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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2151
Location: Plymouth, MA
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 Posted: Thu Aug 22, 2024 8:41 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| Nacho_74 wrote: |
Please post more on the interior door panels. I've been pondering on making my own as well but need some pictorials. Great work BTW!  |
Here's how I make the panels.
Disclaimer: I'm not an upholster. I make a lot of guitar amps and old radio enclosures and I apply my experience with those to panels, whether right or wrong 
First I go through the gallery on this site to find as many pictures original instances of the panel I'm interested to get an idea of how they fit. Then I take detailed measurements from the bus. For the more complex panels I'll make cardboard templates. Having several buses to use as reference is a huge help, especially since this one is cobbled together. Also worth referencing, sgellis made an extremely helpful post with diagrams for all the panels in his amazing '64 camper: https://www.thesamba.com/vw/forum/viewtopic.php?t=...p;start=40.
Once I'm confident with the measurements of the panel I cut them out of 1/8" hardboard with a circular saw for straight cuts and a jig saw for radiuses. I'm using ecualite tile board this time around. It's hardboard but one side has a textured, pvc-like finish. I install the vinyl on the rough, unfinished side of the board. This saves me having to install a vapor barrier or painting the exposed side of the panel so it won't warp over time. I did some adhesion tests on a few different hardboard types. The Weldwood landau adhesive bonds very well to just about anything. I also tested the "dry erase" hardboard and it worked great on that as well, I might use that next. While the weldwood contact adhesive works great, 3M 90 has about half the adhesion. I could pull it off the board without damaging the board where the weldwood would take some of the panel off with the material, meaning a very strong bond. Here's a link to these panels at home depot: https://www.homedepot.com/pep/EUCATILE-32-sq-ft-96...lsrc=aw.ds
Long Panel cut out:
Today I did the passenger side walk through partition panel, so we'll focus on that. I used a gray sealer on the rough side as an experiment to see if it would absorb less glue, but it didn't make a difference. Either way works.
Next I draw lines where the two pieces of fabric meet. The partition panels only have two "stripes" where all the other panels have three.
I used a fabric kit from https://deutschpolster.com/. It is a drop dead spot on match to the original. It's likely the best quality deluxe bus upholstery kit out there.
Then I lay down the top "stripe" upside-down on the line and start applying glue:
For this one I made today it was very early and I applied the glue with a brush and roller. I'd much prefer to spray it but I didn't want to run my compressor and wake up the neighborhood at 5:30am. It's much more challenging and time consuming to brush or roll this glue. It takes some practice. The goal is to get a consistent thin layer on both the panel and material but it tends to get tacky fast and impossible to spread around with a brush or roller. Spraying is sooo much faster and easier.
The next very, very important step is to wait about 10 minutes for the glue to tack up. Per the instructions, wait until you can touch it with a gloved finger without it pulling off. If you don't wait long enough all kinds of bad things happen, bubbles, bad texture, etc.
Then I very carefully place the first piece of material on the panel, and then smooth it out with a roller:
Next I test fit the second piece of material. I try to get them to butt up against each other like puzzle pieces. You can overlap them, but I think it looks cleaner if you can lay them next to each other. We'll cover most of the seam with the chrome trim later.
Then I mask the first piece of fabric and start applying more glue
Carefully apply the next sheet of material and roll it on:
I let it dry for a bit, flip it and start working on the edges
For the sharp corners I fold the two sides and determine where to make a cut for a clean corner:
For the round corners I cut shark teeth:
Then I glue and fold over all the overlapping material. I try to clean up the excess glue while I'm there:
I intentionally left the bottom material on this panel loose because I'm not exactly sure how its going to meld into the trim and wrap that goes at the bottom of the walk-through partitions. It will most likely just get glued like the rest.
I let that dry for a bit and then start on the beading. After some experimentation I landed on using 1/4" staples to attach the beading with small bits of scrap vinyl on top to act as a spacer and buffer so the staples don't poke through the finished side. Installation is pretty straight forward:
I cut shark teeth into the beading when we get to the radiused corner:
Finally I adjust the staples with some pliers to get the beading where I want it. You can adjust it in our a bit and drive home any staples that didn't fully seat:
Here's the finished product, minus the chrome trim.
When it gets installed the beading presses up against the panel and looks a lot cleaner. I'll take some pics when I get that far.
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'63 Samba Conversion ::(photo album)
'65 Westfalia
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Stocknazi
Samba Member
Joined: June 18, 2004
Posts: 5543
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| Posted: Thu Aug 22, 2024 2:20 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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Nice panel construction. The material along the bottom of the walk through bulk head panels tucks under the aluminum trim. It isn't folded and glued to the underside of the panel originally.
Looking forward seeing how you tackle the trim strips on a new panel board.
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2151
Location: Plymouth, MA
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| Posted: Tue Sep 10, 2024 6:57 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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I've been working on the interior. I have all the panels finished. I'm just waiting on the last armrest to install the long panel. I had two originals which I restored.
I'll need to make a spare tire cover.
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2151
Location: Plymouth, MA
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| Posted: Sun Sep 15, 2024 10:01 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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I installed all the panels. I'm really happy with how they came out. I just need to finish the rubber wrap that goes around the walk through partitions. The chrome strip that Wolfsburg West includes with their walk through trim kit is useless. I bought a different pre formed pair from West Coast metric and it worked great.
I didn't realize that deluxe walk through buses have an extra metal channel that extends past the chrome trim on each side.
