1980 Tin-Top Chronological PIC Build Thread ~Karmann Vandiego~

[captmatthew1]

Began building a new front bumper for the van today.

*edited to add more photos
_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[captmatthew1]

_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[jimf909]

I love this thread, love the van and all you've done to it. Pretty neat!
_________________
- Jim

[whafalia]

This is an amazing story and you really deliver with pictures, thank you!
The family picture of you all is one of the best things I've seen lately, you are in the Vanagon sweet spot for sure,

I was recently pondering the bumper choices we have and that none of them quite do it for me. Yours work well. I think with some work on the lower outside corners to work with the rocker lines people would want one.
_________________
84 westie 2.2 w/ digijet, AT

[whafalia]

Is that the original paint cleaned up?
_________________
84 westie 2.2 w/ digijet, AT

[captmatthew1]

Thank you very much for the kind words. The lower outside corners of the bumper do strike me as slightly odd looking, but shaping metal and welding is not something I am proficient in yet. I am in no way a professional, just a guy with an imagination that's not afraid to build what I can't afford.
_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[captmatthew1]

[jimf909]

[captmatthew1]

After returning home from town today, I found the exhaust system had broken at the muffler flange. Taking a break from the front bumper, I set off on fixing the damage.

Luckily, I had this muffler sitting in the shop that was sourced from a baja bug.

I cut the exhaust piping to fit, and mocked up the new muffler.

The muffler strap, and its bracket had rusted badly. They fell apart while dismantling the exhaust.

I cut the rusted strap, salvaging the ends that were still in good shape. Then cut a new section out of stainless, and riveted the ends to it.

To be continued.
_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[captmatthew1]

Muffler strap and bracket completed.

_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[captmatthew1]

Muffler replaced. Unfortunately, I ran out of Argon while building the bumper, so flux core wire had to be used instead. Functional.

_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[whafalia]

Great work! is your gas welder 110 or 220?
_________________
84 westie 2.2 w/ digijet, AT

[captmatthew1]

[captmatthew1]

A few months ago I acquired this Audi A6 Avant for next to nothing. I began to build a camping support vehicle. The project stalled and it has been sitting to the side.

Curious, I pulled the front brakes to compare the A6 calipers to the factory Vanagon calipers. Very close to the same bolt spacing.

I suspect I will be exploring brake upgrade options in the near future.
_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[whafalia]

Inspiring! Thanks Captain!
_________________
84 westie 2.2 w/ digijet, AT

[captmatthew1]

I spent some time this afternoon customizing this pillar pod to fit. Pretty happy with how it turned out.

_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[captmatthew1]

I was looking through pictures this morning comparing 2014 to 2020.

_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[captmatthew1]

After spending some time this afternoon, I was able to get the bumper to sit much more square. I had not realized that the front bumper support was not a flat mounting point, resulting in the sides of the bumper sitting at an angle.

_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[captmatthew1]

Shifting from the bumper project to start yet another project, I have spent the last couple of days designing and building an overhead console/shelf above the windshield. Forgot to take pictures along the way, but here it is in it's current state.

I still have a lot of work to do. Finish mounting shelf, mount sun shades, wire 12v for aux power and CB, and add map lights. I plan to add a switch panel later on. I will also be adding a rubber or foam bumper strip to the front edge of the shelf.
_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion

[captmatthew1]

Through the course of this time spent at home, I have decided to start a youtube channel based around my Vanagon, "Karmann Vandiego". I figured I would share the link here in my own thread, so people that are interested in my Vanagon ownership journey can tune in.

I have posted a few videos already, each one a little better made than the last. I am not proficient with shooting or editing film yet, so please don't offer too much criticism...I know the audio is 'meh' at times...I need to invest in a better mic.



Link

_________________
Matthew Alig
1980 VW Vanagon Tin-Top Camper Conversion