CaveVan Forum
Pictures and tall tales!! => Share your adventures! => Topic started by: wildenbeast on July 29, 2015, 10:10:18 am
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I had been lusting for a Eurovan for awhile. As I was fully immersed in the Vanagon scene for quite some time, I thought the Eurovan brought some nice features when compared to my other vans. You still could easily camp, escape rain, play cards on the weekender table, and have a bit more modern components. The main drawback was that we never got the Syncro version in the USA. As I ski and bike religiously, a Syncro would be really nice to have. I scoured the internet almost every day to see if someone who was lucky enough to import one, was getting ready to move on. I did come across a few but the sticker price was $50k or more. That $50k also was an entry price as each van I saw needed major work. Finally, the holy grail appeared about a month ago: a 1993 weekender where someone imported all the Syncro parts and even had a spare viscous coupler and rear diff. It had a high mileage 2.5 engine and was listed for $25k. After talking to the mechanics that worked on it, I offered and bought it for an even $20k. It was located 500 miles from my house so I had to wait a few weeks to go and pick it up due to our family's schedule. During that time I sold my "never to be sold" restored Vanagon.
Upon pickup, I was impressed. The PO had most major records and showed me the ins and outs of the van. He was a cabinet maker and had crafted a great replacement table for the standard weekender one. I drove it the long way back home, traveling Hwy 40 through Steamboat Springs, up Rabbit Ears Pass, and then completed the voyage via Trail Ridge Road through Rocky Mountain National Park (I even came across some Moose). The van was a bit underpowered on the steepest of grades but was very fun to drive overall. It is the short wheelbase model with 16" wheels so it felt more like a car than my previous vans.
A week of driving it around town and I was anxious to do some upgrades. I put in a new stereo and had been talking to Cole about some Cavevan improvements. On Sunday, as I was driving to meet Cole, the front driver's side wheel popped off my van on a major highway. I was surrounded by K-rails on both sides of me but luckily was able to control the van as it drove on one front wheel and one front rotor until the K-rails ended and I veered it into the shoulder to a stop. There wasn't much warning and I feel lucky that we weren't hurt (my 10 month old son was sleeping in his car seat during the whole ordeal and slept another half hour on the side of the road while we waited for a tow). An interesting start to my first week of adventures in my "new" Eurovan.
Attachments below...
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Wow what a start. Very glad to know you were able to safely bring the van to a stop. Tragedy averted.
I don't know how others feel about this situation -- but if you haven't removed those wheels since owning -- I would be talking to previous owner to first get a sense of what work was done when/where to those front wheels, and also to discuss the costs of the repair. Check the wheels that are the van (they do appear to be the factory wheels?) and they may not be designed for the weight of the van. You want to make sure that specifications for those are correct -- and that the proper size wheel bolts were used -- otherwise they can back out.
EDIT: Factory wheels?
(http://www.geek-out.com/vw/pr.jpg)
http://forums.vwvortex.com/showthread.php?5102707-FS-15-quot-Eurovan-Alloy-Wheels-AS-Tires-and-Steel-Wheels-Snow-Tires-in-Cols-OH (http://forums.vwvortex.com/showthread.php?5102707-FS-15-quot-Eurovan-Alloy-Wheels-AS-Tires-and-Steel-Wheels-Snow-Tires-in-Cols-OH)
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Can't wait to see it in person!
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These are factory wheels but obviously didn't come on a 93 van originally. Proper wheel bolts are on there now. The head scratcher on this one is that I drove from Salt Lake City to Boulder just fine, then a week around town just fine, then suddenly this happened. I have the van back at my house now. One thing that I have seen others post is when a wheel bearing fails / splits, it can back out the wheel. I am just happy that we were not hurt and that the van has minimal damage. Now that it needs a front left brake, I am going to upgrade all of them to the 2001-03 Eurovan brakes which are much larger than the stock 93 front discs and rear drums.
Wow what a start. Very glad to know you were able to safely bring the van to a stop. Tragedy averted.
