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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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 Posted: Tue Mar 26, 2019 4:40 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| bally wrote: |
Keep up the great work and updates. Thanks. Dave |
thanks!
This morning I started gathering and cleaning up the underside components for reassembly. The brake fork and pushrod were a pain. I had to cut the pin, press it out (and even then it wasn't easy), weld, drill, tap, thread etc. The threads were so rusted on the push rod that the nut just slid down the threads. I cut it and welded the nut on to it to get it out of the fork and then made a new one.
Here's the next round of parts to be sandblasted and painted:
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Tue Mar 26, 2019 1:39 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| edgood1 wrote: |
parts sandblasted, painted and incubating.
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That blue looks nice. I can't wait to see it. That same thing happened to my MC pushrod, then it pretzeled when I finally got it out. Are you going to use a dual circuit master cylinder? What are those brackets for that look like they would fit around the beam or axle tubes for?
Nice work! |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Wed Mar 27, 2019 12:08 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| Burlyhammer wrote: |
| edgood1 wrote: |
parts sandblasted, painted and incubating.
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That blue looks nice. I can't wait to see it. That same thing happened to my MC pushrod, then it pretzeled when I finally got it out. Are you going to use a dual circuit master cylinder? What are those brackets for that look like they would fit around the beam or axle tubes for?
Nice work! |
I'm going to go with a dual circuit master cylinder. From what I'm reading I can use a late bay master cylinder with a rabbit reservoir and a spacer ( any caveats to that?). I think I have the master cylinder and reservoir in my parts stash. I'll have to dig them out.
Those clips go on the axle tubes for the brake lines. Later versions have them welded right on the tube but the older models used bolt on brackets. I don't know when that changed though, pretty sure before 1962. Might not be correct for my year but my panel bus has some slight modifications anyways.... And its a bolt on change.
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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Burlyhammer
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Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Wed Mar 27, 2019 9:45 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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[quote="edgood1"][quote="Burlyhammer"]
| edgood1 wrote: |
parts sandblasted, painted and incubating.
I'm going to go with a dual circuit master cylinder. From what I'm reading I can use a late bay master cylinder with a rabbit reservoir and a spacer ( any caveats to that?). I think I have the master cylinder and reservoir in my parts stash. I'll have to dig them out.
I have heard the same thing. There is a few threads about this.
Those clips go on the axle tubes for the brake lines. Later versions have them welded right on the tube but the older models used bolt on brackets. I don't know when that changed though, pretty sure before 1962. Might not be correct for my year but my panel bus has some slight modifications anyways.... And its a bolt on change. |
That's what I figured by the size of them. |
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edgood1
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Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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djfordmanjack
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Joined: June 15, 2009
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Location: Graz, Austria, Europe
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Tue Apr 02, 2019 5:39 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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I started bolting on parts and doing the brake lines.
Question for the masses, was the routing of the lines different on busses that had belly pans, other than the obvious exception of the long line going under the belly pan?
_________________
1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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edgood1
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Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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edgood1
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Joined: September 30, 2004
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Location: Plymouth, MA
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Peter_N
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Joined: February 19, 2014
Posts: 321
Location: The Netherlands
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| Posted: Wed Apr 10, 2019 6:42 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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Wow, you're doing a great job restoring this bus!
I also saved the original heater duct isolation lol 
There's also something like 'aussen' printed on it
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Thu Apr 11, 2019 5:40 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| Peter_N wrote: |
Wow, you're doing a great job restoring this bus!
I also saved the original heater duct isolation lol
There's also something like 'aussen' printed on it
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thanks! glad i'm not the only one crazy enough to clean those wraps up!
I had to make a longer pushrod for this particular master cylinder. I installed it and got it adjusted nicely. I spent the rest of the morning making some seat belt mounts for the rear seat which will go in front of (behind?) the gas tank and 2 in the floor.
here's the front wrap sections back in the bus. they're pretty ratty but they are original to the bus. I put more bubble insulation under it so it bulges out a bit more than normal.
original(?) shift coupler and new rear seat belt mounts incubating
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Sat Apr 13, 2019 2:20 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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The rearmost heater wrap section needed more soaking and scrubbing than the rest. It was black, soaked in oil and grime. I can't believe how clean it came out. When I pulled it out of the water the stitching had come apart and I could see inside. these are little pillows with some kind of foil inside. there wasn't much left of the foil so I replaced it with more bubble insulation.
I then installed the seat belt mounts that I made:
I think that wraps up (no pun intended) all the underside stuff. I can't think of anything else to do while its up on its side. I guess shes going to get righted again soon.
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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bally
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Joined: April 29, 2006
Posts: 1182
Location: Melbourne, Australia
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| Posted: Sat Apr 13, 2019 3:28 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| Very nice. I look forward to the righting ceremony! |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Fri Apr 19, 2019 11:02 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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I started on tearing down the reduction gear boxes to swap in the good axle tubes.
Here is version 2 of my home made bearing puller:
I ground down the heads on some long bolts to a shape that will fit inbetween the bearing races, then can be turned to grab them.
having a spent bearing on the bench helps
this is inserting it:
this is with the head turned 90 degrees and locked in place:
It worked like a charm:
_________________
1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Mon Apr 22, 2019 5:05 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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I have the good axle tubes on. I'm just waiting for some new seals. I thought I had some but they weren't the right ones.
I spent a good chunk of time chasing ALL the threads on the axles tubes. That should pay dividends when installing the assembly back into the bus.
_________________
1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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BarryL 
Samba Member
Joined: November 01, 2004
Posts: 14257
Location: Casa de Oro, California
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| Posted: Mon Apr 22, 2019 6:47 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| I love your invention for the puller. Bench grinder or what? |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Thu May 02, 2019 12:41 pm Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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| BarryL wrote: |
| I love your invention for the puller. Bench grinder or what? |
yes, exactly!
I made some progress putting the transaxle back together:
_________________
1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Sun May 12, 2019 4:21 am Post subject: Re: '63 Panel Camper to Deluxe conversion project |
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The rear axle is back together:
This morning I dug out all of the sunroof parts I've gathered over the past few years. now i gotta figure out what to do with it all. I'm considering buying most of what I already have from klassicfab and sell some of this original stuff. It might make for a more enjoyable experience.
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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