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Vova
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Joined: April 09, 2015
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Location: Los Gatos CA
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chabanais
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Joined: July 27, 2002
Posts: 4866
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 Posted: Sat Nov 26, 2016 11:21 am Post subject: Re: 1975 Highroof camper build |
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Really spectacular.
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"I spud therefore I yam." |
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Martin Henriksson
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Joined: September 15, 2004
Posts: 212
Location: Sweden, Europe
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| Posted: Mon Jan 16, 2017 2:03 pm Post subject: Re: 1975 Highroof camper build |
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Thanks for the feedback guys!
Here is a small update: Have not got very much done lately. As my first son (1 year old) takes most of the time now. So that more important at the moment. But Im trying to push forward on the bus too, couple of hours after work and on weekends etc.
Soon have all doors and lids in primer and then it all just needs a easy sanding and then its time for a paintjob! Have also sandblasted the fueltank cover and bellypan and got them painted and ready too.
Hope to start rebuild of the 1800cc Type 4 engine in begining of February also! Whats the best source for parts (bearings, pistons, cams etc) for Type 4? Url?
More to come, but thats it for now, here is some pics...
Blasted and epoxyprimer, ready for topcoat in VW factory greyish
Baremetal then yellow epoxy/zinc primer
Topcoat in VW L20a Marino Yellow with 2K polypaint with elastic characteristics. So the stones wont chip the paint.
Backside/inside, would be nice with some kind of stainless heat protecting metal inside here for protecting paint against the hot Eberspacher Ba6. Any ideas or is it overkill?
Cant wait to get it painted now!
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notchboy
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Joined: April 27, 2002
Posts: 22462
Location: Escondido CA
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| Posted: Mon Jan 16, 2017 3:26 pm Post subject: Re: 1975 Highroof camper build |
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I think the belly pan is fine  Unless you plan on driving gravel roads for miles, and miles and..... 
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| t3kg wrote: |
OK, this thread is over. You win. |
Jason "notchboy" Weigel
1964 1500 S
1964 T34 S Convertible
1977 Westfalia Camper pop-top |
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VW.parrothead
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Joined: January 16, 2016
Posts: 27
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| Posted: Mon Jan 16, 2017 7:40 pm Post subject: Re: 1975 Highroof camper build |
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Fantastic work! I love it.
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1970 Tin Top Westy |
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coxbzh
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Joined: March 01, 2016
Posts: 22
Location: Brest meme
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| Posted: Tue Jan 17, 2017 1:37 am Post subject: Re: 1975 Highroof camper build |
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I follow your post/ job since the beginning, it looks so easy and yet ....
congrulats! |
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Martin Henriksson
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Joined: September 15, 2004
Posts: 212
Location: Sweden, Europe
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| Posted: Sun Jan 22, 2017 9:18 am Post subject: Re: 1975 Highroof camper build |
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Jason: I was meaning the inside of the pan, like a heatsheild for the Ba6. Because usually the buses with ba6 from factory have much surface rust on the pan around the area where the ba6 is mounted, I guess is the heat from it creating this. But its probably nothing to care about.
Anyway...started to disassembly the engine this weekend. A stock Type 4 1800cc AP case (no hydraulic lifters) and dual Solex carbs. Plan is to resurface the heads, 96mm cylinders, better carb setup and a better flowing exhaust system. Probably going to keep the stock camshaft ratio, because it gives maximum torque already around 2200 RPM, wich is perfect for a heavy bus and hills.
The engine was already unbolted when I got the bus and I did not know anything about it, more than it was a AP 1800cc VW type 4. I saw it was cleaned a little bit and the cylinders looked to have new paint on them. So somebody have started to restore it was my guess. But I saw that the lower cylinderhead cooling thins was missing, so I got a little suspicious about how good restored it really was going to be when important parts like that not was installed back. Hmm!
Here we go...
What I had to start with. Dirty old lump!
