TheSamba.com :: View topic - Bus rear torsion is cut out, what are my options?

Tue Jul 08, 2025 10:34 am

I have a 1963 double door panel bus that somebody cut the entire rear torsion and suspension out of. So now I am thinking I would like to replace it with IRS.
But I do not know if I should use:
A- Beetle IRS complete torsion assembly.
B- '68-'71 Bus complete assembly.
C- '72-'79 Bus complete assembly.

Plan is to build a lowered daily driver that can be driven anywhere reliably, and only haul light loads. I do want 4 wheel disc brakes, either 944, CSP or CoolRydes. I do preffer porsche bolt pattern.
Not going to be slammed. Probably only lowered 3-4". My '63 single cab has just removed gear boxes, then dropped spindles and it drives great.
I would consider air bags though. I like seeing buses parked on the ground! I just have never tried this before.

I plan to convert to walk through so I can add a little leg room moving the seat back some. I know I will have to add belly pans.
Back end of this bus is very rough, but I have bought all new metal for the outsides and a donor clip from a walk through bus to repair the area above the motor. And I have bought clips for frame parts from different years of buses just in case too.

Wheels will be 17x7. Tires will be 205/40 fronts and 225/45 rears.

I am open to ideas on transaxle to use. I have bus 3 rib and beetle irs to use and plan on getting one rebuilt just for this build. Or I know where I can get a 914 5 speed and I already have bug@5speed conversion kit.

I have 7 different welding machines all from Miller. I weld for a living. I'm just not a bus expert yet. I spent most of my vw obsession with 1950's and '60's bugs. I do have several buses for parts.
Sorry I wrote so much. I just am hoping to be clear on exactly what I'd like to build before the comments start.
Thank Y'all in advance!

Tue Jul 08, 2025 10:37 am

Quote: C- '72-'79 Bus complete assembly.

This ^^^! Converted Both the '65 Dormy and the '68 Plump Truck to narrow 5 late bay suspension! 8)

Tue Jul 08, 2025 10:40 am

Thank You PyrOman.
I am parting one out now. 3 rib or beetle IRS transaxle?
I looked and found your pictures of these. I am guessing that you used beetle transaxles from seeing how you modified the bus spring plates?

And did you have to narrow the torsion tubes? I see that you narrowed the trailing arms using heim joints.

I like how you did this! Thank You!

Tue Jul 08, 2025 11:23 am

To be sure, got yourself quite the serious project! Fabrication and McGyvering will have to happen! :shock:

I preferred to go with type 2 suspension for better components like brakes and such instead of type 1. 8)

For some reason my pictures are no showing in my IRS thread, so this link should take you to them. :?

https://www.thesamba.com/vw/forum/album_search.php...t_dir=DESC

Tue Jul 08, 2025 11:33 am

Thank You! I went through your profile pictures to see everything. Then I clicked on the link to find the forums showing the pictures, but they came up blank.
I will be using these as references.
Thank You!

I have a nice AutoTwirler rotisserie and everything needed. I have made cars using parts from 2-5 car clips before, so this isn't going to be a problem. I've just never did what you have done yet. I want to drive this bus though! Has to happen.

Tue Jul 08, 2025 11:17 pm

be careful of the position and width of the torsion bar.
i think late bay is wider. the springplates are definitely longer on the newer setups (with 5x112 pattern). your wheel will not be centered in the rear arch. it works, but it looks odd
i have a stock torsion/early bay setup in my panel (see my thread) and it works ok

Wed Jul 09, 2025 4:47 am

My opinion would be use what you have and go with the bay rear and 3 rib. But since you have the welding skills go air ride and modify the crap out of this one to lay it out on the ground. It’s already been cut up for parts so who cares it’s not like you’re cutting up a pristine bus.

Wed Jul 09, 2025 7:35 am

It seems like a ton of time and expense for a fried egg panel van with massive rust issues in some challenging places. Correctly fixing the drip rail alone is a substantial undertaking. That’s even before all the fab work for the running gear.

There’s 7-10k in just panel cost alone… and a drivable comparable example is worth.. 7-10k… it would be possible for someone to straight-up buy one and save a year (or more) of their lives in the shop AND be financially more ahead.

I admire the dedication but perhaps a better starting point would be something to consider.

Wed Jul 09, 2025 10:44 am

Thank You all for your input. Very Much!

Karl H- Wow! What a thread! I read all of it. This bus is cut about 8" ahead of where the torsion tube used to be. So, I can use whatever this thread comes up with. I do intend to machine the bay spring plates like pyrOman did if I go with a bay torsion. Narrowing the torsion is a possibility. May have to cut the torsion bar ends and take some out of the tubing. My guess is 1.5-2" total is probably safe to do. Also guessing the best way to cut torsion bars would be in a lathe and have oil sprayed while being cut?

