The wiring was a mess (for all equipment) so a new control panel with automatic fuses was installed togheter with new wiring. The 230v wiring (camping power) was also updated with automatic ground fuse and two new sockets with combined USB outlets.

The old interior lightbar was only 230v, but it was a great design so you can flip/turn the light angle. So I took it apart and converted it to 12v with LEDs. An extra LED light with two touch dim/settings was mounted up in the front of the sealing/roof also.

Under the rock n roll sofa I made space for 200amp of batteries (dual 100amp). These I connected to the car/start battery thru a relay, so the car alternator will charge all battery’s. These batteries are connected thru Bluetooth to my cellphone so I can see how much power is left and how much is charging. The solar panel (portable 120w) have a quick connection to these battery’s. Also the 5kw diesel heater is installed under the sofa. It takes air from outside and diesel from the main tank, and the exhaust is routed thru a silencer and out. It runs on diesel and 12v so it can be used anywhere for a very longtime, no need for 230v power. It has a digital display, and a thermostat so it will keep the inside toasty warm on winter. It can be started thru GSM net with my phone. I routed the heater outlets to the main floor and one to the back/bed. It works great and produce a lot of warm dry heat!

The walls, doors and roof was already insulated with 50mm cellplastic, thats very good! But I had some extra aluminium/bubblefoile rolls that I put inside some of the doors and walls for some extra insulation and vapor barier.

#vwt3overland

Have been working on the camping interior lately. The old interior was crappy and looked like shit, it had some structure wall weave/papper that hade been rolled with paint 10 times, the touch and feel was like a 40 grit sandpaper so it needed to go. But it was a good design/plan layout on the cabinets and storage. So I decided to keep the base of it and make a new outside finish on it in light grey oak vinyl.

All cabinet doors was made new in 12mm Medium Density Fibreboard and painted in medium gloss grey with paintgun. Countertop was made new in black colored MDF with semi-gloss clear coat, now with space for a portable kitchen / stove. Above the stove space I made a 12v kitchenfan with outlet, the fan is moving 3,8 squaremeters of air per minute so now you can make bacon with closed doors without smoke/smelling anything 😉

All the old gas equipment was removed, and the old fridge was replaced with a modern 12v Waeco 48L fridge with freezer. A new black sink and a new Reimo water tap was mounted. And all new waterlines, pump and 20L freshwatertank. Before the water ran straight out on the ground, now it goes into a 10L tank first, with a valve so the water can be emptyed. This is good of you are using water when you are on a parkinglot, ferry or on a big camping with neighbors.

Part 2 is coming on Tuesday…

#vwt3overland

Another generation to the collection, at the moment I now have T1, T2 and T3 buses. This one is going to be the offroad bus and for autumn/winter camping/expeditions 🙂

It’s a 1983 Transporter with 1,6 Diesel and 4-speed transmission. It has a ugly camping interior already fitted that will get a refresh/restoration. A Webasto/Planar diesel heater with thermostat will be installed to the interior in future, so you can stay warm on the winter. New 12v fridge will be installed and the gas stove will be replaced with a new small portable gas bottle one.

The goal is to have it pass the MoT / Safety Inspection before the winter comes. The engine starts but is not running very well. It has a new cam, timingbelt, waterpump at the moment. Going to align the timing belt better because it squeaks at lower RPM right now. Also the diesel pump is needing adjustment with special VW TOOL 2066.

Some meaty offroad tires (Malatesta Kobra) have been fitted on stock VW 14″ steel wheels, that was sandblasted and painted. Looks badass now! The diesel tank have been drained on old diesel and a new fuel filter fitted. Also added some anti-bacteria and injectioncleaner to new diesel. New oil (15w-40 mineral) and filter in the engine too. New air cleaner filter added. Injection pump adjusted with micrometer (vw2066) up to 00,95, before was only 00,81. Engine now runs much smoother but need to align the timingbelt before any real test drive can be done. More too come soon…

The new heater is now installed and incorporated with the old heater system design on the Highroof bus. Easiest and fastest way to install this would be to just place it under one of the sofas inside the bus and pull the heater hose out. But I decided to complicate it a little more but in the end with a much better result I believe. My bus had the Eberspacher heater M-code from factory so my idea is to remove the old heater and replace it with a new modern diesel heater.