Teardown started, cylinderheads is off! Something have happend in cylinder nr 1 at some point. It had small marks and dings on the combustionchamber and on top of the piston. Nothing to serious tho. Maybe a washer or parts of a valveseat? One of the valves was new too. Funny thing is that the piston that had marks was now installed in cylinder nr 2. Not a good thing to mix them up on old used cylinders. But doesn’t matter now since I will replace them with all brand new 96mm cylinders and pistons.
When I pulled of the no 4 cylinder I found a rag inside the case(!) Somebody probably forgot it there. Ig the engine had been started up it would not run for a long time thats for sure! It was now confirmed that a total crackhead had restored my engine before.
The good thing is that the cylinderheads are the ones with partnumber ending with an “S”. And have the biggest valves VW ever put in any bus! Intake 41mm and exhaust 34mm. Bingo! Only Porsche 914 had bigger, and they also had a different angle on the sparkplugs for better performance/combustion. Heads will get rid of the headgaskets, resurfaced 0,5-1mm, new valve guides, new machined valveseats in a better material (Type 4 engines are famous for dropped valveseats) and new valves and new springs etc.
Everything removed and all bolts and washers etc. Ready to split!
Every part labeled and bagged, keeping it organized and clean is a must when building a motor.
Camshaft totally shot! And nr 1 cambearing was worn down to the copper. Camshafts are almost never in good shape on the Type 4 engines, even worse on the later ones with hydraulic lifters.
Crank out looked good
93mm 1800cc going to be replaced with 96mm making it a 1911cc
Inspection done, cleaning next on the list. Degreaser and hot highpressure washing etc.
Thats it for now...
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Vova
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DougB
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Joined: January 09, 2007
Posts: 1076
Location: Falls Church, Virginia, USA
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| Posted: Thu Apr 06, 2017 8:03 am Post subject: Re: 1975 Highroof camper build |
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This is one of my favorite topics on TS. Thanks for posting so many pics!
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'75 Campmobile (tin-top to SpaceRoof)
'73 Fastback
'52 BMW R67/2
'41 Zundapp KS600
'55 Puch SGS250
A very, very understanding wife |
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Sloride
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Jim Hunter
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Joined: February 14, 2014
Posts: 107
Location: MB, Slovenjia
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| Posted: Sat Apr 08, 2017 2:50 pm Post subject: Re: 1975 Highroof camper build |
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I do not like bays much BUT after I saw this awesome build I have change my mind and now I think it is time to find one!!!
Congratulations for an awesome transformation Martin! |
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Martin Henriksson
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Joined: September 15, 2004
Posts: 212
Location: Sweden, Europe
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| Posted: Mon Jun 19, 2017 2:56 am Post subject: Re: 1975 Highroof camper build |
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Thanks for the kind reply guys!
Here is finally a update! It have been so much to do lately with work and family and other resto projects so the bus have fallen behind a little. But some progress have been done the roof is painted and done, the last few bits is being prepared for paint also right now. Hopefully I will paint the bus next week!! Still waiting on the machine shop with engine parts so I will start on the interior in meanwhile. Insulation will be first step...
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notchboy
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mnskmobi
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Joined: February 28, 2005
Posts: 536
Location: Melbourne, Australia
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| Posted: Tue Jun 20, 2017 7:38 pm Post subject: Re: 1975 Highroof camper build |
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"93mm 1800cc going to be replaced with 96mm making it a 1911cc"
Are these going to be biral cylinders (or Nickies  )? Conventional wisdom is that 96mm cast iron cylinders are too big for a Type 2. |
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udidwht
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Joined: March 06, 2005
Posts: 3779
Location: Seattle, WA./ HB, Ca./ Shizuoka, Japan
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| Posted: Wed Jun 21, 2017 12:43 pm Post subject: Re: 1975 Highroof camper build |
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| mnskmobi wrote: |
"93mm 1800cc going to be replaced with 96mm making it a 1911cc"
Are these going to be biral cylinders (or Nickies )? Conventional wisdom is that 96mm cast iron cylinders are too big for a Type 2. |
Go with the biral 96mm. I'm running them and they are working great now 19,XXX miles and counting with zero issues. I'd also consider going with new head castings. The casting is the foundation of a sold long performing reliable head. Either from Adrian or Len Hoffman.
