Westfalia/Bus/Vanagon Restoration Stories

[Ettolitro]

Hours and hours of work, and still not be finished I'm driven by passion for these great van car with must history and charm.

http://http://cubelounge.blogspot.it/


This forum is the best!!!

[msinabottle]

These are such lovely and inspiring stories. I do love to hear of machines left for junk restored, running, and returned to good service.

I have a van!



Best!
_________________
'Winston,' '84 1.9 WBX Westy
Vanagon Poet Laureate: "I have suffered in
many ways, but never, never, never in silence."

[Gzhang]

Hi Jeff,

Good job done on your van. It is my dream state for mine.

[/code]

[Gzhang]

Hi Jeff,

Good job done on your van. It is my dream state for mine.

[delibessleep]

[plummerdesign]

It is so nice to finish a project.
Last year I knew this one was on the calendar...to do the bodywork. Now it is done. The camper is all dressed up and ready for summer.
.
The two year restoration mark has been noted. Some highlights since last May:
- Restored a used slider door (creased/orange color)
- Replaced all vaccuum hoses
- New panel clips, new handle (rekeyed as well) seals and trim for slider
- Replaced TPS, o2 sensor, dig. idle stabilizer
- New pass. quarter panel metal, new rear drivers rear wheel arch
- New GoWesty hook ups
- New decals for post-repaint
- New window seals and chrome trim
- New chrome door scrapers *AMEN*
- Repaint

Full details/images here:
http://www.plummerdesign.com/picts/vanagonBodywork4.pdf
.
Cheers,
Jeffery
.
(Westfalia travel/camping videos at YouTube link below)
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9

[plummerdesign]

Today I went to see the camper at the paint shop. It had only emerged from the oven an hour or so earlier. My goodness, they painted it nice.
Next week it will be picked up and brought back home to reassemble all of the bits and trim.
So let me do a HUGE shout out to the crew at MAACO of Gresham. It is owned by Mr. Jody Noto. Mike did the painting. The big plus was the great customer service given by Joe in estimates. Great team they are. Top recommendation.

MAACO of Gresham 503.618.6997 gresham.maaco.com

Cheers,
Jeffery

(Westfalia travel / camping videos at YouTube link below)
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9

[plummerdesign]

The work continues. There was a rumpled fender flare on the drivers side that made me grab the grinding wheel.

Big thanks to Mr. Tipton for the AWESOME welds! New fender flare puts the project back about two weeks until paint booth day. Full story in pictures at this link : http://www.plummerdesign.com/picts/westfalia-bodywork-3low.pdf

Cheers,
Jeffery

(Westfalia travel/camping videos at YouTube link below)
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9

[plummerdesign]

Okay, let me be the first to admit it- bodywork is more enjoyable than replacing the fuel lines/tank hoses.
That is what was happening in the driveway last year, same time.

Looks like Dick Hanna Auto Body is running a $599. special on paint. Might be just the ticket!
.
Cheers,
Jeffery
.
(Westfalia travel/camping videos at YouTube link below)
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9

[plummerdesign]

Well all it took was for my slider handle to fall off and out came the RotoZip. The rain was steady outside while in the garage some serious metal cutting was happening.
My green camper had a mash at the slider/rear panel. The previous owner (R.I.P) had done the honors. It had taken me the better part of 18 months to procure all panels, seals, trim and hardware before the task could start.

My target for paint is March.

http://plummerdesign.com/picts/westfalia%20bodywork.pdf

Cheers,
Jeffery
.
(Westfalia travel/camping videos at YouTube link below)
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9

[plummerdesign]

Here is my rig at the one-year mark in restoration. At some point I had to stop and snap a photo just to see how far it has come. From black slime and critter nests, broken skylight and windshield...to a trusty ride that is ready to go places. I pause.
.

.
Landsailer: been there. Do not give up. It will be worth the effort. Besides, if you need to bail it can always be sold and you get your coin back. Yet something tells me you have been smitten by it's charms. Ahh springtime romance.
Cheers,
Jeffery
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9

[fastwagens]

that red van is fantastic. great job.

[srmpf]

I'm still in the middle of the restoration of a vanagon that was neglected by the PO - I still wonder if the guy actually had any sense of hygene

best thing so far I've found while digging into the van was a pretty big magnet (!) attached to the frame with a hose clamp - I really don't know why the guy did that - perhaps he was afraid of using a screw or a cable binder.

here's the magnet, not where I found it but to showcase the size (and the strength of that thing):

[Landsailer]

Here's a photo. We won't even talk about rust. Not yet, I am still too weak.

