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lawsan
Samba Member
Joined: March 14, 2018
Posts: 7
Location: Daytona FL
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 Posted: Mon Mar 19, 2018 9:34 pm Post subject: Chopping roof off a Bay Bus. |
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I am planning on cutting the roof off my '73 bus and turning it into a safari beach wagon. Any ideas on how and where to add stiffening rails? I do plan on fabricating a single roll bar behind the front seats. That should help with torsional strength.
Any way to keep a functioning sliding door and not have it buckle?
Thanks in advance for any input. |
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Danpa
Samba Member
Joined: August 21, 2007
Posts: 1253
Location: Valparaiso, in
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| Posted: Thu Mar 22, 2018 10:30 am Post subject: Re: Chopping roof off a Bay Bus. |
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Personally, I WOULDN'T CUT THE ROOF OFF....
But, it is your bus. But before you go so drastic, why not just remove the front doors and the back hatch, along with the side windows. You could get the open air feeling, see if you like it and then decide.
Remember, if you cut off the roof, you have NO shade and you might have to rig up some kind of convertible top.
Again, Please consider carefully before you hack off the roof. These busses are just too valuable, IMHO.
Dan
_________________
67 Beetle (gone)
68 Bay Window Double Cab (gone) sob, sob!
64 Beetle (gone)
77 Scirocco (gone)
73 Squareback (scrapped)
70 Beetle (current, in pieces) |
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67ctbug
Samba Member
Joined: January 24, 2016
Posts: 3622
Location: CT
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| Posted: Thu Mar 22, 2018 12:16 pm Post subject: Re: Chopping roof off a Bay Bus. |
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Please don’t... just no. Please.
_________________
'67 Beetle L41
'74 Westfalia
'69 Plymouth "Adam-12"
'63 Ragtop
'73 914
'72 Dodge Wrecker
Go Cubs!
World Series Champions 2016
| KentPS wrote: |
...or the PO envied the terrorists' bus in "Back to the Future".  |
| mukluk wrote: |
| He's fine, just waiting for the dragon in winklepickers to move out of his lane. |
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lawsan
Samba Member
Joined: March 14, 2018
Posts: 7
Location: Daytona FL
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| Posted: Thu Mar 22, 2018 3:19 pm Post subject: Re: Chopping roof off a Bay Bus. |
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I would love to have her built back to camping standards. The roof is almost a total loss on this one. If I could find a donor I would consider replacing.
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type241
Samba Member
Joined: June 02, 2006
Posts: 972
Location: MOSES LAKE, WA
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lawsan
Samba Member
Joined: March 14, 2018
Posts: 7
Location: Daytona FL
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| Posted: Fri Mar 23, 2018 4:40 am Post subject: Re: Chopping roof off a Bay Bus. |
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That one could not be farther away in the 48. I will keep looking for something closer before I do something extreme.
Maybe I am not searching correctly but I cannot find any type of posts or blog entry on roof replacement. I am confident I can do it but would be nice to see how others have. If anyone has a link please share.
Larry |
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Alan Brase
Samba Member
Joined: March 28, 2004
Posts: 4532
Location: Cedar Falls, Iowa
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| Posted: Fri Mar 23, 2018 8:53 am Post subject: Re: Chopping roof off a Bay Bus. |
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Construction methods are near the same in a splittie bus, so a thread on that forum would be helpful.
I agree, that is not pretty.
Al
_________________
Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home |
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67ctbug
Samba Member
Joined: January 24, 2016
Posts: 3622
Location: CT
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| Posted: Fri Mar 23, 2018 5:36 pm Post subject: Re: Chopping roof off a Bay Bus. |
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https://www.thesamba.com/vw/classifieds/detail.php?id=2159494
Here, add a sunroof.
_________________
'67 Beetle L41
'74 Westfalia
'69 Plymouth "Adam-12"
'63 Ragtop
'73 914
'72 Dodge Wrecker
Go Cubs!
World Series Champions 2016
| KentPS wrote: |
| ...or the PO envied the terrorists' bus in "Back to the Future". |
| mukluk wrote: |
| He's fine, just waiting for the dragon in winklepickers to move out of his lane. |
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Danpa
Samba Member
Joined: August 21, 2007
Posts: 1253
Location: Valparaiso, in
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| Posted: Fri Mar 23, 2018 6:39 pm Post subject: Re: Chopping roof off a Bay Bus. |
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In one of the pictures, it looks like someone pop riveted a piece over a sunroof already.
