Introduction of the 'new' Syncro.

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Re: Introduction of the 'new' Syncro.

Postby slowcoach » 13 Apr 2017, 19:29

What I was thinking! You and irishkeet having nice syncros and then just taking them to pieces... I dunno!

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Re: Introduction of the 'new' Syncro.

Postby irishkeet » 13 Apr 2017, 20:15

slowcoach wrote:What I was thinking! You and irishkeet having nice syncros and then just taking them to pieces... I dunno!

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:rollin the scary bit is what you unearth from something that looks nice on the outside

great work Bene :mrgreen:
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Re: Introduction of the 'new' Syncro.

Postby bene » 18 Apr 2017, 14:45

My syncro isnt nice! ha ha!
Hopefully this is the last bit of rot.... for now....

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Before i started poking (ooo err), I had been working on the suspension stuff...
Trailing arms getting some beating -

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testing the scaffold pole... thanks for the heads up Ian.

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Stacked up ready for blasting and probably galvanising -

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The fuel tank is out and was actually easier to remove than i thought it would be. Behind it was better than i had expected. Sound deadening is in good condition and the metal behind it was too...

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Both rear hubs from the syncro and the 2 spares are stripped ready for blasting.
Spare front uprights are stripped and ready for blasting, along with the spare wishbones (all my front suspension is still on the vehicle... i cant do the front and back at the same time, my head would melt).
God i love having a press...

This weekend was pretty busy, but did get to spend some quality time with the family thank goodness.
I ache though.

Oh and my friendly welding buddy came round to patch up some holes on the bus, along with welding in the new tube on the trailing arms.
We decided to replace the rear jacking points/trailing arm bracket, so he will be coming round to fix the top picture rot and weld those in soon...
Its all got to go back in before the last bank holiday weekend... place your bets please! ha!
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Re: Introduction of the 'new' Syncro.

Postby bene » 09 May 2017, 10:00

So, work work work...
I have been stripping, sand blasting the chassis / engine bay / behind the fuel tank.
My welding buddy has been busy too.
Everything is back from the blasters (not bad for £60), now applying phosphuric acid to convert any remaining rust, then painting.
Rear disc brake kit picked up and hubs machined (cheers Ian).
Calipers and carriers sourced and purchased, along with new discs and pads.
Along side this i have been trying to sort stuff to sell as i seriously need to raise funds to pay for this crazy machine...

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yes, i know one of the shocks is still attached to the front lower arm... the head of the bolt snapped off and i didnt have time to sort it.

Applying the acid -

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Calipers and hangers for rear disc brake conversion -

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Holes -

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I should have bought a wheel arch in hindsight... but he still did a fabulous job. All fabricated from flat sheet metal, using a hammer and an 'I Beam' as an anvil...
I forgot to take a final photo. will add one soon.
Cant wait to put it all back together.
cheers
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Re: Introduction of the 'new' Syncro.

Postby bene » 09 May 2017, 10:14

Forgot to include the trailing arm bracket/jacking point...
It was decided to replace these instead of trying to fix the holes.
lots of measuring and checking and they turned out pretty nice. Good quality items from brickwerks too.

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In the middle of all this, the dog has been to the vets a couple of times (another reason im selling stuff) to have her mammary glands removed as lumps were found, one of which was cancerous but thankfully had not spread. They are amazing creatures, no way i could leap about like she is with a wound like this -

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Anyway... see you at syncropendance!
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Re: Introduction of the 'new' Syncro.

Postby irishkeet » 09 May 2017, 14:58

hello mate, good to see the van progressing

hope the pooch is recovering well :ok
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Re: Introduction of the 'new' Syncro.

Postby bene » 22 Jun 2017, 09:05

Hello!
So, I have some second hand Porsche CVs to go into the syncro but i want to check them for wear...
Does anybody have any pointers of what to look out for?
How much wear is too much wear?
Photos, videos would be lovely...
I have put this question in the mechanical section too.
thanks

Keith - Poppy is doing well... back to her old self! cheers
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Re: Introduction of the 'new' Syncro.

Postby syncroandy » 22 Jun 2017, 09:46

IMO you're looking for smooth shiney wear marks and no 'pits' in the case hardening. After reassembly (keep balls as a set as I'm sure you know), assess the play by hand, if its clearly loose and rattly, then the joint is probably too far gone. This is a bit subjective I guess. I just went through this task the other week and built up two rear shafts after selecting the best of the used joints in my collection. I ended up with 3 1980's vintage VW joints, and one 1997 Loebro, and used original VW boots. When fitted I was really happy with the 'feel' of the shafts in terms of slop in the joints.

eg. Pass:

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Fail:

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Ready to fit:
:D

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Re: Introduction of the 'new' Syncro.

Postby bene » 22 Jun 2017, 10:17

Ooooooo nice.... thanks for the info!
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Re: Introduction of the 'new' Syncro.

Postby bene » 22 Jun 2017, 10:47

On a seperate note... stuff has been happening.
Got the fuel tank back in with nice shiny straps.
It was actually pretty easy especially without the sender in (and nothing around it either, not even the loom was through).

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Started building up the rear disc brake conversion. Its bloody lovely (Thanks Ian).

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Oooo just realised I have not added any photos of the protection going on underneath!!
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Re: Introduction of the 'new' Syncro.

Postby bene » 22 Jun 2017, 11:37

So the protection behind the fuel tank and other places....

Sand blasted using our compressor and hand gun (it was pretty horrendous, I hate sand blasting), then a coating of phosphuric acid -

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Then a couple of coats of Dinitrol RC900 Rust converter (also an epoxy primer)-

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Then a couple of coats of anti corrosion primer -

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Then a couple of blows of top coat (no photo).

Then a coat of Dinitrol ML Cavity Wax (in the cavitys and as a base layer to the next coat, no Photo)

Then a couple of coats of Dinitrol 4941 Underbody Wax (Black). Its a bit shiney in these photos as it had just gone on.

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I re-used the old sound deadening as it was in pretty good condition.
Hopefully the rust should stay away for a while.
Cheers!
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Re: Introduction of the 'new' Syncro.

Postby wolfbus.uk » 22 Jun 2017, 15:34

Starting to really take shape Bene. I think you Keith and I all got our syncros around the same time... do you know that's three years ago!! :D
Glad your pooch is recovering well my old girl had the same and they never returned!
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Re: Introduction of the 'new' Syncro.

Postby bene » 23 Jun 2017, 10:50

3 years.... scary...
mine looks a lot worse than when i bought it! lot more solid though...
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Re: Introduction of the 'new' Syncro.

Postby bene » 23 Jun 2017, 14:15

Oh, and fitting the trailing arm bushes... slippery...

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Re: Introduction of the 'new' Syncro.

Postby Tenere » 23 Jun 2017, 16:09

Nice work, have enjoyed reading through all the work you have done. Gonna be one special syncro


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