Have finally got something done on the old VW Karmann Ghia chassi. Its being converted from swing axle to a better independent rear suspension. It’s just mocked up and tack welded at the moment, test fitted the new rear discbrakes. The fork/frame have been clearanced for Porsche 5speed 901 transmission and also reinforced, welded all around. Probably I will reposition the IRS brackets further in, and mount the trailing arms on the inside of the springplates. Then I will get about 1″ more space against the outer wheel arch and can then fit wider tires. Driveshafts need then be shorter also of course, the left VW type 3 automatic driveshafts are shorter and would be perfect or buy new shortened EMPI’s. Next up is to fabricate front transmission mounts and 911 (or maybe VW) gear linkage.
Have now started with the interior on the Highroof bus. Have put sounddeadning mats in floors and doors, sprayed it all with wax for rust protection. Then added insulation (Refectix) a material of aluminium with plasticcells of air in middle. NASA came up with this tecnology when insulating spaceships actually! After this I put some extra 5mm insulation foamboards (green) then 15mm marine plywood and then a new linoleum carpet in Classic checker pattern, went with light grey to match the grey details on furnitures. The furnitures itselfs is in Light Oak wood finish (laminate). I built it all in a special extra light plywood 15mm. This interior is gona weight nothing!! And thats great in a slow VW bus, all the stuff thats going to be loaded in the cabinets are heavy enought 😉 The kitchen pod/cabinet is featuring a new Vitifrigio fridge on 48 liters + 2 liter freezer. A new small owen in stainless that will be running on 240v (euro). The zink is from a newer crashed/parted out Knaus campervan I bought cheap online. The lid in top is hiding a gastove and the cupboard in bottom will be housing the greywater tank etc.
Still have plenty to do before I can start restoring the 1800cc AP engine.
So the Highroof is now painted at last, in Marino Yellow VW L20a, period correct for 1975. It have been a ton of work and to get that yellow color to cover the bus needed to be painted 4times/coats. That because all yellow (and sometimes red) colors have less pigment than all other colors.
Now the fun can begin, mounting on all new parts like lights, handles etc! Next step will be to start with the interior and begin with insulation in walls and floor. Would be nice to have the most done on interior and exterior until fall so the winter can be focused on engine build and install etc.
A bunch of 1950’s gaspump ready for restoration. Ljungmans Verkstäder, made in Sweden. They have all been sandblasted to baremetal now and bodywork started. Preping for primer and then paint. Will all be painted in diffrent gascompany.
Got inspired to restore my vintage gaspump a 1958 Ljungmans Star 87. Electricmotor, pump, wires etc was removed by me earlier so just the rest of the stuff needed to be taken apart and cleaned and highpressure washed. Lots of old diesel everywhere. Going to be a BP (British Petroleum) again like it was new 1958.
Have not got very much done lately. As my first son (1 year old) takes most of the time now. So that more important at the moment. But Im trying to push forward on the bus too, couple of hours after work and on weekends etc. Soon have all doors and lids in primer and then it all just needs a easy sanding and then its time for a paintjob! Have also sandblasted the fueltank cover and bellypan and got them painted and ready too. Hope to start rebuild of the 1800cc Type 4 engine in begining of February also!
More to come, but thats it for now, here is some pics…
Blasted and epoxyprimer, ready for topcoat in VW factory greyish
Baremetal then yellow epoxy/zinc primer
Topcoat in VW L20a Marino Yellow with 2K polypaint with elastic characteristics. So the stones wont chip the paint. The gloss on the elastic is a little less, but this panel is under the car and you normaly never see it anyway.
Here is some news on the build. Got the fuel tank installed today. With new fuelfiller neck, feeder hose, sender unit, tap and filter. Also replaced all rubber hose connections for the tank ventilation. Next time I will start bodywork on the huge roof…lots of fun…
The engine bay is now ready for the fueltank and later on the 1800cc+ type 4 engine (need to be rebuilt first) to be installed. Today the whole front cab of the bus got sanded down (mostly by hand), front doors removed, masked, seamsealed, prepared for primer and then topcoat in Off White color in 2 layers. Most of this wont be showing when all sounddeadning materials and carpets are in place later but good to have a clean surface for glue and its also nice to know its clean and protected under the carpets.
Next up is; top section of dashboard needs to be removed to paint it in semi-gloss Deepblack (easier to do when windscreen is already out). After this I can start with the outside body of the bus and make it ready for paint. Here is some new pics…
Started to get the other side done, blasted, painted and new bearings and seals. Waiting on some new parts from JustKampers and hopefully I can put the bus back on its own wheels this weekend for first time in 6 months. Also fixed the rusted and dented up front floor cover, blasted and painted ready to be installed when all wires and brakes are fixed.
