1965 Mild Custom Camper From Scratch

[BonTonRoulet]

When you get it all fitted just right, take it all out and do your best to waterproof or seal all the holes for the screws that hold it in place. Here is that lesson learned the hard way.

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Never argue with an Idiot. They'll only bring you down to their level and beat you with experience.

[tkortebein]

[tkortebein]

I've been mulling over the layout of the interior pretty much since I saw the bus. Couldn't tell you how many hours I've spent reading build threads, studying David Eccles' VW Camper - The Inside Story, talking with folks and taking measurements at the OCTO meets.

From the start, I knew that I wanted to make it my own, rather than try to replicate every last detail of something period. I'm definitely not trying to pass this off as a Westy, or even the Sundial it once was. That said, I value simplicity and timeless design above all else, and there are a lot of things that I think those conversion companies got right early on.

I'm going with a vaguely SO-23 layout for a few reasons.
1. I want to reserve the back parcel tray for storage - camping gear, kitchen equipment, food. While Z-beds make quick work of deploying the bed, I don't want to shuffle all our stuff around from the back to side cargo doors every night and morning to use that surface for sleeping.
2. I occasionally use the bus for moving, hauling lumber, etc. and the flat surface of the SO-23 "bed" will still maximize that function without disassembling anything.
3. By building everything from wood, I can make everything to the exact dimensions I like (seat/table height, seating depth, bed length, etc.) and change them at any point down the line.

As well as Sgellis’ build, I also took some inspiration from this '58 PGSG I found on BAT. Is anyone here familiar with it or the talented folks who put it together? It checks almost all my boxes.
https://bringatrailer.com/listing/1958-volkswagen-bus-10/

Here are the sketches I made based on the general interior dimensions of the bus, and what I know about general seating proportion guidelines and what I find comfortable.

I picked up 3 sheets of 3/4" Baltic Birch plywood and 1 sheet of 1/2" to begin. I think it's probably more 3/4" than I really needed, but it'll leave me with extra material in the event that I change my mind about anything down the line. Is it just a coincidence that a 4'x8' sheet of plywood fits perfectly through the back hatch and inside of a bus? Or, like some pickup trucks, were they designed around being able to carry common sizes of lumber?

I cut and rough fitted the two bench seat bases first.

oops! Pocket holes on the wrong piece

Then fitted the front bench top to the bulkhead.

And cut the doors into the top with clearance for stainless piano hinges.

I ended up taking the front bench back out and adding a beam under the back of the bench top for a bit of added support.

Next, I templated and rough cut the cover for my spare tire dish in the bulkhead. Since I plan to eventually build a cabinet in the space between the front bench and the door, I cut it to be flush with the side of the bench.

The top overhangs the sides by 1/8" so the face panel will end up flush under the top, but I'm not convinced that this part is in final form, so it will stay unfinished as-is for now. I may extend it all the way to the driver's side wall as a rest for the front bench backrest, and add some storage in the dead space to the left of the spare tire dish.

Last, I carefully measured and marked on the floor where both benches will be mounted, measured and cut the table, and checked the fitment.

I couldn't resist mocking up the table to check the proportions, but I'll reserve the first bus beer for a more momentous occasion.

[tkortebein]

Some updates. It’s been a busy month as I pushed toward my goal of having the bus camp-able by Silverado 2025. I spent the last few weekends finishing up the first stage of the interior.

I started with installing the backrests on the two bench seats. I was careful to make sure that I liked the angle (110deg.) and ratio of seating depth (18”) to backrest height (17”) that I find agreeable.

I made the table mount support on the left wall, removing material from the backside to fit around the strip joining my wall panels together.

Cut the oval hole through the table riser and installed the latch and its catch.

Next I aligned the table and marked the hinge locations.

Cut holes in the corners of the bench top doors to aid in lifting them open.

And installed the table leg and its hinge to the table to check the fit and proportions of everything.

Then started a full weekend of disassembling everything, routing edges, sanding, and coating with Shellac. I’d like to add a seal coat to everything the next time it all comes out again, but for now I am stopping after the shellac in order to make my deadline.

While everything was out, I added T-nuts through the floor to secure everything down. I figured this was a good way to minimize the number of holes I put in the bus itself, while maintaining a level of adjustability and serviceability with machine screws rather than wood screws.

