Phoxxanator
New member
Are you ready for an affordable, comfortable, and fully-capable basecamp on wheels? Do you want to feel the cross-breeze through panoramic windows protected by no-see-um screens? Do you want a warm cabin, a warm meal, and a cold beverage in your personal ski-out, ski-in chalet? Do you care about getting there, anywhere, and getting home more than you care about having a single color of paint on your rig?
If you exclaimed an emphatic YES! to all of the above, this Syncro is for you.
The “Tin Star” is expedition-ready, fully rebuilt and upgraded by yours truly. I didn’t waste hardly a moment focused on cosmetics, and instead poured all my effort into making a reliable, rugged, capable 4-season overlander.
I have buried this thing up to the frame in mud and punched out easy as you please, snagging the riverside campsites no one else would attempt. I have driven it around the entire country once in a 3-month National Parks tour, to Colorado and back, and to scores of remote trout rivers around New England. I’ve hauled kayaks and motorcycles inside and on racks; I’ve cooked sausage sandwiches while driving (well, someone else did the cooking, but there is nothing like being handed a fresh, hot grinder while you’re behind the wheel cruising at 70); I’ve dressed for a wedding inside; I’ve driven up a frozen river with the rear dif locked and front wheels steady. The only thing I haven’t done is watched C-beams glitter in the dark near the Tannhäuser Gate.
Every mechanical system on the van has been serviced, and nearly all moving parts have been replaced, 95% of the work done by me personally. During every install all torque specs were meticulously honored and only top-quality components installed. There are 215K miles on body, 10K miles on motor since complete rebuild, and less than 20K miles on all other components. Every receipt for each repair, upgrade, and modification is available.
OVERVIEW:
- 1991 Syncro with 2004 Subaru EJ251
- 20K since complete rebuild; drives like a brand new truck
- Every mechanical system rebuilt (details below)
- Cosmetic blemishes
- Van is located in Maine
DETAILS:
Subaru EJ251 Conversion (2020):
- Long-block professionally serviced at dedicated Subaru shop. Engine burns no oil or coolant.
- Pistons honed and re-ringed
- New WRX headgaskets installed
- Pre-installation replacement of every component with top-of-the-line new:
- Timing belt, tensioner, pullies
- Water pump
- Thermostat
- Alternator
- Gaskets
- Crawford oil/air separator; reclaims oil volatilized in crankcase, prevents oil consumption.
- Custom power steering plumbing; hybrid of Subaru and Vanagon
- Small Car 5L shortened oil pan
- Small Car engine bracket/carrier
- Small Car flexible dipstick
- Reversed coolant manifold and crossover pipe
- Custom RJE bellhousing; this is quite simply the best way to mate a Subaru to the Vanagon transmission. This system is superior to all adapter plates and the Small Car bellhousing. Because it uses a hybrid clutch that integrates both Subie and VW components it has none of the throw-out baring issues that Small Car suffers from, and the power transfer is smooth and uniform. Bellhousing is made in England; I purchased this when exchange rates were favorable to US buyers
- Oil changed every 5K and each spring after winterization; Mobile 1 exclusive
Transmission, Driveline, Hubs (2020, unless otherwise noted)
- All ball joints replaced with Moog
- All wheel bearings replaced
- New Burley rear hubs
- All half-shafts and CV joints replaced with Lobro; Porsche rears matched to suspension lift
- New Go Westy doughnutless driveshaft
- Front differential fluid flushed (2016)
- Transmission fluid flushed (2018)
- New clutch (2018)
- Throw-out baring greased and serviced
- New locker solenoid (2016)
- All new T3 Powerflex mounting bushings (the upgraded set with the little nubs)
Wheels, Tires, Suspension, Brakes
- 5X 27/8.5R14 General Grabber AT2 tires with 20K miles; 5-tire rotated every oil change
- 2” lift with heavy-duty Schwenk springs, matched Bilstein B6 shock absorbers, leveling pads in rear.
