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'63 Panel Camper to Deluxe conversion project
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bally
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PostPosted: Sat Aug 03, 2019 4:47 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

Nice work there! It's really shaping up now. Thanks for the updates! Dave
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BarryL Premium Member
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PostPosted: Sat Aug 03, 2019 11:45 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

What ^^^ he said too. There's a lot of force on that slot when the hook grabs ahold. I didn't realize it had all that beefyness.
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edgood1
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PostPosted: Tue Aug 06, 2019 11:23 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

I welded in the front section of the sunroof today:

Image may have been reduced in size. Click image to view fullscreen.

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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
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PostPosted: Thu Aug 08, 2019 8:00 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

I cleaned up the weld on the front today and then made the bracket for the rear cabin light.

My only reference was this picture that everett posted up the other day:
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I made it out of much thicker stock...
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia
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Pietjah
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PostPosted: Fri Aug 09, 2019 1:10 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

Most of the time i just read on here instead of commenting, but I've been following this thread for so long and i just keep loving it.

You've come such a long way and seeing updates always brings a smile on my face!

Keep up the good work!

Pieter
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edgood1
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PostPosted: Fri Aug 09, 2019 9:01 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

thanks for the kind words, Pieter and everyone else!

The clock continues to tick. I have a fairly aggressive timeline to get this finished before I have to move.

I continued work on the rear sunroof opening today. There are two small reinforcment plates under the outermost screw on the sunroof retainer strip. These didn't come on the klassicfab sections. I had one on my donor sunroof:


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the other one returned to the earth:

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I'm a nerd and like to make things like this so...
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I had to harvest some of these nut retainers and retap the rusted threads:

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Then I was ready to start welding the rear sunroof opening onto the bus:

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more to come 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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edgood1
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PostPosted: Wed Aug 14, 2019 12:43 pm    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

puzzle pieces.

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I never know what category to post my photos in, panelvans or deluxes...
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia
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peecee69
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PostPosted: Wed Aug 14, 2019 12:44 pm    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

edgood1 wrote:
puzzle pieces.

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Image may have been reduced in size. Click image to view fullscreen.


I never know what category to post my photos in, panelvans or deluxes...


Makes for much stronger welds!

I'd post them in Deluxes.
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edgood1
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PostPosted: Sat Aug 17, 2019 7:58 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

I have most of the left side skylight section tacked in


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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
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PostPosted: Tue Aug 20, 2019 4:12 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

steady progress:

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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
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PostPosted: Wed Aug 21, 2019 10:18 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

started on the passenger side skylight sections.

these panels needed some major persuasion to get even close to fitting.

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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia
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PeteSC
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PostPosted: Wed Aug 21, 2019 6:16 pm    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

Love the updates, keep up the great work!
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Burlyhammer
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PostPosted: Thu Aug 22, 2019 3:24 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

You’re doing an awesome job fitting those pieces in! It looks massive!
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BarryL Premium Member
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PostPosted: Thu Aug 22, 2019 9:15 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

Plus it appears you have mastered welding. Are you doing inner skylight stampings?
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edgood1
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PostPosted: Sat Aug 24, 2019 6:38 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

BarryL wrote:
Plus it appears you have mastered welding. Are you doing inner skylight stampings?


Thanks guys! Yes I'm doing the inner skylight panels last so I have access to the captive nuts to make sure the sunroof rails and ultimately the sunroof fit. About half of the nut retainers were welded in so far out of place that you couldn't get a screw into the threaded hole.... That's been a real pain in the butt to fix. I have a feeling more tweaking will be necessary. I also was shipped two right side inner skylight panels. I'll just modify one to be a left side panel.
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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
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PostPosted: Tue Aug 27, 2019 11:38 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

more work on the right side skylights. I spent 3 more hours fitting this one panel and then started tacking it in. There is a ton of work behind each of these pics...which all seem to look the same.


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Here are the twin right side inner panels. I cut 3" off the end off one and welded it to the other side to make a left side inner panel... I thought i took pics of that but they've disappeared.

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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia
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Navydave73
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PostPosted: Tue Aug 27, 2019 8:39 pm    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

Great work, I’m doing a similar conversion to my 59 Kombi, but I’m using the WW complete roof. Could i trouble you for a dimension for the relocated rear roof brace? From the edge of the rear sunroof opening to the front edge of the relocated roof support? How did you arrive at your dimension? Ive done some questimating here and there and it has turned out good so far. Especially the corner window frame edge to the rear of the fourth window.... looks like 76mm to me.
Thank you for your time.
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edgood1
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PostPosted: Thu Aug 29, 2019 6:12 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

right side panel is fully tack welded in
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started on the spot welds. I can now see why the right side rain channel was so much harder to remove than the left side. There is a ton more room in the cargo door opening to spot weld the roof panels on. this results in better spot welds. The factory had this same dilemma.

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Started fitting the modified left side inner skylight panel:

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21 windows down, 2 to go!
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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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PostPosted: Thu Aug 29, 2019 8:49 am    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

Quote:
21 windows down, 2 to go!

Very Happy Very Happy Very Happy
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SplitBusVanatic
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PostPosted: Thu Aug 29, 2019 3:23 pm    Post subject: Re: '63 Panel Camper to Deluxe conversion project Reply with quote

Brilliant
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