Dan
_________________
67 Beetle (gone)
68 Bay Window Double Cab (gone) sob, sob!
64 Beetle (gone)
77 Scirocco (gone)
73 Squareback (scrapped)
70 Beetle (current, in pieces) |
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67ctbug
Samba Member
Joined: January 24, 2016
Posts: 3622
Location: CT
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| Posted: Fri Mar 23, 2018 7:38 pm Post subject: Re: Chopping roof off a Bay Bus. |
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| Danpa wrote: |
In one of the pictures, it looks like someone pop riveted a piece over a sunroof already.
Dan |
Even better.
_________________
'67 Beetle L41
'74 Westfalia
'69 Plymouth "Adam-12"
'63 Ragtop
'73 914
'72 Dodge Wrecker
Go Cubs!
World Series Champions 2016
| KentPS wrote: |
| ...or the PO envied the terrorists' bus in "Back to the Future". |
| mukluk wrote: |
| He's fine, just waiting for the dragon in winklepickers to move out of his lane. |
Last edited by 67ctbug on Fri Mar 23, 2018 9:40 pm; edited 1 time in total |
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Alan Brase
Samba Member
Joined: March 28, 2004
Posts: 4532
Location: Cedar Falls, Iowa
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| Posted: Fri Mar 23, 2018 9:37 pm Post subject: Re: Chopping roof off a Bay Bus. |
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| Danpa wrote: |
In one of the pictures, it looks like someone pop riveted a piece over a sunroof already.
Dan |
I don't think he needs the sunroof tray so much as the outer edge. And it almost sounds like the linked bay sunroof clip does not include the gutter edges.
BTW, I am quite certain the early bay 68-73 Westy pop tops just started with a sunroof Kombi model. The later 74-79 had a bigger opening. I rather doubt an original Westy would have the drains from the tray corners installed, but that would be a slick setup, use it like a westy in the summer, then when it gets cold crank the sunroof panel over that hole.
Al
_________________
Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home |
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williamM
Samba Member
Joined: August 07, 2008
Posts: 4333
Location: southwest Arizona
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| Posted: Sat Mar 24, 2018 5:37 am Post subject: Re: Chopping roof off a Bay Bus. |
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 I faced the same problem and ended up grafting a 68 roof to a 78 (with a few adjustments) and it worked out fine. Got the donor for $250 and a rental trailer. Neighbor john did the fit and welding- which for the most part you can not tell.
Here is a few before and after pics.
little out of sequence- but when fitting the grafted roof- use large plywood plugs to hold your dimensions.
cut the pillars and post for minimum welding- didn't cut the rear hatch
just about ready
before pic
This was caused by leaf litter and being parked on the coast in salt spray.
SO- keep that roof rack clean and salt free.
_________________
some days I get up and just sit and think. Some days I just sit.
opinion untempered by fact is ignorance.
Don't step in any! |
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lawsan
Samba Member
Joined: March 14, 2018
Posts: 7
Location: Daytona FL
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| Posted: Sat Mar 24, 2018 8:00 am Post subject: Re: Chopping roof off a Bay Bus. |
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Thanks William! That is the motivation I needed. The safari plan was out of frustration.
Was able to find a few donors within a reasonable drive after I posted this.
All you purist calm down! She will live.  |
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williamM
Samba Member
Joined: August 07, 2008
Posts: 4333
Location: southwest Arizona
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| Posted: Sat Mar 24, 2018 8:09 am Post subject: Re: Chopping roof off a Bay Bus. |
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 She ended up a tin top -until we cut the hole for the Riviera- and the cut out piece was a gold mine for other repairs on 2 different buses- so the old moto of don't throw anything away- is true- the rest of the blue donor has also gone to many places - including Norway, The new "Hasta Alaska adventure wagon and a guy in Switzerland needed seat belt anchors.
Kinda like butchering a pig (I've not actually done that) all thats left id the "Beep Beep"
_________________
some days I get up and just sit and think. Some days I just sit.
opinion untempered by fact is ignorance.
Don't step in any! |
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Alan Brase
Samba Member
Joined: March 28, 2004
Posts: 4532
Location: Cedar Falls, Iowa
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| Posted: Sat Mar 24, 2018 8:39 am Post subject: Re: Chopping roof off a Bay Bus. |
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| lawsan wrote: |
Thanks William! That is the motivation I needed. The safari plan was out of frustration.