- Fully rebuilt rear brakes from Van Café with matched and seated pads/drums
- Brand new pads front (2022)
- Brake fluid flush (2020)
- New master cylinder in 2016; new reservoir gaskets in 2022
Cooling System
- Stainless steel coolant pipes
- Original radiator, flushed and serviced
- All hoses replaced in 2016; relevant hoses replaced in 2018 for Subaru conversion
- Prestone coolant exclusively used
Interior
- “Cavity wax” protective spray behind all panels
- Front seats upgraded to non-swivel camper seats
- Dashboard
- CB Radio included at full sale price
- Heater box removed and rebuilt: NOS heater core (high flow = gets HOT), fan serviced, all selector flaps and wires lubed and re-sealed. All conduits run to proper vents.
- BT radio, custom 6-speaker suite
- Custom switch panel for auxiliary items, dual USB port, and battery monitor
- Gauges display on tablet; fed from BT OBD II at Subaru ECU.
- Rear heater core cleaned and flushed
- 1991-exclusive full interior floor mats
- Can come with a full weekender (little flip-up table and nicer cushions) matched interior if you like
Camping Upgrades
- Insulation installed behind all panels
- Rear seatbelts removed to enhance camping experience
- Custom dual-sided window insulation for all glass (much better than the Go Westy set)
- Van Café no-see-um screens for all windows
- Custom storage cabinet installed
- Diesel heater installed under Z-bed; run exclusively on kerosine.
- Custom dual house/starter batteries with manual isolate/combine switch
- Mouse-proofing installed at all points of entry. No surprise visitors.
Body, Frame, and Exterior
- Complete undercoat by Insyncro Restoration; exterior and frame interior spray with thick Eastwood-type product, interior of body wax treated. Transmission, front diff, and other running gear components treated with Fluid Film.
- “Cavity wax” spray throughout frame and chassis
- New drivers side rocker panel installed
- Offroad LED flood lights added. These work great in the woods.
- Roof rack
- 4X crossbars and custom-height Yakima A1 gutter mounts
- Thule XXL cargo box; this is the largest rooftop box ever made, and is proportional to the Vanagon. Holds spare tire and every accessory you could need. Located for maximum aerodynamic efficiency (yes, seriously).
- Custom BMS HD received hitch and bumper mount. Rated to 500+ libs, this holds a motorcycle firmly, and provides a robust rear bumper if you’re ever rear-ended
- Custom 55-gallon barrel cargo box in clamshell. No space wasted on this van
- Topside body rust treated with wire wheel, rust converter (Ospho), then painted with etch primer, primer, color-match paint, and clear coat. Other patches were later sprayed with color-match Por-15 by Insyncro Restoration
- Original syncro motor/transaxle rock guard lengthened for Subaru conversion and custom skid plate added
- LT mirrors not installed, included with sale if desired
Known Issues
- Passenger mirror largely inoperable
- Radio antenna broken
- Rust hole at driver’s side rear window; water and debris excluded with tape
- Rust hole in driver’s side floor under the mat; non-structural.
- Rust along sliding door track cover
- Respray paint peeling at front and on roof
- Dimpling still visible under paint where body rust was treated by yours truly, but the rust is dead.
- When doing the undercoating, Insyncro ground down a couple of small rust spots and took a primer gun of silver Por15 to them. This froze the rust but left large blobs of silver paint dotting the vehicle.
- Respray of new rocker panel (by the panel installer) does not match original paint color
- Rust at all door handles; surficial, not rot.
- slider door handle broken off; mechanism still works great.
- Transmission weeps at passenger side axle and front driveshaft seals
- Missing rear cargo cushion
- Cracks in Lobro CVJ boots. I called Lobro as these cracked less than 2 years after install and they refused to warrantee this portion of the halfshaft as they outsource it. Very disappointed with the company and the response.
