Long running Custom Bay project - the Rebuild

[dpetteng]

So, a little background...

Bought this van in 2001, it needed some restoration handled by my restorer, Hayden. It had the bottom 6 inches replaced and then a full respray, new interior, refreshed engine. We used it as a regular camper from 2003 to 2014.

In that time I went through a full restoration of a 1967 beetle with Hayden and a show standard Squareback which won Volksworld in 2014!

I knew I was moving to the States for a while so the plan was that while I was away, Hayden could start on a very custom rebuild of the van, starting with removing the rusty old roof and replacing with a sliding sunroof version:

That took a while but we had even bigger plans!

My vision for this bus is a camper that Porsche would have built so the custom areas are - air ride, 1985 911 flat 6 engine and transmission, Porsche boxster brakes, Porsche 911 dash (you have no idea how hard this has been), electronic handbrake, late bay engine hatch (so we can get to the 911 engine) among others.

So, this has taken a long time partly due to it being massively complex and because Hayden has had a lot going on but now, the exciting bit.

I found a new paint shop and Ricky has done me proud. The van is a shiny shade of Porsche Slate Grey and now the van is back with Hayden for rebuild.

This is about as custom as a VW Bay can get so I will use this forum as my rebuild blog to show whats going on and show others the custom work we have done to give others ideas!

let me know what you want to see!

[67rustavenger]

Subscribed!
I'd like to see some pics and description of the 911 conversion process.

There was a fella in California a while back that did a 911 conversion on his DC.
It was a pretty sweet project. Sadly, he hasn't been on here for quite some time.
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I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!

[Shonandb]

Nice! Looking forward to following along.
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76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
Click to view image

[W1K1]

Interesting project
What is in the sloping cabinet behind the seat?

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[dpetteng]

[dpetteng]

[crownline]

No offense. It's a Bus not a van. Say it with me Bus.
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1972 Bus 1700 cc Single Carb. But not a progressive.
Barelymuvin
Wish I still had the ones I got rid of.

"It"s got some dings and dents and neither of us is going to SEMA."(Update, I went to SEMA in 2019 but the Bus stayed home)
[url=http://www.vw-mplate.com/mplate-8446.png]Click to view image[/URL]

[dpetteng]

[germansupplyscott]

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SL

[dodger tom]

[dpetteng]

[dpetteng]

So, a little more rust repair and some progress on the engine hatch plus teasers on the air ride work. Anybody who tells you putting a flat 6 in a van is 4 bolts needs to be shot LOL

[crownline]

Wow! Lots of work going on. What color will it be when done?
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1972 Bus 1700 cc Single Carb. But not a progressive.
Barelymuvin
Wish I still had the ones I got rid of.

"It"s got some dings and dents and neither of us is going to SEMA."(Update, I went to SEMA in 2019 but the Bus stayed home)
[url=http://www.vw-mplate.com/mplate-8446.png]Click to view image[/URL]

[dpetteng]

[poundman]

I want that vanagon engine lid in my bus. Would love to know how you did it.
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Restoring a 1972 Bay Window Bus that has not be registered for the road since 1981.
Sugar Land, Texas

[W1K1]

cut one out of a donor, and weld it in
type 3 works too

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[dpetteng]

[dpetteng]

So.. let's start talking about putting a flat 6 in a VW van.

Some people tell you it is 4 bolts, really easy - they are idiots.

A few challenges are - dry sump so you need an external oil tank, cooling a big flat 6, and that it is about double the weight of a VW engine. That would lead you to ask "why bother?" and the answer is, because its hard!

I am not trying to make the fastest van as you could do that with a turbo type 4 VW engine most likely. I love trying things that not many people have done properly, which means rebuilding the chassis to handle the extra power and weight and combining with brakes that will stop the thing!

The other challenge is using a 915 transmission with a gear shift that is in an entirely different place to a VW.

What you need is a genius fabricator which I am fortunate to have!

So a few teasing pics:

[dpetteng]

So, as you can see, we had significant rust repair to do. Not the sexiest subject but definitely

part of a great project:

[dpetteng]

More rust repair, panel fitting, air ride, Porsche 915 shifter etc. This van has had every major panel replaced. You will also notice some work on the Porsche 911 dash!