Pandoras Box- I was told there are far more options in rebuilding a beetle IRS transaxle, but I do not know this for sure. And I also figure VW used the 3 ribs because they are better. I do not intend to carry heavy weight in the bus. Probably only used for taking vw parts to The UPS Store and trips to pick up shop supplies.I have never used or installed air ride, but I'm very interested. And I am willing to tub this, but only 2" max because my '63 single cab is stock seat and only lowered with dropped spindles and I have to lean forward to see stop lights.

Majoring Martin- I live in Alabama. Only 3 VW shops left in the entire state, zero junkyards left and most VW guys sold the good cars and projects years ago when prices went up. I have recently heard that the North West still has a lot of cars available and at lower prices than what we see on line. Finding a more solid bus down here would be very hard to do.
I have nearly 100% of the new metal and donor metal bought already. This roof is very solid. I only found 2 pin holes and I felt around inside and squeezed the inner structure and it is very solid, no holes or weak areas.
I plan on making this a walk through so I can move the seat back 2-3", and I bought leather BMW seats to use that are very nice. Custom Bus is what I am thinking.
(Side note.. I was born in Whidby Island and lived in Spokane area for several years as a teenager.Family lives on the South Hill still.)

Thank Y'all!

Wed Jul 09, 2025 11:28 am

vw356 wrote: Thank You! I went through your profile pictures to see everything. Then I clicked on the link to find the forums showing the pictures, but they came up blank.
I will be using these as references.
Thank You!

Just in case you missed it... I used the '65 torsion plates and cut them to match the IRS ones, but almost screwed up because they are shorter that the early ones! :?

Measure multiple times!!! :wink:

Wed Jul 09, 2025 11:56 am

Thank You pyrOman. I did not know what year these are, and I assumed they were bay. Now I know. Thank You.
I'm thinking I should go 1" behind the factory frame connections in the middle and use the bay complete rear frame to the torsion. Then mid torsion tube back use early bus donor framing? I have these bought and on site just in case.
I will be finishing a custom 1979 convertible(see my latest gallery pictures) and a '64 ghia convertible projects first, then plan on going into this bus. The current projects are customer cars. The '79 got the bottom 8" or so replaced completely. The '64 ghia is getting the back half reskinned and all inner rust repairs done while the rear skin is off.

Sat Jul 12, 2025 10:22 am

You'll have to re-position the upper shock mount too! :wink:

Sun Jul 13, 2025 1:50 pm

Pic of my 59 bus with 68 bay rear swing-arms

Early bay swing-arms are different than later bay swing-arms.

Sat Jul 26, 2025 10:07 am

Thanks guys. I am surprised to see the early bay trailing arms had to be mounted inside the framing like this. I like how it looks and can see this is a good way to go.
My '63 has zero rear torsion tube in it, so I can use whatever. It is cut about 6-8" in front of the torsion tube.

I have irs beetle transaxles, and 3 rib bay transaxles. Plan to have one rebuilt at Benco.

Parts I already have available:
-944 complete rear torsion but I think it is too wide.
-Split bus complete frame.
-early bay complete frame.
-late bay complete frame.
-beetle rear torsion

Have decided I do want to make it capable of hauling heavy loads.

944 4 wheel disc brakes already here.
2110cc already here.
Wheels are 17x7's with et55 back spacing, already here.
3" lowered front and back.

I just ordered an SFX SLC-2030 laser cleaning machine with an XY attachment so I can clean thin metal and thick metal. I plan on stripping the bus to bare metal in all areas and epoxy priming it. Machine will be here in 5 weeks.

Mon Jul 28, 2025 8:48 am

Fitting a Porsche 915 tranny with 5sp would be tempting at this point.... :lol:

Mon Jul 28, 2025 10:44 am

Thank You Ted698. I do have a 1971 915, but was planning on using it in another bus project I have. I did use my porsche parts to convert a customer's 1964 Ghia convertible to a 915 recently:

I posted this thread looking for the best option to go with on this bus for a reliable daily driver. Really leaning towards beetle IRS or bus 3 rib, definitely wanting to go with IRS.
Is a beetle rear torsion strong enough? Or am I better with a bus torsion? I am new to this specific situation and hoping to do it once and not have any regrets or " I wish I had.." thoughts when done.
I do plan on making the frame still look original again, just with a different torsion tube and transaxle.

Thank Y'all Very Much!