Inside Panels FAQ

[RussellK]

What kind of treatments have been done to your interior panels. I need to replace mine on a '77 Westy. The Shurfit panels from WCM have been discontinued and TMI has a reputation for poor quality. Sewfine is supposed to be pretty good. Any others?
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-Russ
'77 Westphalia
'68 Standard

[poptop tom]

The wood paneling?

I pulled my old stuff out, bought 3mm baltic birch, and
traced the old panels - used them as a template.

I then used a good jigsaw and fine toothed blade (to minimize chipping).
I taped both sides where I was to cut, to also prevent chipping.

After cutting, I sanded, stained, and protected.

Like so.

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'76 Deluxe Campmobile

[RussellK]

I've read about usiing the Baltic Birch. How did you attach it?
_________________
-Russ
'77 Westphalia
'68 Standard

[poptop tom]

I used the same hardware that attached the old panels. After
I cut the new panels, and confirmed their fit, I put the new and old
panels back to back, marked the location of the drill hole, taped over each hole to prevent tearing, and proceeded to drill them
out.
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'76 Deluxe Campmobile

[themarshotel7]

Hey Poptop, im in valparaiso. Where did you find the 3mm baltic? and how much per sheet?
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1971 Westy
1972 Super Beetle
2001 Eurovan
1991 Fox
"Going wrong this curve set up for that unless you got a flat or suspension change even but what I found out was I could throw anything into reverse under ten miles an hour aw gosh good old granny you can allways tell by the fear in your belly how limited y'ar."
-Neal Cassady

[Sk84Jesus3]

[ChiTwnVW]

How many of the 5X5 sheets did you use?

[poptop tom]

[ChiTwnVW]

Someone could probably have a business making those panels.

[westyornot]

I traced my panels just like everyone else; then upholstered them. It's really not that tough to do; just takes some patience and a lot of aerosol glue.

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The best things in life aren't things...

[ChiTwnVW]

My inititial reaction was, why cover up that beautiful wood. But I have to admit it looks nice. Way to go!

[jamesinkster]

i like the upholstered look -- very slick.
how did you attach them? in the pic i don't see any screws, etc... plastic clips in the back?

thanks

[jereandjess]

Hey Tom, that really looks great!

What stain did you use to make it come out so close to the original?
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~Jeremy (and Jessica)
77 Sage Green Westfalia 2.0 FI - since May 2004
78 Blue Landmark camper 2.0 FI - since April 1998
69 Beetle - In the family since new
86 Wolfsburg Vanagon Camper "Weekender" since July 25, 2015

[westyornot]

I'm attaching a few different ways:
- side panels you see are anchored at the top in the channel; then I used screws with finishing washers just behind the seat there and at the floor... they're visible at the other end.
- the front door panels have been drilled and will use the hidden factory clips
- the rear hatch and slider were drilled for the factory chrome headed clips (visible just like they are with the wood panels)

Matt
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The best things in life aren't things...

[poptop tom]

Okay folks, here is some more info from my panels.

It took 2 sheets of 60"x60" baltic birch panels.
This did all westy panels (76-79). No kickboards. No
front panels. No headliner. Just the back hatch, slider,
around the fridge, and the other smaller trim pieces.

I couldn't find the product locally (South Bend), but was referred to a place in Chicago, near Midway. Frank Paxton Lumber. It's
on west 66th.

This stuff is not easy to haul. I had my old Ford fullsize pickup,
and fitting the pieces in the back was challenge, as I didn't want them blowing out, or warping!

Any how, here are more details.

First, the wood is flexible along the grain, and rigid against it. Keep this mind for each piece you cut.

Before doing any cutting, etc., the first thing I did was sand each piece
with 120 grit, and dry clothed it clean.
I then applied Olympic oil base sanding sealer. It took about a quart
to do both sides. Let it set overnight, and came back with 220 grit. WITH the grain! I then tack clothed it good.

Now I traced my lines - on both sides!
Masking tape over the lines (both sides).
Put the back side up, and use a utility knife with a new blade
and cut just inside the line (this will confine the chipping).

I then used a jig saw with a sheet metal blade (>1mm max tooth
spacing) and cut all pieces out.

I then stained 1 coat of ZAR oil-based wood stain - 120 Teak Natural.

Let it dry 3 hrs., or longer, and lightly sand with 800 grit. WITH THE GRAIN! .Wipe clean with tack cloth. Stain it again.

Let it dry overnight (is it dark enough?). If not dark enough,
lightly sand with 800 grit, wipe clean, and stain again to desired darkness.

I used simple cloth stain rags to apply stain.

My panels aren't an exact match (although I've never seen
barnd spankin' new panels to truly compare to), but are very close, and I'm very satisified with how they came out.

There are more pics in my gallery, I believe. I'm satisified with the turnout!
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'76 Deluxe Campmobile

[young5o]

[westyornot]

I opened the channel up a bit; not much at all (hindsight, do it before the paint job!). I used masonite (hardboard?) and have a somewhat thick fabric, so the fit is a bit tight and the panel doesn't go all the way into the channel. I also cut the foam short of the edge of the panel to keep the overall thickness at the edge as small as possible.

I used 1/4 inch upholstery foam; nylon webbing on one side. It doesn't give much lift on the finished product; and acts as a nice transition filler where the holes are in the panels on the front seat stands (see original picture of the backside of one of the panels).

I also used the same cloth material for the headliner above the front seats and have new baltic birch panels and ebony wood stain to keep the natural wood look on the ceiling in the back of the bus.
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The best things in life aren't things...

[Dead 1]

[suzygrnburg]

can anyone hook me up with a copy of a tracing of the kicker panels? I don't have any to go off of and I don't know any bay owners around here.
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Without Love in the Dream It Will Never Come True!

[RussellK]

I'll have mine out over the weekend and can trace the outline
_________________
-Russ
'77 Westphalia
'68 Standard