I don't know how others feel about this situation -- but if you haven't removed those wheels since owning -- I would be talking to previous owner to first get a sense of what work was done when/where to those front wheels, and also to discuss the costs of the repair. Check the wheels that are the van (they do appear to be the factory wheels?) and they may not be designed for the weight of the van. You want to make sure that specifications for those are correct -- and that the proper size wheel bolts were used -- otherwise they can back out.
EDIT: Factory wheels?
(http://www.geek-out.com/vw/pr.jpg)
http://forums.vwvortex.com/showthread.php?5102707-FS-15-quot-Eurovan-Alloy-Wheels-AS-Tires-and-Steel-Wheels-Snow-Tires-in-Cols-OH (http://forums.vwvortex.com/showthread.php?5102707-FS-15-quot-Eurovan-Alloy-Wheels-AS-Tires-and-Steel-Wheels-Snow-Tires-in-Cols-OH)
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Sweet rig and glad no one was hurt during your 3-wheeling adventure. Now you just need to bolt up a TDI to that thing to really wake it up in the mountains.
One thing to note: to upgrade to the rear disc brakes you will need to source rear trailing arms from a disc brake model, 97-03. Also you will need the 294mm rotors and the caliper brackets from the 01-03 16" models along with pads, but the rear calipers themselves are the same as the 15" 97-00 models.
Justin
2000 EVW 5-spd TDI
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Man, your first week was worst then mine! A wheel popping off :o Good luck with it, glad no one was hurt - good driving!
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I think I have sourced all the needed parts from a local yard. One question though: Do I need to use the 294mm rotors? I know that there are also larger rotors that came on the 01-03 Eurovans. Thanks for posting this as I would not have grabbed the caliper brackets otherwise.
Bill
Sweet rig and glad no one was hurt during your 3-wheeling adventure. Now you just need to bolt up a TDI to that thing to really wake it up in the mountains.
One thing to note: to upgrade to the rear disc brakes you will need to source rear trailing arms from a disc brake model, 97-03. Also you will need the 294mm rotors and the caliper brackets from the 01-03 16" models along with pads, but the rear calipers themselves are the same as the 15" 97-00 models.
Justin
2000 EVW 5-spd TDI
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The caliper bracket mounting bolts are also larger than the early T4s. Grab those as well if you can.
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You mean the fronts right Rob? The rear caliper bolts are the same iirc. FWIW, good mech sense dictates that even though they aren't TTY bolts, these are also meant to be used only once and then new 18m OE bolts sourced, p/n: N 90911801
Bill: the rear 01-03 T4 rotors are 294mm (p/n 7D0615601C), the frts 313mm (p/n 7M3615301).
Justin
2000 EVW 5-spd TDI
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Thanks for all the replies. I was able to get the caliper brackets and I found some good 16" wheels on craigslist locally to complete everything. I am looking forward to having the bigger brakes and a nice ride. - Bill
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Yep. I mean the front bolts.
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Such a cool T4!
It's sitting at my house at the moment getting ready for some fun upgrades. ;)
Picked these up the other day.
All the parts we should need for a 4 wheel/big brake conversion for the syncro. This thing should stop MUCH better when done. Also snagged a late model cup holder console for it.
(https://farm1.staticflickr.com/346/20187626278_7a76a450dc_o.jpg)
Just to give a perspective of size. These are the 2001-2003 front calipers next to my size 45(about a 10.5 us) Sidi Adventure motorcycle boot.
Once I get all these parts cleaned up I will put up a comparison photo to the old parts that come off.
(https://farm4.staticflickr.com/3686/20188973429_56ab8bdce8_o.jpg)[/url]
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Wow - fantastic, this will be a great upgrade. Cole, I've read your post before where you said the the EV brakes are actually very good -- looking forward to seeing some part comparisons.
If its ok with the owner -- can you guys post some pics of the rear set up? I'm curious to know how much of whats there is applicable for a haldex conversion.
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It's ok with me to post a ton of pictures. Obviously this upgrade also means we are switching out the wheels from 15" to 16".
