Restoring a flipseat SO-35 Westfalia

[DJ Pierre]

Hello!
We are DJ Pierre and Evelyn and we’re currently restoring a 1961 Westfalia SO-35.
I (DJ Pierre) grew up with VW Busses. I always spent my holidays in a T2b Helsinki camper from my 4th year until 9. These holidays took us to every part of Europe but most of the time we went to the UK.

Years later, my girlfriend Evelyn and I decided we wanted a VW Bus. Since we didn’t have a lot of money we bought a T3/Vanagon from 1983. It was a rough machine with a crappy 2.3 Ford V6 engine and full camper interior. We spent 5 summerholidays in the Vanagon and seen a lot of Europe. But the car needed a lot of attention so we decided it had to go.

I wanted to buy a T2b Westy myself but Evelyn was very clear. She wanted a Split bus. Very cool but also very expensive. After seeing a SO-33 irl we both wanted a spit-camper. It had to be a real Westy for both of us, so we started our search. She would love to buy a Dormobile, i was instantly in love with the Flipseatmodels.

After months of searching we found the car I was looking for. A May 1961 Westfalia SO-35 with factory Safari’s. It should be Mouse Gray / Pearl White SK1022 with Mouse Gray dash.

All the cabinets where there in decent shape, flipseat was there, all the bedparts and original headliners also. Fairly complete so to speak.

Less pretty was the amount of rust. The body was nice but the floorsection was in really bad shape. We thought the price was right so we bought the car after all.
Although the bus looks funny with the old lady, she really had to go. We want it to be as original as possible. The only improvements will be a dual 12v powersupply, bigger engine and csp diskbrakes. And maybe a dormobile top. But our subhatch roof is in mint condition, don't know if i'll ever regret this 'hack'. But the girl loves it, that's something to think about too.

So we started our project. It all started with disassembling. Took some effort, a lot of nuts and bolts had never been touched. Next job was stripping the paint.

The car had to be sandblasted because of the rust in the frame. This was not something I was happy with but it had to be done.

The result is a bare bus-shell in 2K Epoxypaint.

Now the car was ready for phase 2: the welding. We chose not to weld it ourselves. The amount of welding was huge and I do not have the skills to do a job like this. I did buy all of the sheet metal myself to be sure everything is A-quality. A lot of Funky green and Autocraft had been used and also some OG metal. Some bits had to be made by hand also.

And off we go! Next stop is the painter. Fase 3.

During the time the bus was at the welder I had the time to fix all the parts that needed attention. Also found and bought some missing parts.

Rechromed parts:

Headlights before:

And after:

Fueltank painted:

Parts powdercoated:

Wipermotor refurbished and converted to 12v:

Taillights all buffed out:

The car came with a 1300sp engine when we bougt it. Just a lame bug engine but it was still running. Since we are planning on using this car as a real camper we need something better. I’m planning a 1900sp stroker engine but we found a good 1600dp engine to start with. It has been tested and it’s running fine. Compression is perfect also an no signs of oilleaks. Also bought a taiwan exhaust and 38mm heaterboxes. The cooling tin will be powdercoated before we install the engine.

Westfalia parts fixed / bought:

Repro Awning, we also have the OG Foyer Tent:

Front beam is totally refurbished. All the parts that can move are new now, beam has been powdercoated and the beam has been made ajustable. Not that we will lower the bus but now we can level the car properly.

We made a tool for the ventwindows:

The process of restoring the cabinets. Took quite some time to get the old finish off. We did it with paintstripper and a scraper. Luckely we do not have to fix any damage.

And painting them with 2k clear paint:

They look great now!

Last job I did was together with my mother. She’s handy with sowing so she’s the right person to do the upholstery. I bought 7 meters of repro material witch is an exact copy of the original cloth. It’s not the same colour that was used on our car originaly but we like it. The OG upholstery is beyond saving.
OG:

New:

Our car was missing the folding jumpseat when we bought it. We found one in Germany in good shape but in the wrong color.

To be continued!

[campingbox]

Awesome bus. I would hate to see a dormobile top instaled on such a rare model bus.

[maddriverman]

Very nice,I say yes on the dormobile as long as the work is of high quality.

[JustBarry1972]

[vw7266]

looks awesome.....I dont know what to say about the top...

Have any of that og tattered fabric left over?

[DanM]

[DJ Pierre]

[DJ Pierre]

[campingbox]

[66busman]

Beautiful!
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'66 SO-42
'73 Bay
'75 Type 181

[KombiMarc]

Looking great, Keep up the good work and update when you can...!!! Don't convert the top!!!
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Thanks Marc
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'65 Type I
'65 Type II Kombi Rebuild Thread
http://www.thesamba.com/vw/forum/viewtopic.php?t=459009

[Z]

Really nice bus and work - great pics, too. I love dormy tops, and it would be a cool camper with one on it, but...jeez, that's a rare bus to cut like that. I'd have to say keep the original roof.

[sled]

that would be fucked if you hacked in a dormobile top.

finish the bus as original and sell it to buy a dormobile if that is what you need to camp in comfortably.
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drive your split.

[Z]

[williamblanda]

Cool bus, but I think you're pulling our leg with the dormy top install.

I'm just going to post this as a hint. I don't think a westy rack would even work with a dormobile top.

Either you're very tricky, or you just pulled a "D'oh!" moment.

Can't wait to see it in paint!

[BarryL]

That will be a nice camper. I swear I've seen a picture of that paint job before. You better send me that hand throttle as that doesn't go with an SO-35.

[tev]

I recently sold a 63 EZ camper with a dormy top and the only rack that will work is a custom/tiny rack or an original dormobile rack (at least I think dormobile made one). That top doesn't leave much room. Listen to the voices of experience - keep it original.

Too bad that cab interior couldn't be kept original. That dash looked really nice.

[Erik G]

Did I sell you a different mouse grey/pearl white subhatch westy, that was not a flipseat?
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[vw7266]

[DJ Pierre]

Thnx guys for all the feedback and compliments!
At the moment the bus is in the paintshop, so a Dormy conversion is not a short term plan. First rebuilding, enjoying and driving!

@ Erik G: This is my first Split, I bought the Bus in Belgium in Nov. 2008. As far as I can tell, it never drove in Belgium, it was already a projectbus when it left Germany (until ca. 1970 it was on the roads there). So the honour is to us to get it back on the roads when it turns 50! Still have 8 months to complete that...