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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2123
Location: Plymouth, MA
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 Posted: Yesterday 6:51 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| crofty wrote: |
| Looks great! |
Thank you Crofty! I just installed those cot brackets you graciously sent me. Thanks a ton!!!
I trimmed and welded in the short rocker panel today
I took a good while making sure the cargo rocker lined up
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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crofty
Judas of the North
Joined: August 09, 2000
Posts: 19824
Location: Land of Whine and Phonies
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| Posted: Tue Aug 05, 2025 6:45 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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Looks great!
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| HamburgerBrad wrote: |
I slept on crofty's tent once. I passed out drunk from two bottles of Everett's brother's wine. |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2123
Location: Plymouth, MA
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| Posted: Mon Aug 04, 2025 5:02 pm Post subject: Re: 1965 SO42 Westy Nr 0021 |
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The floor section is welded in
I tried to duplicate all the visible factory welds
I was also able to "adjust" the side rear cargo door by wedging a screwdriver in the hinge and forcing it closed. It worked shockingly well. The doors are perfect now
I got some grinding to do.
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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: 2123
Location: Plymouth, MA
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2123
Location: Plymouth, MA
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2123
Location: Plymouth, MA
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| Posted: Thu Jul 31, 2025 5:44 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| BarryL wrote: |
| You won't be installing the mid stiffener and go right to the outer? Looks good for how crustry it was. |
The Wolfsburg west outer rocker comes with the middle strengthener panel already welded to it, which is nice
The rocker is done. I prefit the floor section to make sure the doors close and latch
I'm going to do the front wheel well fixes next, then the floor and the short rocker last. Leaving it to the end gives me a little more access when welding in the floor section.
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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: 15228
Location: Casa de Oro, California
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| Posted: Wed Jul 30, 2025 6:13 pm Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| You won't be installing the mid stiffener and go right to the outer? Looks good for how crustry it was. |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2123
Location: Plymouth, MA
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| Posted: Wed Jul 30, 2025 7:21 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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I got the inner rocker panel fitted and welded in.
Next is the outer rocker and short rocker panel. I fitted them both and just need the paint to dry to weld them in. This is the first time I've used "wolfsburg west" panels (not sure who actually makes them), but they are really good. I always expect to have to tweak new panels to get them to fit but these will fit right in, which is a pleasant surprise. They're very accurate to the originals as well.
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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: 2123
Location: Plymouth, MA
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| Posted: Sun Jul 27, 2025 8:17 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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After cutting off some rust metal to assess the repair needed I decided to bisect the top hat section of the front outrigger and fab up a patch panel. I'm trying to save as much good metal as possible and all the replacement metal is from the panel sections I cut off my 63 bus.
Fabricobbled this replacement piece...
Welded it in ( and cleaned up the mess my spot weld cutter made)....
And cleaned it all up. I drilled the hole the original had, not exactly sure what it's for but it's there.
I'll fix the surrounding sheet metal next and then start fitting the inner rocker.
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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: 2123
Location: Plymouth, MA
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| Posted: Sat Jul 26, 2025 11:03 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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More rust repair behind the short rocker
There was a mouse nest in the top hat section in the jack point that rusted it from the inside out. I cut out the rust and added this piece to restore the integrity. Not intended to be pretty as this will get hidden by the floor
The front section is up next
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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: 2123
Location: Plymouth, MA
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| Posted: Tue Jul 22, 2025 8:14 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| velvetgreen wrote: |
Where's the pads-or is that what the brown parmesan cheese dust is in the drums  ?? Nice work looking fwd to seeing it back on the road |
Yeah the liners came out with the drums on both sides. They weren't stuck, just sitting lose between the drum and the shoe metal. There's no fluid in the lines either, but some of the soft lines replaced and look new and still have the ate tags on them.
I'm going to Go through the entire brake system and make sure everything is in order. Most of it will probably get replaced.
I had this and the 63 bus side by side doing rear brakes yesterday 
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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velvetgreen
Samba Member
Joined: August 17, 2004
Posts: 2893
Location: Canada
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| Posted: Tue Jul 22, 2025 6:47 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| Where's the pads-or is that what the brown parmesan cheese dust is in the drums ?? Nice work looking fwd to seeing it back on the road |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2123
Location: Plymouth, MA
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2123
Location: Plymouth, MA
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| Posted: Sat Jul 19, 2025 6:47 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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I had to cut out the rocker assembly. It wasn't solid enough to save.
As usual the rust was worse the further I dug into it. It's not terrible though and should be a straightforward repair.
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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vwuberalles
Samba Member
Joined: October 18, 2003
Posts: 1479
Location: Richmond, VA
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BarryL
Samba Member
Joined: November 01, 2004
Posts: 15228
Location: Casa de Oro, California
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| Posted: Sat Jul 12, 2025 6:25 pm Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| I looked at mine today. On the opposite side is a perfect hole. Both sides are blocked from going all the way through with a strand of plastic. Strange...I'd love to know for sure. It looks like you could put a spare fuse or two on the long slot. |
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LAGrunthaner
Samba Member
Joined: March 18, 2007
Posts: 5596
Location: 1st Coast
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| Posted: Fri Jul 11, 2025 3:18 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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Wow BarryL that is an interesting design I wonder if it is for another tool to get some torque.
| BarryL wrote: |
| edgood1 wrote: |
My son and I were just going through it and found the toolkit and original jack 
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I always wondered what the slot in the screwdriver handle was for. |
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| Lind wrote: |
| Have you considered simply starting with a nicer bus? I don't know what your skills are, but the race is easier if you can see the finish line. If you are not a runner, don't start off doing a marathon. |
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BarryL
Samba Member
Joined: November 01, 2004
Posts: 15228
Location: Casa de Oro, California
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| Posted: Thu Jul 10, 2025 6:13 pm Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| edgood1 wrote: |
My son and I were just going through it and found the toolkit and original jack
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I always wondered what the slot in the screwdriver handle was for. |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2123
Location: Plymouth, MA
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| Posted: Thu Jul 10, 2025 6:05 am Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| swharris wrote: |
| edgood1 wrote: |
. It seems just about every part is there, including all the rare westy bits.
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So you have the big top tent/poles/rail bracket, cot canvas/poles/bag, Westfalia woodslat rack, ladder? If so, now that is a score! I do see you have the ultra rare accessory wiper knob in ivory  Congrats on the bus! |
No tent or ladder but I have the roof rack and the cot. I was/am very happy to have the uber rare early clamshell lights, early water pump along with all the other unique things about a super early so42.
Today the engine went in.
I rewired it, trying to return it as close to stock as possible. There were some shenanigans in there like a starter relay and a 6v to 12v converter which are now gone. It went in really smoothly. Just one literal snag with the right side heater box having an unnecessary extra lever that got in the way. I cut that off and it went right 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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swharris
Samba Member
Joined: September 10, 2010
Posts: 640
Location: N. Orange County
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| Posted: Wed Jul 09, 2025 1:45 pm Post subject: Re: 1965 SO42 Westy Nr 0021 |
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| edgood1 wrote: |
| von_hansel wrote: |
what a score! Looks fairly dry too. The paint should buff out nicely.
Looking forward to seeing updates.
Please take pictures of the water tank if you pull the ice box out. |
It's pretty dry. The cargo floor needs some attention the long rocker and short passenger rocker have a few small rust holes but should be easy fixes. This is definitely one of the better condition buses that I've found. This will probably be a preservation as opposed to a full restoration. We plan to use it as it was intended.
My son and I were just going through it and found the toolkit and original jack
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A day or two soak in cleaning vinegar will clean those up nicely. |
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