Doing it this way, I will get a modern reliable diesel non explosive/safer heater than the old which ran on petrol. I will automatically get digital display with timer, remote start, thermostat control and much more. I will not loose space or hear the noise from it (like if it was installed inside the bus) because the heater will now be outside under the middle floor (inside the protective splashpan) where the old factory heater was mounted. I will now get heat not only in the rear of the bus but also in front cab and windshield ect. I will also add some extra airflaps in the heaterchannel so I can adjust the heat to only front or back to the rear floor, bed and top bunk. I will then insulate all pipes with aluminum air bubble foil to protect the heat from the cold surrounding. More work doing it like this but I think it will be all worth it in the end.

I started by removing the old crusty Eberspacher BA6 heater that was mounted in the center under the floor, mounted a new 90mm center pipe under floor instead (like on a ordinary Baywindow without the BA6 heater option). The new parking heater was the installed on the side of the new center pipe. It was a really tight fit, the height of the heater is 140mm and the space under floor was 145mm. I had to cut a 3-40mm notch out in one of the floor supports to make it even possible. The heater exhaust was wrapped in “header wrap” for less heat radiation and was routed out back to a muffler and then out in front of the left rear wheel. You don’t want to route the exhaust fumes out on the sliding door side of course! The fuel pump was mounted in a rubber holder in 40 degree angle on the frame of the bus, filter was put on outside for easier change in future. The air intake for the combustion chamber was routed back (don’t place it against wind/driving direction) and a filter bolted in the end. The air inlet to the heater fan is hooked up to the stock inlet pipe (from a hole under the rear rock n roll sofa). This means it will circulate warmer and warmer air, and don’t have to warm it up from ice cold outside air all the time. It will make it produce more heat too. The heater outlet is connected to a air flap (where I can choose where I want the hot air, front cabin or rear. I also made a extra heat pipe for the rear bed and top bunk, so you can feel the heat directly in the bed when you turn it on in the morning. 🙂 You can see the heat outlet in top bunk on the last picture. Stock is only rear floor otherwise. The small 10 liters diesel tank will be mounted under or behind the front passenger seat, this way you can easily see when it’s time to refill. It consumes only between 0,19-0,5 liters per hour. So on one tank it can run on full blast for about 20-24 hours before it time to fill it up again. Insulated all pipes from back/rear of the engine to all the way to the front cabin. Still have some electric wiring left to do before it all done. Can’t wait to test this beauty out!!

Piece by piece it’s coming together! I Have been fixing with the bumpers and wheels lately. It have all been sandblasted, welded, epoxyed, sanded, primered and painted in same white as the roof. Really starts to come together now, some light in the tunnel. But still lots left to do, here is some new pics…

#highroofbayproject

Slow with updates? Thats because I have been busy doing bodywork on the Highroof bus. A very boring, dusty and time consuming work. But now its in surffacer/filler/primer and ready for more sanding again, and hopefully thats it before paint. Paint for roof (white) and body (VW L20a Marino yellow) is bought. Still have all the doors and lids to do also! Got some new parts too, new lids for electric 240v hook up and fresh watertank filler with lock. A Vitrifrigio C60 fridge in stainless will chill the drinks and food nicely, its 60 liters and 10,5 liter is freezer. Danfoss compressor of course!

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Test fitted the Fiamma Turbo Vent 28×28 on the bus, better before than after paint! It has a built in fan on 12v that can blow out or in fresh air. Will be nice on warm summer days and night I think.

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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…

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Yeah! The bus is now rolling on its own wheels again, after been standing like a empty shell in the air for 7 months. Still need to route new brakelines and brakehoses, and bleed the whole system. Must also restore the factory installed Eberspracher BA6 heater that are going to be installed under the center floor. But now its time to start with paint and body. The engine compartment and front cab need to get painted in VW L20A Marino yellow first, then I can start working on the outside. Lots of work still left to do, but much have been done on places you normally dont see…

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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.
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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…

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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!

Here is some new pics…

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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…

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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…

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After alot of bodywork and sanding it was time for topcoat paint in VW Marsala Red H3D. Looks nice in red! Also got new Deepblack paint on the sun grey faded trim and parts like the front grills, handles, air intakes, wipers etc. I think all the black parts will match the black wheels perfect when its all together. The wheels from Germany will arrive this week and the other new VW parts from Just Kampers will be here tomorrow!

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