- Passenger seat missing one armrest
- Drivers side seat butt-cushion is original passenger cushion and has fraying fabric
- Odometer and fuel gauge do not work. Speedometer and clock do.
- Weatherstripping around all doors and windows is pretty rough
- Thule Hullivators NOT included with sale
If you exclaimed an emphatic YES! to all of the above, this Syncro is for you.
The “Tin Star” is expedition-ready, fully rebuilt and upgraded by yours truly. I didn’t waste hardly a moment focused on cosmetics, and instead poured all my effort into making a reliable, rugged, capable 4-season overlander.
I have buried this thing up to the frame in mud and punched out easy as you please, snagging the riverside campsites no one else would attempt. I have driven it around the entire country once in a 3-month National Parks tour, to Colorado and back, and to scores of remote trout rivers around New England. I’ve hauled kayaks and motorcycles inside and on racks; I’ve cooked sausage sandwiches while driving (well, someone else did the cooking, but there is nothing like being handed a fresh, hot grinder while you’re behind the wheel cruising at 70); I’ve dressed for a wedding inside; I’ve driven up a frozen river with the rear dif locked and front wheels steady. The only thing I haven’t done is watched C-beams glitter in the dark near the Tannhäuser Gate.
Every mechanical system on the van has been serviced, and nearly all moving parts have been replaced, 95% of the work done by me personally. During every install all torque specs were meticulously honored and only top-quality components installed. There are 215K miles on body, 10K miles on motor since complete rebuild, and less than 20K miles on all other components. Every receipt for each repair, upgrade, and modification is available.
OVERVIEW:
- 1991 Syncro with 2004 Subaru EJ251
- 20K since complete rebuild; drives like a brand new truck
- Every mechanical system rebuilt (details below)
- Cosmetic blemishes
- Van is located in Maine
DETAILS:
Subaru EJ251 Conversion (2020):
- Long-block professionally serviced at dedicated Subaru shop. Engine burns no oil or coolant.
- Pistons honed and re-ringed
- New WRX headgaskets installed
- Pre-installation replacement of every component with top-of-the-line new:
- Timing belt, tensioner, pullies
- Water pump
- Thermostat
- Alternator
- Gaskets
- Crawford oil/air separator; reclaims oil volatilized in crankcase, prevents oil consumption.
- Custom power steering plumbing; hybrid of Subaru and Vanagon
- Small Car 5L shortened oil pan
- Small Car engine bracket/carrier
- Small Car flexible dipstick
- Reversed coolant manifold and crossover pipe
- Custom RJE bellhousing; this is quite simply the best way to mate a Subaru to the Vanagon transmission. This system is superior to all adapter plates and the Small Car bellhousing. Because it uses a hybrid clutch that integrates both Subie and VW components it has none of the throw-out baring issues that Small Car suffers from, and the power transfer is smooth and uniform. Bellhousing is made in England; I purchased this when exchange rates were favorable to US buyers
- Oil changed every 5K and each spring after winterization; Mobile 1 exclusive
Transmission, Driveline, Hubs (2020, unless otherwise noted)
- All ball joints replaced with Moog
- All wheel bearings replaced
- New Burley rear hubs
- All half-shafts and CV joints replaced with Lobro; Porsche rears matched to suspension lift
- New Go Westy doughnutless driveshaft
- Front differential fluid flushed (2016)
- Transmission fluid flushed (2018)
- New clutch (2018)
- Throw-out baring greased and serviced
- New locker solenoid (2016)
- All new T3 Powerflex mounting bushings (the upgraded set with the little nubs)
Wheels, Tires, Suspension, Brakes
- 5X 27/8.5R14 General Grabber AT2 tires with 20K miles; 5-tire rotated every oil change
- 2” lift with heavy-duty Schwenk springs, matched Bilstein B6 shock absorbers, leveling pads in rear.