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Wow - fantastic, this will be a great upgrade. Cole, I've read your post before where you said the the EV brakes are actually very good -- looking forward to seeing some part comparisons.
If its ok with the owner -- can you guys post some pics of the rear set up? I'm curious to know how much of whats there is applicable for a haldex conversion.
I've got lots of pictures. I was nice to finally see one in person.
I've had the same ideas about using Haldex stuff.
I'm also picking up a 1200lb crate of Syncro conversion parts tomorrow to do another van :o
I'll post lots of pictures later!
I've been degreasing and media blasting all the parts for This van today. They are cleaning up nicely.
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Here are a bunch of pictures from under the Syncro.
(https://farm1.staticflickr.com/541/19758166284_2c61fd829a_c.jpg)
The cross member that the Syncro rear diff mounts to is about 1/3 the way into the spare tire well. So there is no space to mount a spare tire under the van. This is one of the issues Bill and I have discussed, but without a clear answer just yet.
you can see the white body cross member right next to the syncro mount. That cross member is normally dead center of the spare tire.
(https://farm1.staticflickr.com/413/20354587076_164cda4df9_c.jpg)[/url]
Drive shaft and center shaft support.
(https://farm1.staticflickr.com/308/20194191189_c3cce26d8d_c.jpg)
Center shaft support.
(https://farm1.staticflickr.com/418/20372288582_76d1f70ea7_c.jpg)
Rear shaft to hub.
(https://farm1.staticflickr.com/482/20386992681_ab90f9b58e_c.jpg)
Drive shaft coming out of the transfer box on the transmission.
(https://farm1.staticflickr.com/365/20372276292_14707673b1_c.jpg)
Looks like a pretty straight forward system to install. (or modify to accept the Haldex)
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I'm not done cleaning up and painting the parts yet, but here is a little teaser of the progress. ;)
(https://farm1.staticflickr.com/349/19761605854_14a658fb60_c.jpg)
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Great pictures -- thanks guys.
Cole,you mentioned that Eurovans are already setup with the channel for the driveshaft - and I see the channel under the gas tank. But, is the difference in the rear sub frame - or is it just the wheel hub?
I think moving the spare tire to rear hatch is a good idea for all vans -- after seeing the condition of those spare tires that you repainted. Do you think if the struts were upgraded, that a tire mount could be bolted/reinforced from within onto the back door? One thing I have seen is the Gary Lee racks (made locally to me) - but man alive they are expensive! Link: http://www.telusplanet.net/public/gary2a/EV/ev.htm (http://www.telusplanet.net/public/gary2a/EV/ev.htm)
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Great pictures -- thanks guys.
Cole,you mentioned that Eurovans are already setup with the channel for the driveshaft - and I see the channel under the gas tank. But, is the difference in the rear sub frame - or is it just the wheel hub?
I think moving the spare tire to rear hatch is a good idea for all vans -- after seeing the condition of those spare tires that you repainted. Do you think if the struts were upgraded, that a tire mount could be bolted/reinforced from within onto the back door? One thing I have seen is the Gary Lee racks (made locally to me) - but man alive they are expensive! Link: http://www.telusplanet.net/public/gary2a/EV/ev.htm (http://www.telusplanet.net/public/gary2a/EV/ev.htm)
I'm sure it could be done.
I built Jeeps for many years and the tailgate mounted spare tires, even in the stock size, would often destroy the tailgate. The tire bounces around just a touch on every bump in the toad and it eventually cracks the steel.
Using one of the tailgate mounted racks might help with the issue. Obviously you would need to upgrade the struts to make it work.
You will lose some visibility out the back, but not a huge deal.
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Okay,
It's finally time to post some long overdue updates to this van.
I've had Bill's van for awhile now. First we were collecting parts. Then waiting on the body shop to filling and repaint the rusty windshield area.
This is the wind deflector that sits right above the windshield. You can see how much rust it pulled off when I pulled the deflector off. :o
(https://farm1.staticflickr.com/656/21185525122_0a6754e3fd_c.jpg)
The body shop cut back the rust and filled and painted it in.
