Tips on converting a syncro to westfalia camper

1
Hi Everyone,

I'm new to this group and have only been driving my 91 syncro for 2 weeks but I
love it even more then when I was researching the van on the net. The AWD in the
wet tonight handles so well for such a large vehicle, though the guy who sold it
said it has aftermarket shockies. I also happened to purchase an imported LHD 83
westfalia wreck, and am now looking at the process of turning my RHD syncro into
a camper - any tips / help / advice much appreciated!

There is just a few questions I was hoping you guys could help answer for me... :)

1. Details of any VW wreckers / mechanics near the Castle Hill NSW?

2. Should I be paying $130 for new drum brake shoes?

3. I've been quoted $700 (without seeing the car) to have the pop-top cut from
the westfalia and put on the syncro. Can anyone give me an idea (or website!)
about what's involved in this?

4. The syncro doesn't have many windows and I would like to put in the windows
from the westfalia. Ideas on what's involved, and can i do this at home with an
angle grinder and some putty or how much should I expect a body shop to charge me?

5. Will be cutting / welding the swivel seats from the westfalia to the syncro.
But any tips on fitting the seat rails to an aftermarket seat?

6. Any tips on pulling all the cupboard / fridge stuff etc and converting
cupboards from LHD to RHD?? :) Is there a haynes manual or something that covers
all the westfalia cupboards?

7. Some time in the future I would to put in a VW 2.5l TDI, is there anyone in
Australia who sells kits / does conversions putting in the newer VW diesels or
will I be looking at stuff from the US?

8. Should be a 2L air-cooled engine and gearbox left over (been in storage for 13
years), can I post here occasional spare part up for grabs?

Sorry for so many questions but I think I've been bitten by the syncro bug past
month or two! And I'm sure more questions will come to mind as the conversion
starts to take place.

Thanks for the syncro group!
Sam
---- Msg sent via @Mail v4 - http://atmail.com/
2
> 3. I've been quoted $700 (without seeing the car) to have the pop-
top cut from the westfalia and put on the syncro. Can anyone give me
an idea (or website!) about what's involved in this?

I think that it is easy to do it yourself.

> 4. The syncro doesn't have many windows and I would like to put in
the windows from the westfalia. Ideas on what's involved, and can i
do this at home with an angle grinder and some putty or how much
should I expect a body shop to charge me?

Probably will not fit.
>
> 5. Will be cutting / welding the swivel seats from the westfalia to
the syncro.

Should fit if they are genuine.

> 7. Some time in the future I would to put in a VW 2.5l TDI, is
there anyone in Australia who sells kits / does conversions putting
in the newer VW diesels

2,5 too hard, use the 1,9 TDI

or will I be looking at stuff from the US?

yep
3
Sam,

Welcome to the Australian Syncronauts, sometimes referred to (and
with some accuracy) as the Syncronuts.

There are several very good Syncro websites on the Yahoo groups in
South Africa and America. It is well worth joining them as well
because a lot of good information flows through them.

I have interspersed some answers to your questions following.

--- In Syncro_T3_Australia@yahoogroups.com, Samuel Arnold <me@s...>
wrote:
Hi Everyone,

I'm new to this group and have only been driving my 91 syncro for 2
weeks but I love it even more than when I was researching the van on
the net. The AWD in the wet tonight handles so well for such a
large vehicle, though the guy who sold it said it has aftermarket
shockies. I also happened to purchase an imported LHD 83 westfalia
wreck, and am now looking at the process of turning my RHD syncro
into a camper - any tips / help / advice much appreciated!

There is just a few questions I was hoping you guys could help
answer for me... :)

1. Details of any VW wreckers / mechanics near the Castle Hill NSW?

2. Should I be paying $130 for new drum brake shoes?

3. I've been quoted $700 (without seeing the car) to have the pop-
top cut from the westfalia and put on the syncro. Can anyone give
me an idea (or website!) about what's involved in this?

This is not a big job. Take the top off the wreck (I am assuming
that it is a T3) and you can then see where the roof has to be cut.
This can be done with a good jigsaw. You will need a padsaw to get
through the roof bows. It is VERY important that you treat all the
cut edges of metal to prevent rust.

4. The syncro doesn't have many windows and I would like to put in
the windows from the westfalia. Ideas on what's involved, and can i
do this at home with an angle grinder and some putty or how much
should I expect a body shop to charge me?

The window apertures of the blind van and the window van are the
same. It is simply a matter of cutting out the fill panel to the
same size as the donor vehicle. Again, it is most important to
treat all the cut edges to prevent rust.