[Landsailer]

After discussing where our future was headed with my wife, we both decided that "on the road" should be a major part of it. I a looked around for a while at what vehicle makes best home/go anywhere machine and found the Syncro Westy. My wife would say that I am a glutton for punishment and live by the motto go big or go home. I wouldn't settle for anything less than a Syncro Westy. That being said, I am fairly resourceful and do the majority of my own mechanic work. It seemed like a good fit. I stumbled upon one after looking for a couple of months that was a good price, needed some work, but supposedly ran great. After debating over, and losing some sleep, I was in. And the horror began.

First, the van drove wonderfully; just enough to hook me fully into the experience. Winter was coming on, so camping was out of the question, but I assumed I could do some fixing over the winter and drive it every now and then and be ready for spring. Then came the issues. Small coolant leaks. I identified about 8 and sealed them up. I have a Canadian version, so the Webasto was there with it's confusing coolant routing. Leaking in there as well. Drove fine for a week. Next week, slave clutch poops the bed and I fix that. Next week, the dreaded rubber head gasket leak. I limp it along, vowing to make it work. I learn this tactic doesn't work. It gets worse. In the mean time, the real head gasket on that side has begun letting exhaust into my coolant. Sweet. In addition, poor idle kicks up. I fix that. I finally get it into a garage to regasket on side of the engine (only rebuilt 5k ago, I have the reciept, I figure the other side is good, wrong but I won't know that until later). This goes well with one exception. Removal of the exhaust stud reveals some aluminum shavings. Nice. When I put it back in, I was really careful and it held. Yeah me. Also, finally removed all of that Webasto hose. The thing didn't work anyway. This is where the van really hooks me and the fam and we fall hopelessly in love. I drive it for a week, paranoid as hell that the coolant will come pouring out any second. It doesn't. IT DRIVES LIKE A DREAM!!!!!!!!!! We take it out one nice day, sun is out, play in the snow with the pop top up. It's right out of fantasy. On the way home, I see through the auto bleeder that the OTHER head has begun putting exhaust into my coolant. I feel like throwing up. Back to the shop. This time on of the water pump bolts strips on removal. I am ecstatic at this point. I retap and it's good. The head comes off and goes on fine (with the exception of the already dicey exhaust stud, it gets worse, but I am not pulling that head for anything to fix it, plus it still feels good, not great, but good). I fire up the engine and notice that yes, in fact, I have mis-seated a push rod and now I need a tube and push rod. I fix this. Now the exhaust is super sooty. Awesome. The O2 sensor has shorted onto it's shielding. I fix this. Now I take it in because I have an emissions state and it's needs tuning via exhaust sniffing so I can pass. They claim it's close after valve adjustment so I need to drive it a bit to heat up the cat to burn out the soot from the O2 sensor. I do. I drive it 140 miles, and it's glorious. Holds coolant and oil. No issues until I get home. I hear a wired sound like air escaping and see that the exhaust stud has given up the ghost and I have exhaust blowing out of head. Nice. I take it back to the shop where they have to proper tools to fix and that's where it is right now. From the time I bought it, I get to drive it about a week, then it's down for two, then I get a week, then down for two. You get the picture. Also, I bought two other parts vans which I have been ravaging to fix the Westy. My wife thinks I have a sickness.

What I don't understand is that after all of this abuse, I cannot wait to get in and drive it again.

[tschroeder0]

I bought my 85 weekender in one day of looking in Denver in 1999. I had just finished a 3 1/2 month mountain biking trip from Canada to Mexico, I got a taste of real freedom and decided a camper van should be the next step...I knew nothing about them, other than working on a few in a close friends shop...

I arrived via rental car to Denver, checked the local adds found one listed, showed up with about 3 others, made an offer, called my bank and actually was able to get a loan for the full amount 2300$

Since that time I have continually been upgrading, but at the same time always travelling/camping and using it often as my daily driver, it has truly been a life changer. I have taken at least one trip every year since then and often 2 or 3 trips.
Last year I spent almost as much time in the van as I did in my bed at home....it now has new suspension, a fresh 2.1, 15 inch rims, the interior has been sound proofed/rust proofed, new paint, new canvas...soon a new cooling system and wiring harness and in the near future a TC engine..I can't wait.

But, never put shiny stuff on that will take the place of a trip, the traveling should always win

[plummerdesign]