Was able to find a few donors within a reasonable drive after I posted this.
All you purist calm down! She will live. |
My best hope would be to change only the skin and perhaps the over the top structure. Split it at the spot welds in the gutters. welding mig spots in the gutters, one would barely need to do any post weld grinding.
Further, this would not affect getting every single window opening right.
Of course, maybe this is not possible.
I'm sure many splittie bus guys have done it.
I might have more than usual interest in this as I have a 1970 Westy that a tree fell on the roof at the left A pillar. The front of the roof is deformed slightly. I think a frame machine pull will fix it, but still keeping my options open.
Also open to changing the top to a DORMOBILE or RIVIERA top as the Westy top has some damage and I like the other two better.
Al
_________________
Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home |
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lawsan
Samba Member
Joined: March 14, 2018
Posts: 7
Location: Daytona FL
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| Posted: Sat Mar 24, 2018 9:21 am Post subject: Re: Chopping roof off a Bay Bus. |
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| Alan Brase wrote: |
| lawsan wrote: |
Thanks William! That is the motivation I needed. The safari plan was out of frustration.
Was able to find a few donors within a reasonable drive after I posted this.
All you purist calm down! She will live. |
My best hope would be to change only the skin and perhaps the over the top structure. Split it at the spot welds in the gutters. welding mig spots in the gutters, one would barely need to do any post weld grinding.
Further, this would not affect getting every single window opening right.
Of course, maybe this is not possible.
I'm sure many splittie bus guys have done it.
I might have more than usual interest in this as I have a 1970 Westy that a tree fell on the roof at the left A pillar. The front of the roof is deformed slightly. I think a frame machine pull will fix it, but still keeping my options open.
Also open to changing the top to a DORMOBILE or RIVIERA top as the Westy top has some damage and I like the other two better.
Al |
Rain gutters are gone on mine. Warm Florida salt air eats everything that is not cleaned. If it was just sheet metal replacement I would have it done already.
I am going to go ahead with the roof swap as the rest is more then savable.
Plan is find donor make reinforcements before cutting off close to the bottom window line.
Then cut my roof off mid pillar. Should be able to make exact measurements at that time.
Maybe weld small alignment rods in the pillars so if I need to make adjustments I have meat to weld to.
Brainstorming out loud now.
Larry |
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Mike Fisher
Samba Member
Joined: January 30, 2006
Posts: 17970
Location: Eugene, OR
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| Posted: Sat Mar 24, 2018 11:07 am Post subject: Re: Chopping roof off a Bay Bus. |
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Project the cutting lines with a laser level? 
_________________
https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold
Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey |
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lawsan
Samba Member
Joined: March 14, 2018
Posts: 7
Location: Daytona FL
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| Posted: Sat Mar 24, 2018 11:19 am Post subject: Re: Chopping roof off a Bay Bus. |
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| Mike Fisher wrote: |
| Project the cutting lines with a laser level? |
Still need to account for cutting width of tools and amount of cheap beer consumed. The math gets tricky. |
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Alan Brase
Samba Member
Joined: March 28, 2004
Posts: 4532
Location: Cedar Falls, Iowa
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| Posted: Sun Mar 25, 2018 10:36 am Post subject: Re: Chopping roof off a Bay Bus. |
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| Mike Fisher wrote: |
| Project the cutting lines with a laser level? |
I'm more familiar with Porsche body work than VW type 2's. Porsche books show window GAUGES to be used when welding an opening.
I wonder if such stuff exists and if they are still available?
Likely Celette made them.
For modern vehicles, Celette USA will rent the fixtures to shops. (Usually if you have one of their high priced benches!)
It sure would ensure an accurate repair with no worries that the glass would fit after all painting is done!
Al
_________________
Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home |
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Mike Fisher
Samba Member
Joined: January 30, 2006
Posts: 17970
Location: Eugene, OR
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| Posted: Sun Mar 25, 2018 11:50 am Post subject: Re: Chopping roof off a Bay Bus. |
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A sawzall does a good/straight job & you could just shim it up the other pillars with the thin sawzall blade for tacking/welding each corner. We are doing a sunroof squareback roof swap here.
_________________
https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold
Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey |
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