- Fully rebuilt rear brakes from Van Café with matched and seated pads/drums
- Brand new pads front (2022)
- Brake fluid flush (2020)
- New master cylinder in 2016; new reservoir gaskets in 2022
Cooling System
- Stainless steel coolant pipes
- Original radiator, flushed and serviced
- All hoses replaced in 2016; relevant hoses replaced in 2018 for Subaru conversion
- Prestone coolant exclusively used
Interior
- “Cavity wax” protective spray behind all panels
- Front seats upgraded to non-swivel camper seats
- Dashboard
- CB Radio included at full sale price
- Heater box removed and rebuilt: NOS heater core (high flow = gets HOT), fan serviced, all selector flaps and wires lubed and re-sealed. All conduits run to proper vents.
- BT radio, custom 6-speaker suite
- Custom switch panel for auxiliary items, dual USB port, and battery monitor
- Gauges display on tablet; fed from BT OBD II at Subaru ECU.
- Rear heater core cleaned and flushed
- 1991-exclusive full interior floor mats
- Can come with a full weekender (little flip-up table and nicer cushions) matched interior if you like
Camping Upgrades
- Insulation installed behind all panels
- Rear seatbelts removed to enhance camping experience
- Custom dual-sided window insulation for all glass (much better than the Go Westy set)
- Van Café no-see-um screens for all windows
- Custom storage cabinet installed
- Diesel heater installed under Z-bed; run exclusively on kerosine.
- Custom dual house/starter batteries with manual isolate/combine switch
- Mouse-proofing installed at all points of entry. No surprise visitors.
Body, Frame, and Exterior
- Complete undercoat by Insyncro Restoration; exterior and frame interior spray with thick Eastwood-type product, interior of body wax treated. Transmission, front diff, and other running gear components treated with Fluid Film.
- “Cavity wax” spray throughout frame and chassis
- New drivers side rocker panel installed
- Offroad LED flood lights added. These work great in the woods.
- Roof rack
- 4X crossbars and custom-height Yakima A1 gutter mounts
- Thule XXL cargo box; this is the largest rooftop box ever made, and is proportional to the Vanagon. Holds spare tire and every accessory you could need. Located for maximum aerodynamic efficiency (yes, seriously).
- Custom BMS HD received hitch and bumper mount. Rated to 500+ libs, this holds a motorcycle firmly, and provides a robust rear bumper if you’re ever rear-ended
- Custom 55-gallon barrel cargo box in clamshell. No space wasted on this van
- Topside body rust treated with wire wheel, rust converter (Ospho), then painted with etch primer, primer, color-match paint, and clear coat. Other patches were later sprayed with color-match Por-15 by Insyncro Restoration
- Original syncro motor/transaxle rock guard lengthened for Subaru conversion and custom skid plate added
- LT mirrors not installed, included with sale if desired
Known Issues
- Passenger mirror largely inoperable
- Radio antenna broken
- Rust hole at driver’s side rear window; water and debris excluded with tape
- Rust hole in driver’s side floor under the mat; non-structural.
- Rust along sliding door track cover
- Respray paint peeling at front and on roof
- Dimpling still visible under paint where body rust was treated by yours truly, but the rust is dead.
- When doing the undercoating, Insyncro ground down a couple of small rust spots and took a primer gun of silver Por15 to them. This froze the rust but left large blobs of silver paint dotting the vehicle.
- Respray of new rocker panel (by the panel installer) does not match original paint color
- Rust at all door handles; surficial, not rot.
- slider door handle broken off; mechanism still works great.
- Transmission weeps at passenger side axle and front driveshaft seals
- Missing rear cargo cushion
- Cracks in Lobro CVJ boots. I called Lobro as these cracked less than 2 years after install and they refused to warrantee this portion of the halfshaft as they outsource it. Very disappointed with the company and the response.
- Passenger seat missing one armrest
- Drivers side seat butt-cushion is original passenger cushion and has fraying fabric
- Odometer and fuel gauge do not work. Speedometer and clock do.
- Weatherstripping around all doors and windows is pretty rough
- Thule Hullivators NOT included with sale