5. Will be cutting / welding the swivel seats from the westfalia to
the syncro. But any tips on fitting the seat rails to an
aftermarket seat?

The swivel seat mechanism is actually a standard VW part and the
installation is bolt-on. I have them fitted to my Trakka Syncro.
The swivel plate engages with the seat slides of the standard VW
seat; the VW seat then slides on the track on the swivel plate for
fore and aft adjustment. The swivel plate then bolts to the
original lower seat slide. If you want pictuires of this, e-mail me
direct on:
leslieharris@optushome.com.au

6. Any tips on pulling all the cupboard / fridge stuff etc and
converting cupboards from LHD to RHD?? :) Is there a haynes manual
or something that covers all the westfalia cupboards?

There are loads of Westfalia pics on the Internet that should help
you.

7. Some time in the future I would to put in a VW 2.5l TDI, is there
anyone in Australia who sells kits / does conversions putting in the
newer VW diesels or will I be looking at stuff from the US?

Use your WBX until it becomes uneconomic to keep it, then consider
your options. If I have to replace my WBX, I would be looking at a
2.5 Subaru engine as the best outcome for outlay result. There is
loads of information for Subaru conversions on the American
Subaruvanagon Yahoo group site. Even the 2.2 does a very good job.
Several Australian Syncronauts have done the 2.5 and the 2.2
conversion. But don't rush into this until it becomes a necessity.
Although the diesel has a lot going for it, the price of distilate
has to be taken into account.

8. Should be a 2L air-cooled engine and gearbox left over (been in
storage for 13 years), can I post here occasional spare part up for
grabs?

By all means post it on this site, but also put it into the VW Club
of NSW newsletter - that will probably draw the best response.

Sorry for so many questions but I think I've been bitten by the
syncro bug past month or two! And I'm sure more questions will come
to mind as the conversion starts to take place.

Sam, this is why I set up this Internet site in the first place. We
are few in number and scattered all over Australia, so thanks to the
Internet and to the Yahoo groups, we can be in instant and permanent
contact with each other. And there are several very enthusiastic
owners in and around Sydney. (I am in Melbourne)

Thanks for the syncro group!

Sam
> ---- Msg sent via @Mail v4 - http://atmail.com/
4
Sam & Les,
 
Welcome Sam.
 
I have to disagree with Les about the side windows.  The external panels look right for windows, but in fact window vans have a small lip bent in right around, where the rubber sits, and internally there will be a whole subpanel missing (sort of forms the internal 'windowsill').  I transferred my home built camper set up (no pop top) from a 2wd window van to an ex Telstra syncro panel van, and had to rebuild a bit to allow for this difference. I thought a lot about installing windows at the time but never got around to it because it looked too hard.  Now I actually prefer the extra privacy and storage potential of the panel van, so I'd suggest you live with it for a while before you decide to cut. If you don't have a sliding door window (most ex Telstra panel vans had that originally, I think) you may want to put an aftermarket one in there, as it is the most important one for vision for parking/turning etc.
 
There is lots on the American Syncro site about installing a Westfalia top.  It sounds like it is not quite as simple as it first seems, especially if you want a flat surface for the upper bunk. So $700 might be an OK price, but you might have trouble keeping your installer to that, if he also doesn't realise what's involved.
 
Brian Reed
Fairfield, Melbourne
5
Oh dear! I was working from memory and it is clear that it was most
defective. Brian has the windowless van and doesn't have to rely on
memory!!

Les


--- In Syncro_T3_Australia@yahoogroups.com, "Brian Reed"
<breed@b...> wrote:
> Sam & Les,
>
> Welcome Sam.
>
> I have to disagree with Les about the side windows. The external
panels look right for windows, but in fact window vans have a small
lip bent in right around, where the rubber sits, and internally
there will be a whole subpanel missing (sort of forms the
internal 'windowsill'). I transferred my home built camper set up
(no pop top) from a 2wd window van to an ex Telstra syncro panel
van, and had to rebuild a bit to allow for this difference. I
thought a lot about installing windows at the time but never got
around to it because it looked too hard. Now I actually prefer the
extra privacy and storage potential of the panel van, so I'd suggest
you live with it for a while before you decide to cut. If you don't
have a sliding door window (most ex Telstra panel vans had that
originally, I think) you may want to put an aftermarket one in
there, as it is the most important one for vision for
parking/turning etc.
>
> There is lots on the American Syncro site about installing a
Westfalia top. It sounds like it is not quite as simple as it first
seems, especially if you want a flat surface for the upper bunk. So
$700 might be an OK price, but you might have trouble keeping your
installer to that, if he also doesn't realise what's involved.
>
> Brian Reed
> Fairfield, Melbourne
>
> No virus found in this outgoing message.
> Checked by AVG Anti-Virus.
> Version: 7.0.323 / Virus Database: 267.8.11/44 - Release Date: 08-
Jul-2005
6
Hi Again,

Yep it's an ex-Telstra syncro panel-van and does have one window in
the sliding door. Would still like add 2 windows I'm thinking.