If you go with the new head castings it's highly recommended to replace all the hardware in them....everything.
As for camshaft. http://www.webcamshafts.com/
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1972 Westy Hardtop/Type-4 2056cc
96mm Biral AA P/C's~7.8:1CR
Headflow Masters New AMC 42x36mm heads w/Porsche swivel adjusters
71mm Stroke
73 Web Cam w/Web solids
Dual 40mm IDF Webers - LM-2 - 47.5 idles/125 mains/190 air corr./F11 tubes/28mm Vents - Float height 10.45mm/Drop 32mm
Bosch SVDA w/Pertronix module (7.5 initial 28 total @ 3400rpm)
Bosch W8CC plugs
Pertronix Flamethrower 40K coil
S&S 4-1 w/Walker QP 17862
3 rib 002 Trans
185R14 Hankook tires |
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Martin Henriksson
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Joined: September 15, 2004
Posts: 212
Location: Sweden, Europe
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| Posted: Wed Jul 05, 2017 3:02 am Post subject: Re: 1975 Highroof camper build |
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Jason: Haha! Well the camera didnt record when I was painting  Hardcto tell and controll when its wraped up in plastic and using touchscreen with rubbergloves! But I will try when doing the wheels later on!
Probably I will just go with stock cylinders instead of 96mm. Feels like the cylinderwalls will be to thin for a camper bus that will run long and hot!
Some news! The Highroof is now painted at last, in Marino Yellow VW L20a, period correct for 1975. It have been a ton of work and to get that yellow color to cover the bus needed to be painted 4times/coats. That because all yellow (and sometimes red) colors have less pigment than all other colors.
Now the fun can begin, mounting on all new parts like lights, handles etc! Next step will be to start with the interior and begin with insulation in walls and floor. Would be nice to have the most done on interior and exterior until fall so the winter can be focused on engine build and install etc.
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lil-jinx
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Martin Henriksson
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Joined: September 15, 2004
Posts: 212
Location: Sweden, Europe
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| Posted: Wed Jul 05, 2017 12:51 pm Post subject: Re: 1975 Highroof camper build |
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| lil-jinx wrote: |
| Great work,But you are missing the spring clips that keep the star adjusters on the rear brakes from backing off,got to have brakes. |
Didnt have them back then when I took the pictures but they are on now so you dont need to worry
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airkooledchris
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Joined: January 25, 2005
Posts: 2713
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| Posted: Wed Jul 05, 2017 12:59 pm Post subject: Re: 1975 Highroof camper build |
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that is one of the most beautiful busses ive seen here. nice work.
is that a siren for the roof? |
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Martin Henriksson
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Joined: September 15, 2004
Posts: 212
Location: Sweden, Europe
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| Posted: Sun Jul 30, 2017 3:34 pm Post subject: Re: 1975 Highroof camper build |
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Okey guys, I have now started with the interior on the Highroof bus. Have put sounddeadning mats in floors and doors, sprayed it all with wax for rust protection. Then added insulation (Refectix) a material of aluminium with plasticcells of air in middle. After this I put some extra 5mm insulation foamboards (green) then 15mm marine plywood and then a new linoleum carpet in Classic checker pattern, went with light grey to match the grey details on furnitures.
The furnitures itselfs I built by myself at work, when I dont paint I build special lots of special stuff in wood for exhibitions and furnitures for offices and so on. I went with Light Oak wood finish (laminate). I built it all in a extra light plywood 15mm. This interior is gona weight nothing!! And thats great in a slow VW bus, all the stuff thats going to be loaded in the cabinets are heavy enought 😉 The kitchen pod/cabinet is featuring a new Vitifrigio fridge on 48 liters + 2 liter freezer. A new small owen in stainless that will be running on 240v (euro). The zink is from a newer crashed/parted out Knaus campervan I bought cheap online. The lid in top is hiding a gastove and the cupboard in bottom will be housing the greywater tank etc.
Still have plenty to do before I can start restoring the 1800cc AP engine.
More to come...
Insulation
Were you see the marker lines Im going to add what VW forgot; a inspection lid/cover for fuelsender unit 
Work in progress
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