The deflector was stripped of all the crap and remounted with 3M moulding tape.
The next step was to mount the cool synthetic blue 3 window top
(https://farm6.staticflickr.com/5690/20878189008_7ca6e4dbd2_c.jpg)
Unfortunately, the top was cut short, which is why this picture isn't of a fully mounted top :-\ We are waiting to hear back on a replacement. I even had all new shiny screws for it since a few of the old ones needed to be cut out!
Finally made some room in the garage to start taking it apart. ;)
(https://farm6.staticflickr.com/5774/21169170866_22c9e3a013_c.jpg)
Here is a 1993 front disc brake next to the 2001-2003 disc brake that will be replacing it.
(https://farm6.staticflickr.com/5655/21169166786_97df17ca3e_c.jpg)
(https://farm6.staticflickr.com/5682/21169166266_1e84970b66_c.jpg)
Old disc next to new disc. The rear is also going to discs from drums so this thing should stop MUCH better.
(https://farm1.staticflickr.com/619/21185075992_86333626b2_c.jpg)
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Wow - what a difference in the brakes.
FWIW -- My 02 weekender had the upper wind deflector melt off last summer, and there was rust there as well. >:(
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The rusty nasty parts are starting to come off!! Some are taking a little extra oomph to get them free but things are starting to shape up. ;)
Upper ball joint that I'm pretty sure is original.
(https://farm6.staticflickr.com/5815/21071758948_94c7835b7b_c.jpg)
The lower ball joint and shock that Bill surfed his van down the highway on. Notice the shaved off nut and ball joint post!!
(https://farm6.staticflickr.com/5834/21071759898_7265ece860_c.jpg)
When I cut open the tie rod end boots they dropped about 1/4 quart of fluid out :o You can see it all over the frame@! The joints on the tie rods were so bad they just flop freely, you can rattle them around like a party favor.
(https://farm1.staticflickr.com/779/20636967524_77f6753561_c.jpg)
New parts starting to go on!!! 2003 brake calipers, rotors, knuckle, new upper and lower ball joints, new it rod ends, soon to be a new rack ::), Koni adjustable shocks, Steel braided brake lines!!
(https://farm6.staticflickr.com/5637/21259672755_03ddc82901_c.jpg)
(https://farm1.staticflickr.com/584/21267720561_64e855ba56_c.jpg)
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Whew.........
I know it's been awhile since I've added any information about Bill's Syncro. He has been VERY patient while we have waited for parts and fought through a few rusty bolt and other issues.
To complicate things I ended up buying another house and had to prep my old one for rental, move into the new one, and keep work moving forward on this Syncro.
I think we are now back on track and hopefully Bill will be enjoying his Syncro soon.
Here is a shot of the rear discs and the Syncro stuff! All installed with Powerfex bushings, Koni adjustable shocks, new hardware, stainless steel lines replaced all the old rubber hoses and brand new rear parking brake lines off a 2001-2003 to work with the rear discs.
(https://farm6.staticflickr.com/5828/22820887311_7273fc778b_z_d.jpg)
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Powerflex bushings on the rear control arms, front sway bar.
(https://farm1.staticflickr.com/622/22809684815_858464e21e_z_d.jpg)
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The rear drum parking brake line is shorter and has a different fitting on it. So to make the parking brake work right you need to replace the two rear parking brake lines. These are direct bolt on and only eprequired minor adjustment to make them work perfectly. (And soaking the adjuster overnight in naval jelly to free the rust ::))
This project has been plagued with small rust issues that have stopped progress for days at a time.
(https://farm6.staticflickr.com/5774/22391322478_19fb924cd6_z_d.jpg)
The original lines needed replacement anyway.
(https://farm1.staticflickr.com/586/22796194432_67c7ab0a56_z_d.jpg)
(https://farm1.staticflickr.com/761/22621683730_c6001158f4_z_d.jpg)
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When I popped the steering rack boots off to swap in new tie rod ends about a pint of fluid came out. Boot and rack were totally dry on the outside!! :o Giving zero indication of a leak. Both sides did the same thing.
