Betsys 2wd to Syncro Conversion

It’s happenening! I’m going all out on quality hardware; Burley gear, GT hardware, etc. This may take a year to complete!

08/01/2018 - Decided I’ll need the diesel syncro fuel tank $243

10/30/2018 - GoWesty fuel tank refresh; sender, vent nipples, straps - $452

11/09/2018 - I have a sale pending for a fuel line fire syncro donor for $3500!

Research

Transmission

Gearing

This is always the tricky part.

The consensus is a 4.86 Ring & Pinion is the way to go for a TDI transplant.

As for the gearing;

1.88 for 2nd is popular if you use a Euro mainshaft

1.14 is popular for the 3rd gear.

As always 4th is all over the map, likely due to tire sizes. The most popular from known drivers are;

• 0.77 with 30" tires

• 0.73 with no larger than 28" tires

Now, let's look at the RPM for my sort of driving 63-70mph

Most common tire sizes; 27-30 that I may do:

Ratios

RPM Calculator

26"

@ 1.14 @ 2850rpm @ 39.8mph

@ 0.70 @ 2850rpm @ 64.8mph

@ 0.73 @ 2850rpm @ 62.2mph

@ 0.77 @ 2850rpm @ 58.9mph

@ 1.14 @ 2950rpm @ 41.2mph

@ 0.70@ 2950rpm @ 67.1mph

@ 0.73@ 2950rpm @ 64.3mph

@ 0.77@ 2950rpm @ 61.0mph

@ 1.14 @ 3000rpm @ 41.9mph

@ 0.70@ 3000rpm @ 68.2mph

@ 0.73@ 3000rpm @ 65.4mph

@ 0.77@ 3000rpm @ 62.0mph

27"

@ 1.14 @ 2850rpm @ 41.3mph

@ 0.70 @ 2850rpm @ 67.3mph

@ 0.73 @ 2850rpm @ 64.5mph

@ 0.77 @ 2850rpm @ 61.2mph

@ 1.14 @ 2950rpm @ 42.7mph

@ 0.70@ 2950rpm @ 69.6mph

@ 0.73@ 2950rpm @ 66.8mph

@ 0.77@ 2950rpm @ 63.4mph

@ 1.14 @ 3000rpm @ 43.5mph

@ 0.70@ 3000rpm @ 70.9mph

@ 0.73@ 3000rpm @ 68.0mph

@ 0.77@ 3000rpm @ 64.4mph

28"

@ 1.14 @ 2850rpm @ 42.8mph

@ 0.70 @ 2850rpm @ 69.8mph

@ 0.73 @ 2850rpm @ 66.9mph

@ 0.77 @ 2850rpm @ 63.4mph

@ 1.14 @ 2950rpm @ 44.3mph

@ 0.70@ 2950rpm @ 72.2mph

@ 0.73@ 2950rpm @ 69.2mph

@ 0.77@ 2950rpm @ 65.6mph

@ 1.14 @ 3000rpm @ 45.1mph

@ 0.70@ 3000rpm @ 73.4mph

@ 0.73@ 3000rpm @ 70.5mph

@ 0.77@ 3000rpm @ 66.8mph