The one year mark.
.
It has been a long journey. The Camper started as a total pig, a very needy pig at that. Along the highway of restoration it has been a great travel rig, albeit one that always had a checklist of “to-do” projects. So I did them.
But there was forever ONE LOUD LIFTER. If you have a 1.9 you know this sound, as both of mine have done it.
The lifter was silent unless I chose to start the van only to move it. Then it clattered. It would clatter until I took it out on the highway for a drive. That drive had to be 15 miles, no less.
The lifter job was this week. I booked 5 hours to rid the world of this exuberant clattering. I also chose to do 2 lifters while at it.
It seemed worth following up on the time it actually took to replace 2 lifters on my Camper. The lifters and spring loaded tubes were from CIP. I also ordered a new oil pressure switch from Van Café just because I would be wrenching in the general area.
.
The project started at 11:08 as the van was driven onto the ramps. Removed the tin, valve cover, drained the oil, pulled the rocker assembly, pulled and cleaned the push rods, crushed the push rod tubes (and applied a twist to make them drop), pulled the lifters out with a DENTAL PICK, cleaned the surfaces.
.
The new lifters got some pre-oiling before being dropped into the holes. Once the pushrod tubes were in place, a spoonful of oil was fed into the tube from the head. Push rod tubes dropped in and with care all was aligned and torqued to 11 ft. lbs.
Then changed the filter, added oil and put it all back together. Cranked it without coil for a bit, and then fired it up. No leaks, all good. Cleaned up the tools and went in to eat.
It was 2:30. That made me smile.
.
Drove it for 5 miles, clatter was gone. AMEN.
.
It must be said that I am at one year this week of wrenching, restoring, updating and replacing all vital systems and mechanical tidbits. The wallet needs a break too.
The Camper and I have a new agreement… From here on out the Camper will be rewarding me with a confident season of travel.
.
Cheers,
Jeffery
.
.
(Westfalia camping videos at YouTube link below)
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9

[chojinchef]

Bought the 'Thingamajigger' in January after looking for a while. Not that I was looking for a cherry Vanagon, as I frankly did not have the budget for it. But what I did have was time, some Vanagon knowledge and some basic skills.

Despite the winter we had in the Northeast, I have managed to do the following (working in driveway) up until now:
Full tuneup
Fuel lines
New brakes all around - went all new from rotors, drums and calipers to lines, bearings and seals. Added longer studs and stud conversion on front from T3 Technique.
Nokian tires on Mercedes alloys.
Hardwood floor in passenger area - leftover from neighbors install
Soundproofing in cab area / doors, rear passenger area, slider door and above rear enging area. Also in seat pedestals that I opened up for storage and amp mounting use.
New audio system - 5.25 and 4 inch in front doors, 6x9's in bed pedestal, 5.25's above bed in cabinet. Amp installed under drivers seat and all new 14 ga wiring throughout for speakers.
Repaired exhaust - removed cat, replaced muffler and gaskets at engine. (had shop do this)
Pop top seal kit, repaired vent mechanism.
Headlamp relay upgrade
Second battery kit (just need battery now)
Sewfine carpet kit
New propane tank bought, but not installed yet.
Refurbished a Transawn awning (that came with van), repaired mounting bracketry and remounted. (needs a pressure wash)
Weitec springs
Bilstein shocks

Current issues I am tending to this week while I am off-
Need to drop tranny to deal with leaking rear main (just waiting for my clutch kit to show up)
Trace horn problem, wiper washer motor, new wiper switch arm
Install said propane tank

Needs a real good cleaning to be ready for end of May
_________________
Its a mistress; an expensive, whiney, needy bitch of a mistress. She is a chunky, dirty girl with bad skin, little motivation and yet she always makes me smile. She sure has been around before shacking up with me. She has a direct line to my wallet, plays with my emotions, is consistantly jovial yet with a sarcastic and sardonic side, is consistant in her inconsistancy, and every once in a while gives me a great ride and a fantastic memory.

[plummerdesign]

Thought it worth following up on the Westy restoration since September.
Also that on a nice, sunny day my wife and I stopped to see the family who sold us the camper. They were thrown back by how well it came back from rot. Glad also that it had found a good home. Perfect storybook ending. However my work continued…a blend of basic 28 year refurbishment and some wish-list goodies.
.
New brake master, replaced faulty rear cylinder (warranty), then power bleed
Head unit/S35 speakers (in original grills), new 14 gauge speaker wire run (hassle)
Hella 500 Fogs
Cargo shade (custom)
Vent Shades
OEM Mud Flap
All new illumination to dashboard
Gas Tank reseal
Fuel line replacement
Injector replacement
…and this week:
Carat Alloys/Shocks/Ball Joints/Steering bellows/lube (Nolan’s Tire Factory)
Refinish Propane tank shield.
.
THEN it goes on a road trip in May. This time we will not have issues (praying + AAA). Next up is some bodywork and paint, then block rebuild. The GoWesty heads installed this summer are great, and everything else is new save for the block (pistons, crank, bearings and seals). If I could get a TenCent block without the heads I would be pleased.
.
.
Cheers,
Jeffery
.
(Westfalia camping videos on my YouTube channel below)
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9

[plummerdesign]

These are great stories!
QUESTION:
Has anyone purchased the carpet kits from GoWesty? I am wondering if the color is a match for the original 1982-1984 Westfalia brown carpeting.
.
Cheers, Jeffery
.
.
1984 1.9 Westfalia
"I can always sell it!"
_________________
It is old and green and it makes me grin.
1984 Westfalia 1.9