Our syncro Caravelle

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Re: Our syncro Caravelle

Postby silverbullet » 06 Dec 2018, 22:29

Ladies and gentlemen, syncronauts one and all, a small announcement if I may...

Atlantis is no longer a rustbucket!

A few teaser pics before she goes for paint:ImageImageImage

Many thanks to Gary Wilkie for his patience with my re-engineering design ideas, the long list of upgrades from basic C spec and making it all a reality.

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Re: Our syncro Caravelle

Postby Aidan » 07 Dec 2018, 07:46

is that an old SAAB I spy ?
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Re: Our syncro Caravelle

Postby silverbullet » 07 Dec 2018, 09:32

Gary has a thing for a V4 Svenska Aeroplan

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Re: Our syncro Caravelle

Postby jebiga41 » 07 Dec 2018, 10:46

looking good Ian so do have a list of all the mods you did would be interesting to see what others are doing
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Re: Our syncro Caravelle

Postby silverbullet » 07 Dec 2018, 11:57

I'll write up whats been done and the thinking behind it. Probably not for everyone, but feel free to copy/ borrow/adapt my ideas if you are looking at major rebuild work. None of it is bolt-on and a couple of things were ditched because of the knock-on effects.

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Re: Our syncro Caravelle

Postby silverbullet » 07 Dec 2018, 20:43

Here's my school of thought:

The T3 has a relatively flexible bodyshell, lacking in torsional stiffness even in tin-top form and I think that this contributes to seam rash, because they are constantly being flexed and worked.
If you've ever driven a lowered 2wd over a cross-camber pavement into a petrol station forecourt and heard the sliding door seal creaking or the central door lock chattering, you'll appreciate my concerns.

The second area of concern was brought about by a samba topic on "syncro crease" aka the phenomenon of rear wing panel deformation near the rear wheelarch forward corner and whilst this was never adequately explained or investigated (overloading is almost certainly a factor), it got me thinking about the rear spring platform area and how the forces are distributed and the load paths involved.
(I am not that convinced that the 16" rear internal plating is terribly effective, it was probably as much as VW&SDP could do without impacting on all the vehicle variants, especially Westies)

Finally, I wanted to make the relatively vulnerable sills more robust without sacrificing the jacking points to bolt-on bars, with a view to taking part in the odd trials event and maybe joining my local AWDC club without worrying about damage.

My solution package included:
Increasing the sill cross-sectional area, to make them stiffer in torsion.
Reinforced/heavier gauge sill bottoms to resist impacts.
Compression & tension triangulation struts in the rear spring platform area, to transmit forces and reinforce the rear chassis area.

I considered a front strut-brace between the damper top mounts to strengthen the front suspension too, but it would have intruded into the cab area and passed right through the handbrake lever! I may revisit this idea later...

Pics to follow!

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Re: Our syncro Caravelle

Postby silverbullet » 07 Dec 2018, 21:32

Outer sills first: the bottom of the sills are rwinforced with a pair of 40x40x3mm SHS side by side, which run from the full length between the jacking points. This worked out nicely in that the sliding door roller track panel sits directly on top of it.
Directly inboard of this is a folded section around 110mm square that greatly increases the sill cross-sectional area.
The bottom of the front jacking point outrigger was also closed off, so it improves the strength at this end which is somewhat compromised by the deep slider channel cutting into the lower B post/sill junction.
The front JP was also raised a little, to make it less exposed iircImageImageImageImage

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Re: Our syncro Caravelle

Postby silverbullet » 07 Dec 2018, 21:49

Out back, the idea was to increase the "overlap" between the mid and rear chassis components at the firewall by triangulating the rear spring platform (to resist a big hit from twisting the rear chassis rails, which causes the rear wing panel crease as it deforms the rear deck panel upwards and horizontally pulls the rear arch seam inward) and then feeding those forces down into the inner and outer chassis rails.

A tension strut triangulates the rear arch area, to "tie down" the spring platform and bump stop, the resultant "rocker arm" feeds forces down into the chassis by a pair of compression struts which will hide below the rear bench area:ImageImageImage

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Re: Our syncro Caravelle

Postby silverbullet » 08 Dec 2018, 09:42

All in all, its some discreet additions that don't weigh much but should make the bodyshell more resistant to twist and flex, which should bring benefits as well as helping to shrug off the odd hidden obstacle or tricky stepover.

I want to fix some replaceable scuff plates to the bottom of the sills too, probably made from Tufnol or similar material, around 10mm thick should be enough to be durable in service.

Can't wait to get it back and get some Oettinger fitted ;-)

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Re: Our syncro Caravelle

Postby rollercoaster » 08 Dec 2018, 14:49

Very good!
You are a real trailblazer, some of that i would definitely ask him to do for me..
Is he in Aberystwyth? Thats going to be nearby soon could be the go to place for any rusty bits?

I am also hoping you detail the preventative measures you take to keep it all good.

Following with interest thanks.
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Re: Our syncro Caravelle

Postby silverbullet » 08 Dec 2018, 17:31

Thanks, I'm just addressing what I see as its obvious failings while I have the opportunity.

Yes he's inland from there. I think that he is already loaded up for 2019, not taking on any more major restoration work for next year.

It's going to be Dinitrol'd to death, wheelarch liners fitted etc etc

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Re: Our syncro Caravelle

Postby DSM » 10 Dec 2018, 16:39

Bravo! Is this the recipient for the flat 6? :ok
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Re: Our syncro Caravelle

Postby silverbullet » 10 Dec 2018, 21:43

I may have to slum it with the 2.5 for a while, depends on how the six rebuild progresses. I've got most of the parts laid in now but the cam is still a problem area.

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Re: Our syncro Caravelle

Postby jebiga41 » Yesterday, 16:10

Interesting and nicely thought out mods Ian will great to see her in a muddy field in wales
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Re: Our syncro Caravelle

Postby silverbullet » Yesterday, 19:27

Thanks and yes it will be!

I should say that all fabrication and resto-mod work was carried out by Gary Wilkie.

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