 pm we had removed all the front suspension, cut off the 2wd panels. Also we had removed the exhaust and the gearbox was unbolted and ready to remove. The engine had been lowered and the syncro engine mount fitted. Petrol tank was removed.

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Day 2

Mike worked on his own as I couldn't get over due to hospital appointment and Jeff Beck gig in the evening. Apparantly things didn't go to well. He spent over an hour trying to get his welder working, then his angle grinder packed up. By the end of the day he had fabricated the new syncro steering rack panel all welded in place and prepared the chassis for the front subframe. Bolted in the new subframe and fitted the front suspension.
The front has been fitted with 2wd springs and the shocks have been modified to give extra clearance. New disc and pads and top ball joints were fitted (from Brickwerks).
Mike also removed the 2wd gearbox.


Day 3

I cycled over to Mikes from my house in Denholme 22 miles, calling at Machine mart to buy some cutting discs. I also brought over some clutch pipe fittings and flaring tool. The clutch pipe was badly corroded where it went through the chasis at the rear. When I got there Mike was busy working away. I started fitting the new stainless exhaust (from Brickwerks) cuting the rear panel that goes under the engine pulley, drilling new holes. There were some clamps missing for the exhaust (a quick call to Simon and the were posted out Cheers). I then made up a new clutch pipe this was fitted and bled. Mike had been working on the water pipes in the engine bay getting ready to take the fuel tank. My LPG wiring was in the way and had to be moved. The syncro tank was then fitted with its straps. This was quite tricky as there was the LPG tank in the van under the seat where Mike was drilling. The centre panel was cut to allow clearance for the prop. Mike fitted the fuel pump and filter. Syncro shocks and springs were fitted to the rear along with Brickwerks spacers.

Day 4

Mike worked all day, I took the afternoon off work and cycled up to Mikes arriving at 2.30.
Mike had been busy altering water pipes. The thermostat top was turned through 90 deg some pipes were cut a tee piece was made. We then realised that the main L - shaped pipe at the side of the engine was badly corroded and leaking. A replacement must be found. (Simon had one in stock). We then fitted the gearbox and drive shafts and some fuel filler pipes. At 5.00 pm we called it a day. The van was back on its wheels. It would have driven home were it not for a corroded water pipe. And some LPG , oil pressure and fuel pump wiring.
My new Syncro was A-framed back to Denholme by Limey

For Photos see Brickyard link

http://www.brick-yard.co.uk/forum/topic ... tml#313136" onclick="window.open(this.href);return false;

[Aidan]

Lookin good that Dave, you and Mike been well busy. Look forward to seeing it at the next event hopefully, enjoy.

[Pickles]

Not been on 80-90 much or doing anything to the Van.
Been waiting for an operation on my Arm. So mechanicing has been out of the question.

Some pics of my Van in France earlier this year

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France Aug 09 353.jpg

France Aug 09 352.jpg

Was going to get Baxter do some work on my Van.
Replace upper wishbone bushes, lower arm bush, lower ball joint, repack cv joints and fit front drive shafts. Renew front wheel bearings and longer studs. And then tracking Camber etc.
Can't believe he could do all that in 8 - 10 hours. Would take me weeks.
Anyway Wife decided that the money would be better spent on the house.
So I have to get cold and oily.

Will get the tracking done by the Baxter.

Any way work commenced.

Replaced the upper wishbone bushes.
Not as bad a job as I thought (thanks for the tip Mike)



Inner bit removed, 4 cuts with angle grinder on big end, then knock out centre metal sleeve
Then hacksaw carefully through the outer metal sleeve. Once cut through, it knocked out easily.



Pile of dead bushes







All bushes from Baxter. Not GSF crap.

Next job

Lower arm bushes, I understand these can be done with the arm still on the van.
Anyone done it. Any tips.

Also going to install longer studs in the front hub.
I remember reading that the hub can be gently teased off without removing the bearings.
Then refit, I assume the inner race comes out with the Hub. Anyone done it this way.


I Set the upper wishbone as far out as it would go with the ecentric washer. Is that right.
I know baxter said that raised syncros were on the limit of adjustment.
Van On 2wd front springs.

Will get it set up properly

[Pickles]

Didn't post all the photo's

Replaced the upper wishbone bushes.
Not as bad a job as I thought (thanks for the tip Mike)

DSCF3167.jpg

Inner bit removed, 4 cuts with angle grinder on big end, then knock out centre metal sleeve
Then hacksaw carefully through the outer metal sleeve. Once cut through, it knocked out easily.



Pile of dead bushes

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All bushes from Baxter. Not GSF crap.

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Next job

Lower arm bushes, I understand these can be done with the arm still on the van.
Anyone done it. Any tips.

Also going to install longer studs in the front hub.
I remember reading that the hub can be gently teased off without removing the bearings.
Then refit, I assume the inner race comes out with the Hub. Anyone done it this way.


I Set the upper wishbone as far out as it would go with the ecentric washer. Is that right.
I know baxter said that raised syncros were on the limit of adjustment.
Van On 2wd front springs.

Will get it set up properly

[Pickles]

Whilst on holiday earlier this year in Brittany, France. I saw a really nice Syncro DOKA at a petrol station. Got talking to the guy about Syncro's. He then invited us to his workshop. I have enclosed the photo's

France Aug 09 331.jpg

France Aug 09 333.jpg

France Aug 09 335.jpg

The guys name is

Yvan Bourges
Vroom motor services
44250 St Brevin

[Pickles]

More photos

[Pickles]

A few more

[Pickles]

Got the lower arms off and the uprights off.

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Have renewed the lower arm bushes with Baxters Polybushes.

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Used heat on the old bush steel sleeve. Pushed this out then pulled the rubber bush out.
Didnt take long

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[Pickles]

New bushes awaiting pushing in

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Next job was to renew the lower ball joints.
These were knocked out with a lump hammer.

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Fitting the new one wasn't as easy

Used a large flat punch made a bit of a mess off the edge.
Ball joint ok though. Need to find a better way to do the next one.

Next job renew the studs to the hub.
And examine the CV joints and repack.

If only I could get the Brake Caliper carrier off (Mike).
Cannot shift them bolts.

[Pickles]

Some Pics from earlier in the year when the conversion was done.

[Pickles]

Front subframe fitted

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Front Suspension

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Rear spacers fitted and syncro shocks and springs

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[Pickles]

Awaiting fuel tank

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Fuel tank Petrol

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Tank in place

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[Pickles]

Now that Baxter chap is a TOP Bloke

Was strugling to fit the ball joint and then thinking about fitting the wheel bearings and studs.
Couldn't even get the brake carrier bolts undone.
A quick call to Baxter, shot over in the 928. And watch the man in action with the press.

Excellent job ! Cheers.

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Bearings and longer studs fitted

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Ball Joints Fitted

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One side fitted

Got both sides done.
Macho's on
Lets play in the Snow
Oh now Flat Battery

[Pickles]

Why I need a Syncro

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[Simon Baxter]

Ditto what I said to Lloydie, a*** kissers don't get discount!

You caught me on a good day when there was a bit of "slack" in the system.
Glad it's all going back together.
Oh, and proper tool ordered, sick of making do with the 2WD tool now.