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1991 VW T3 Syncro Conversion — Final Paint & Reassembly Begins

Knowing we were due for a scorcher, I got out early and Raptor coated the front half of the underbody. It looks great and I was thrilled that it was finally done, because that meant it was time to start assembling. As I was peeling off the masking tape and paper, I had the realization … Continue reading 1991 VW T3 Syncro Conversion — Final Paint & Reassembly Begins

1991 VW T3 Syncro Conversion — Raptor Coating & Subframe

It was going to be really hot today and I wanted to get the Raptor sprayed early to avoid shortening its pot life. Besides, I was pretty eager to see how it turned out. The Raptor kit comes with 4 750ml bottles of product, a 1000ml bottle of catalyst and a spray gun. It is … Continue reading 1991 VW T3 Syncro Conversion — Raptor Coating & Subframe

1991 VW T3 Syncro Conversion — A Mess and New Parts

I awoke feeling somewhat like a zombie. My first task was to disconnect an AC line in order to reroute it, because once again it is different on a Syncro. I was so focused on the disconnect job that when I removed said line from the compressor, the system was still under pressure. I was … Continue reading 1991 VW T3 Syncro Conversion — A Mess and New Parts

1991 VW T3 Syncro Conversion — Organization & More Welding

Confession: I'm tired. I'd really been going at this thing doing 12 hour days and since I'm waiting on tools, materials and parts and didn't have a clear path of work to do, I took it a little bit easier today. This turned out to be a good thing, as I discovered some more modifications … Continue reading 1991 VW T3 Syncro Conversion — Organization & More Welding

1991 VW T3 Syncro Conversion — More Parts Removal and Prep

As mentioned, I intend to add a decoupler to the 4WD system (center knob on the Syncro control panel).This is a pneumatically controlled device that disconnects the front drive shaft from the transmission and allows the van to be driven regularly as a 2WD vehicle. VW shipped all their US-bound Syncro Vanagons with a "viscous … Continue reading 1991 VW T3 Syncro Conversion — More Parts Removal and Prep

1991 VW T3 Syncro Conversion — Interior Electrical

There isn't much to actually see here, but this was a fair amount of work. Basically, my van was a 2WD, automatic, Wesfalia with cruise control. The donor was a 4WD, manual, 7 passenger without cruise control. I wanted to have as clean an installation, electrically, as possible (automotive electrics are a bit of a … Continue reading 1991 VW T3 Syncro Conversion — Interior Electrical

1991 VW T3 Syncro Conversion — Converting the Front Suspension

Here's a window into my soul. This was the part of the job I was really intimidated by and I have, literally, lost sleep over this during the entire year (I bought the Syncro donor in August of 2015!) leading to this moment. The hardest most tricky part of the conversion is changing the front suspension. … Continue reading 1991 VW T3 Syncro Conversion — Converting the Front Suspension

1991 VW T3 Syncro Conversion — Stripping the Van

The van had been at the body shop for 6 weeks. During that time the 2WD fuel filler door was removed and the 4WD fuel door was added to the rear quarter panel. I also had a couple of small dents removed, the rear side marker lights shaved (I've always hated those things), the nose … Continue reading 1991 VW T3 Syncro Conversion — Stripping the Van

1991 VW T3 Syncro Conversion – Rebuilding

I took all the Syncro parts to Full Spectrum Powder Coating for coating. They did a great job from blasting to masking to coating and the price to do all 62 parts was beyond reasonable. A few of the coated parts In the meantime, I'd ordered some parts from a really great place called T3 Technique. I … Continue reading 1991 VW T3 Syncro Conversion – Rebuilding

1991 VW T3 Syncro Conversion – The Donor

Once the shop was pretty much finished, I was able to set about putting der Thunderwagen on the lift and begin the process of stripping it. First thing I did was take photographs of how the Syncro system was setup for reference. For the few months the van sat while the shop was being constructed, … Continue reading 1991 VW T3 Syncro Conversion – The Donor