I tried to shape the useless ww chrome strip for it but it just fell apart. It's like trying to shape tin foil.
I'll have to come up with something else instead.
I really like the West coast metric trim here
It's coming together. I can see the finish line. I have a bunch of odds and ends left.
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EverettB 
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Joined: April 11, 2000
Posts: 71823
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| Posted: Sun Sep 15, 2024 11:01 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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Nice work.
I'm not sure what you mean on the extra metal panel For Deluxes, I guess I better go look at my 15-Window
Edit:
Oh yeah, this
It looks like you are still working on the rear deck carpet?
If so, it goes straight across where the latch is on 15/23-Windows.
Your carpet:
My original '63 15-Window carpet
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BarryL
Samba Member
Joined: November 01, 2004
Posts: 15420
Location: Casa de Oro, California
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| Posted: Thu Sep 19, 2024 11:25 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| The extrusion for non-walkthrough should be the same profile if you had that to bend isn't it? |
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edgood1
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Joined: September 30, 2004
Posts: 2151
Location: Plymouth, MA
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| Posted: Fri Sep 20, 2024 9:45 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| EverettB wrote: |
Nice work.
If so, it goes straight across where the latch is on 15/23-Windows.
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Everett - thanks a ton for those pics. They helped me make these:
I'm going to replace that carpet at some point, it's one I had that I just threw in there. I actually have the entire 12 piece kit which I looks nice but I'll resist putting it in.
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Stocknazi
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Joined: June 18, 2004
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| Posted: Fri Sep 20, 2024 9:48 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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You may try annealing the WW aluminum trim before trying to bend it.
Color the area you want to bend with a black Sharpie marker. Gently heat that area with a torch until the ink disappears, which happens almost the same time after reaching the proper annealing temperature.
Aluminum melting and annealing temperature is fairly close, so this prevents overheating and melting what you are trying to anneal.
_________________
WANTED:
58 Westfalia cabinet knobs (3 needed), roof rack, and (7) privy tent poles (silver painted).
"When the people are afraid of the government, that's tyranny. But when the government is afraid of the people, that's liberty."
"The tree of liberty must be refreshed from time to time with the blood of patriots and tyrants."
Thomas Jefferson |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2151
Location: Plymouth, MA
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| Posted: Tue May 27, 2025 2:49 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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Long overdue update. I'm considering this project done. It only took me 20 years . They're never really done, but it's to the point where I can drive it and enjoy it. There are a couple things left to do that I'm not stressing over, like the bumper trim, correct middle seat grab bar and the rear seat kick panel, but I'll get them done at some point. Its not perfect but I couldn't be happier with how this one came out. I'm proud of it and that's what this vw hobby is a about.
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BarryL
Samba Member
Joined: November 01, 2004
Posts: 15420
Location: Casa de Oro, California
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| Posted: Tue May 27, 2025 6:29 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| Better than fresh out of the Germany Factory. |
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PeteSC
Samba Member
Joined: January 26, 2011
Posts: 934
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| Posted: Wed May 28, 2025 1:47 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| Well done! Congrats on seeing it through to completion...not an easy endeavor, I'm sure. Enjoy the drive! |
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Blue Baron
VW Aficionado
Joined: June 16, 2006
Posts: 28321
Location: Free State of Florida
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| Posted: Wed May 28, 2025 5:47 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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Wow. 
No one would suspect that had once been a panel!
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SplitBusVanatic
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Joined: August 16, 2005
Posts: 355
Location: Co. Mayo. Ireland
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| Posted: Thu May 29, 2025 3:24 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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Only one word comes to mind.
WOW |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2151
Location: Plymouth, MA
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| Posted: Fri Jun 06, 2025 10:11 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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Thanks for the kind words!
This is something that's been on my mind for a very long time while working on the bus; posting before and after pictures. I did my best to duplicate the photos I took the day I bought it, by taking the same shot today. Here they are:
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'63 Samba Conversion ::(photo album)
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Last edited by edgood1 on Fri Jun 06, 2025 12:33 pm; edited 1 time in total |
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edgood1
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EverettB
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edgood1
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Joined: September 30, 2004
Posts: 2151
Location: Plymouth, MA
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| Posted: Wed Jul 16, 2025 8:59 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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I've put maybe 100 miles on the bus, working out small issues here and there as I have time. I was waiting for parts for one of the other buses so I decided to take apart the rear end to 1.) fix an oil leak in the driver side reduction box, 2.) raise the rear height a tad, 3.) inspect the brakes, which were grabbing at times and the ebrake wouldn't release without juicing it a little.
There was a ton of brake liner debris in there for such little mileage. I suspect this is from a "rough" drum surface. I ordered new drums, shoes and springs. That might also explain the grabbing and ebrake issue.
The oil leak is from these 3 studs:
They were drilled and had helicoils installed. I can't remember if I did that or they were like that. In any event, oil was leaking through the studs and/or helicoils. I used some red loctite and sealant to seal them up. I put it all back together and filled it with oil and I'll see if it leaks before the new brake drums arrive. 
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'63 Samba Conversion ::(photo album)
'65 Westfalia
'65 Bug |
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edgood1
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Location: Plymouth, MA
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scottvw
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Location: Centennial, CO
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| Posted: Tue Aug 05, 2025 11:47 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| Nice job. Beautiful bus. |
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BarryL
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Location: Casa de Oro, California
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| Posted: Tue Aug 05, 2025 6:17 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| From inception to completion is not even fathomable by me. The word stunning describes the feeling to start. |
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