Have now started with the rear end of the bus, hope to soon have it rolling on wheels again, after 6 months in the air. Dismantled the rear IRS trailingarms, removed all old bearings and seals, cleaned it up and sandblasted everything. Then all parts was coated in zinc primer and the Deep black satin finish paint. All new wheelsbearings and seals pressed in, new bushings everywhere and also nuts/bolts. All new brakeparts and brakedrums too. One step closer…
Have finally got some stuff done on my own project, Baywindow Highroof 1975. The frontend is all done, just need to mount the new brakelines etc. The sandblasted and painted beam have all new needlebearings, new centerpin/arm bushings, new grease zerks, torsionarms have new balljoints, new swaybar bushings, new shocks, new steeringdampner, new tie rods and draglink, steeringbox is adjusted (no more play) got new oil too and a new rubber/steeringplate. Wheels bearings are new and packed with fresh grease, new brakediscs, new speedocable and brakecalipers have been blasted, and have all new seals and pistons, brakepads etc. New masterbrakecylinder and new brakebooster is in place too. Basicly every nut and bolt are new on this car!
Today the bus was dropped of at the glasshop for new front windscreen and installing all windows with new rubber seals. The last final parts (bumpers) are getting painted tomorow or on Thursday. They were handpainted with brush, twisted, rusty and lots of small dents. After sandblasting they got welded, straightned and all dents hammered out. Then a light coat of bodyfiller to make them straight again, then Zinc rustprimer and after this surfacer/ground primer to get them smooth again after the sandblasted surface. Next up is some more sanding and then Deepblack paint. New covers and bolts are waiting from Just Kampers! The bus should be ready for the road in the end of the week! More pics to come…
Wheels have been fitted, needed 5mm spacers all around and longer wheelstuds (56mm) in the rear and new bolts. Wheels are 17″ inch with 225/45 tires, offset 35. Need to make a custom centercap for the speedometer tho. Lots of new parts have been installed from Just Kampers, like new taillights, fuelfiller neck, footsteps, roof ventilation, mirrors, windowfelt trim in front doors etc. Waiting on tailgate seal and new clips for the freshly painted front grills. Bumpers have been blasted and are now getting welded, straightned up and removing big dents before paint in Deep Black. Next big step is taking it to the glass shop and get all windows installed with new rubber seals! Then its ready for the road…
All the places that have been sanded and sandblasted down to the bare metal have been painted with yellow 2k epoxy rust primer for protection. After this, all the small dents, scratches and imperfections in surface/metal after sandblasting etc have been filled up and sanded smooth and all the seams have been sealed up with new seamsealer. Then it was covered in yellow epoxyprimer again. When it was all dryed it just needed a light sanding before 3 coats of grey surfaceprimer was added. Now it has to dry a couple of days before it can be sanded down again, but this time more carefully and must be perfect! When this is done its ready for topcoat paint in VW Marsala Red H3H3.
Bumpers and some smaller parts is at the sandblasters at this moment and more new parts from Just Kampers in UK is on its way right now. Time to choose some cool wheels also, stay tuned for more pics and updates!
Stephans VW Bay project moves on and here is some pics from the transmission overhaul made last week here in the garage. The transmission is a 002 case, 3 rib from late 1973. Code CK. The Baywindow buses are famous for their poor gearshifts. If you have a sloppy gearstick on your bus, first check all bushings in the gearlinkage that runs thru the floor from front to back. If the shifting still is bad, then its possible that the gearleveler balljoint (made in plastic) inside the nosecone is worn out. I replaced this balljoint on this tranny for one made in metal instead, so it will last for ever! The magneticplugs was cleaned, oil drained, all gaskets and seals new and then a coat of fresh paint. Now its ready to be bolted back in the bus again.
Yesterday the Coke machine was finished. Got the new lite-up sign to glow with new lightbars. Also added a cold white LED stripe to the bottle/door and a red stripe in bottom off front door. The Coke gets really cold just after a couple of minutes when running. Drop by the garage if you are thirsty! 🙂
Almost finished with the Coke machine! I cut the metalsign up and converted it to a lite-up sign instead, this was an original option on these machines. Powdercoated the frame that was left in silvermetallic and installed two LED lightbars 3000K warmwhite color. Cleaned up the shelfs and compressor, checked all wires, oiled up the coin mechanism. Got all new emblems, locks and water decals on. Only waiting for the stickers on the sides of the machine “Have A Coke” the ones I got from US was in wrong color. Soon its time to load it up with bottles and just plug it in! The last final pics coming soon…
Looked like this 6 days ago (!) Quick turn around time!
Today I started to sand down the black surfacer/primer so it was all smooth! Found some new dents that needed to be fixed also. And when it was all done it was time for shooting the Coca-Cola red paint. It was a hardtime to find the paintcode. Maybe it is trademarked. But the paintshop sells paint directly to the Coca-Cola company in Sweden so they had all the codes. It turned out great, looking really good. Next up is mounting back all hardware, trims and logos etc. The sign was in metal on the machine but Im going to convert it to a light up sign instead and using modern LED lightning. Also going to check up the compressor and all wirings before its ready to be put in service.