Being ex-Telstra I'm trying to find a standard towball that I can
replace the big tow-shackle thing with. Any ideas?

Haven't been able to find much info at all about putting the westfalia
roof on a van (which American Syncro site? I've been looking at HEAPS
of stuff on the web! Gives me too many ideas and not enough $$!)

Les- can you send me photos of your swivel seat - I'm pretty sure my
ones are going to have to be cut and welded. I'm also thinking about
cutting the original seat rails so I can bolt them to the bottom of an
aftermarket bucket seat.

Am going to give the roof guy another call tomorrow and have a chat.
Also going to give an engineer a call re: roof, seats, and seat belt
mounts for the rear fold-out seat.

Lots of work to be done!
Sam

--- In Syncro_T3_Australia@yahoogroups.com, "Leslie C E Harris"
<leslieharris@o...> wrote:
> Oh dear! I was working from memory and it is clear that it was most
> defective. Brian has the windowless van and doesn't have to rely on
> memory!!
>
> Les
>
>
> --- In Syncro_T3_Australia@yahoogroups.com, "Brian Reed"
> <breed@b...> wrote:
> > Sam & Les,
> >
> > Welcome Sam.
> >
> > I have to disagree with Les about the side windows. The external
> panels look right for windows, but in fact window vans have a small
> lip bent in right around, where the rubber sits, and internally
> there will be a whole subpanel missing (sort of forms the
> internal 'windowsill'). I transferred my home built camper set up
> (no pop top) from a 2wd window van to an ex Telstra syncro panel
> van, and had to rebuild a bit to allow for this difference. I
> thought a lot about installing windows at the time but never got
> around to it because it looked too hard. Now I actually prefer the
> extra privacy and storage potential of the panel van, so I'd suggest
> you live with it for a while before you decide to cut. If you don't
> have a sliding door window (most ex Telstra panel vans had that
> originally, I think) you may want to put an aftermarket one in
> there, as it is the most important one for vision for
> parking/turning etc.
> >
> > There is lots on the American Syncro site about installing a
> Westfalia top. It sounds like it is not quite as simple as it first
> seems, especially if you want a flat surface for the upper bunk. So
> $700 might be an OK price, but you might have trouble keeping your
> installer to that, if he also doesn't realise what's involved.
> >
> > Brian Reed
> > Fairfield, Melbourne
> >
> > No virus found in this outgoing message.
> > Checked by AVG Anti-Virus.
> > Version: 7.0.323 / Virus Database: 267.8.11/44 - Release Date: 08-
> Jul-2005
7
Sam,

Answers interspersed:

--- In Syncro_T3_Australia@yahoogroups.com, "pootaguru" <me@s...>
wrote:
Hi Again,

Yep it's an ex-Telstra syncro panel-van and does have one window in
the sliding door. Would still like add 2 windows I'm thinking.

Being ex-Telstra I'm trying to find a standard towball that I can
replace the big tow-shackle thing with. Any ideas?

The Telstra/Telecom towbar is extremely strong and worth keeping for
that reason alone. If you want something a bit stronger and a lot
neater, refer to the photos of the towbar that I made for my Syncro
in the Photo file.

Haven't been able to find much info at all about putting the
Westfalia roof on a van (which American Syncro site? I've been
looking at HEAPS of stuff on the web! Gives me too many ideas and
not enough $$!)

It isn't a complicated job. Take the top off the wrecked Westfalia
and this will give you the roof cut-out information. Switching the
furniture from left to right is another matter but not insoluble.
If you want more information, ring me direct on 03 9327 7609.

Les- can you send me photos of your swivel seat - I'm pretty sure my
ones are going to have to be cut and welded. I'm also thinking
about cutting the original seat rails so I can bolt them to the
bottom of an aftermarket bucket seat.

Send me your direct e-mail address and I will send the pics to you
direct. I don't want to clutter the website with high resolution
pics and therefore eat into our allocated capacity allocation. It
is most unlikely that the swivel bases are not original VW genuine
parts.

Am going to give the roof guy another call tomorrow and have a chat.
Also going to give an engineer a call re: roof, seats, and seat belt
mounts for the rear fold-out seat.

Lots of work to be done!

Sam