So.......in went a new steering rack!
(https://farm6.staticflickr.com/5676/22621688750_721e272c7f_z_d.jpg)
Of course, when I pulled the rack out I also discovered that the steering shaft from the steering column to the rackets bad. So we had to track down a replacement. No longer available new.
(https://farm6.staticflickr.com/5833/22783677446_0fd0692b77_z_d.jpg)
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With the brakes and steering on and mostly sorted I spent some time adding all new AC components.
(https://farm6.staticflickr.com/5808/22417492459_b8e5df67e2_z_d.jpg)
(https://farm6.staticflickr.com/5648/22391308748_4b70b2c5cd_z_d.jpg)
(https://farm1.staticflickr.com/740/22621679330_57fdab20da_z_d.jpg)
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Unfortunately it wasn't smooth sailing as this line self destructed when coming off :( I stole one off my own van as a replacement since I wasn't able to source one quickly.
(https://farm6.staticflickr.com/5704/22820859731_5b32b8d04d_z_d.jpg)
There is still a fault in the system somewhere as it won't accept coolant. Compressor doesn't turn on, so there must be a bad pressure switch or ?
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(https://farm6.staticflickr.com/5772/22783660886_faa0d85d43_z_d.jpg)
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These are the new 16" wheels we had to put on to clear the big brakes. You can see how the brakes fill the wheel!
These still need refinished and big tires installed!
(https://farm6.staticflickr.com/5672/22796170822_aa9991b9c4_k_d.jpg)
(https://farm6.staticflickr.com/5697/22417297909_211a603120_k_d.jpg)
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First round of bed liner today! It's a charcoal grey that matched the bumpers that were in the van. Now they are bed lined too!
More to come!
(https://farm6.staticflickr.com/5758/23057281574_7f6ebefc22_b_d.jpg)
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We finally got another top back. I've had the manufacture make multiple changed to the top. I've also sent them 3 factory tops to try to get the fitment better. It's really unfortunate that the other distributors that have been working with this company have never noticed the flaws.
This still needs minor twerking but I think this is the top that will stay on it this time.
The near zero temps have been keeping me from finishing the blue stripe of the bed lining. Just can't get the inside of the shop warm enough to do it.
(https://farm6.staticflickr.com/5788/23912312881_494027128b_c.jpg)
(https://farm6.staticflickr.com/5785/24111080225_6767534464_c.jpg)
I did manage to get the vinyl flooring in though.
(https://farm2.staticflickr.com/1641/24085062076_aca55a4f37_c.jpg)
And the Heating elements are now in the front seats.
(https://farm2.staticflickr.com/1516/23482874704_3e4f1a5463_c.jpg)
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FINALLY got the top totally on the van. I've installed, removed and installed this top 5 times now due to manufacturing defects. I've installed MANY of these tops before and the blue one is the only one that has been wrong. Now it is "close enough" that I'm declaring it good. (Unless Bill hates it ;))
(https://farm2.staticflickr.com/1710/23933251599_5d6c861a11_c.jpg)
Also finished the heated seats for the driver and passenger. This is the custom switch panel.
(https://farm2.staticflickr.com/1634/23674208103_4f069ee73f_c.jpg)
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It looks like it fits quite nicely, especially when I am able to view it much larger on the computer than on my phone. I am interested to see why you think it isn't perfect.
FINALLY got the top totally on the van. I've installed, removed and installed this top 5 times now due to manufacturing defects. I've installed MANY of these tops before and the blue one is the only one that has been wrong. Now it is "close enough" that I'm declaring it good. (Unless Bill hates it ;))
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Added the Smirfadelic stripe yesterday!!
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(https://farm2.staticflickr.com/1566/25530879186_a90be93006_c.jpg)
(https://farm2.staticflickr.com/1652/25438434462_37cfc89573_c.jpg)
(https://farm2.staticflickr.com/1679/25464115791_1f62e9d54d_c.jpg)
(https://farm2.staticflickr.com/1552/25189314549_748cfeb944_c.jpg)