I made a trip to the local foam shop (Mailex Foam in Compton, CA) where I sat and laid on several densities and types of foam in the 4” thickness I planned for until I found the right one, and they cut it to the exact dimensions I asked for. This was a really cost effective way to obtain the foam. Some folks have recommended buying foam mattresses online and cutting them to size, but I can’t imagine it could be much cheaper or better quality than this. Then again, I guess not everyone has the luxury of a local foam shop...

Finally time for assembly.

Some additional sound deadening on the firewall.

Assembled the benches.

I added a leather strap with a Tenax fastener to the bottom of the table to hold the leg up when folded.

Added strips of felt to the bottom and wall-side edges of the benches where they rest against the floor and wall.

Installed the benches which lined right up to the T-nuts in the floor.

Added another leather strap to the ceiling to hold the table up when packing the bench storage compartments.

At this point I realized that the way I had sketched and purchased the foam wasn’t ideal - the backrest sitting all the way down behind the bottom cushion. While it made for four identical cushions, the bottom has a tendency to slide forward when you sit. Also, I don’t think it looks as nice.

So I trimmed a section off each backrest and glued it to the bottom cushions, giving me a 21" bottom cushion and a 14" inch backrest.

And made some temporary backrest supports until the side cabinets are present for them to rest against.

I have’t fully settled on a color scheme or fabric pattern that I want to use for the interior, so for the time being I picked up some cheap dead stock red tweed from the foam shop that matches the front seats okay.

Cut and sewed one backrest cover to check that my pattern fit correctly.

Then made the three remaining seat covers.

And Voila! We’re ready to go camping.

I hope to see some of you at the Silverado Campout this weekend!

[Peter_N]

Hi,

Amazing to see your skills and thoughtful design of interior.
Very warm ambiance with all the wood and dark red upholstery.

Happy camping!
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My 1958 PGSG project topic

[vwuberalles]

That looks really good, nice job!
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1973 Superbeetle: 1st car, owned since age 12. Update thread --> https://www.thesamba.com/vw/forum/viewtopic.php?p=9919140#9919140
1967 Kombi: Owned since age 17, Dad's retirement project.
1966 Beetle: My new project. (SOLD) Build thread--> https://www.thesamba.com/vw/forum/viewtopic.php?t=678040

[LAGrunthaner]

[BarryL]

Elegant simplicity shows a ton of work and planning.

[silkvw]

Top quality work. You really pay attention to detail.
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'64 single cab Big Bend Bus Bash 2015 '16
'59 camper BBBB 2017 '18 '19 '20 '22 New Mexico
'70 Ghia........Bonneville,........TX Mile,........142 mph......(sold)

https://www.thesamba.com/vw/forum/viewtopic.php?t=641871&highlight=

[Buggeee]

This is an Awesome camper!!! What a great design!

Go! Go! Go!
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Big Time 1988 Vanagon Westy
Release the Krankenwagen! 1966 Sportsmobile Camper
Dr. Kompressor 72 Super Duper
61 Turkis Pile (adopted out)

[tkortebein]

It has been a busy summer so far, so very little time to work on the bus. However, with a trip coming up in September, there are a few important items to tackle.

The first of which was to set up the westy tent in the back yard and make sure I have all the parts. This was a gift from my bus friend Paul, and it seems to be in incredible shape considering that it’s now 55 years old. Just a few small tears to repair. It will give us some much needed space and protection from the wind and sun as we drive up the coast into Northern California.

Next I reinstalled the old headbanger that I removed over a year ago when I started to work on the interior. I wanted to put it back in and adjust the fitment to use as a template in making a new one. But it will stay in place temporarily for the rest of the summer. It makes for a great storage space for my folding chairs.

Next on the to-do list is to make some curtains for all the windows…

[mtnbus]

great work here ! love it

[oakman]

Very nice work on your interior, it looks great!

Beautiful bus! Hopefully I can check it out one day.
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Brandon

[SplitBusVanatic]

This a nicely laid out thread. Nice and simple interior.
You have made it look so neat. Really really nice job you’ve done.
Well done.

[tkortebein]

I appreciate all the encouragement. Sometimes I question my own sanity, but I love the experiences I get to have in the bus.
Reading all of your threads here has given me tons of information, motivation, and inspiration. If this documentation of my progress serves anyone else a fraction as much It’ll be worthwhile.