Off road modifications for your bus FAQ

[Shonandb]

[Shonandb]

[jeffreezeyeti]

[lonewolfone]

New bumper build

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63 bug "black beauty"
79 bus "sunny" (sold)
76 westy tdi swapping
65 sundial "trailer special"
75 riviera "red rocket "

[[email protected]]

From this:

To this:

Few mods:
-Brand new 1955 Engine
-Rebuild 091 transaxle
-Stock front beam with adjusters
-Stock spring plate (1° more than stock)
-Bespoke skid plate based on tow hitch
-EMPI Cro Mo CV's
-Custom full length roof rack with sunroof hole

Actually on stock wheels, but plan to put some 15 Appliance Wheels

[Shonandb]

[cdennisg]

[Shonandb]

Bought 2 new Goodyear Wrangler Load C tires for the front to match the rears. We are now pretty much level with the two of us sitting in the front seats. I really like the look now as the front wheels looked a bit anemic before at 26.5".

These are 205/80/16 (28.9") and the rears are 225/75/16 Load E (29.2")

Have a bit of rubbing when making sharp turns so I may look for 16" ET40 or ET43 instead of the ET33 rims for the front that I'm currently running.
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76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
Click to view image

[rsbadura]

Hello everyone,

My travels in Europe, Africa and Asia over the last 15 years have often taken me to the sea or along gravel roads over mountains or a bit into the deserts.

cyclone air filter

For use in sandy deserts like the Sahara I installed a cyclone air filter (which bring the sucked-in air into a rotating air stream in order to filter out and collect the heavy particles as sand and dust). For the Vanagon T3 there was/is a small cyclone air filter with VW order number 025 129 695 with a transparent collecting container. I placed this above the battery using a self-made holder. The cardboard pipe for the air supply off the type 4 engine with carburetors usually ends there too. On my last trip to the Sahara, it was filled with more than an inch of fine sand powder.

air compressor and recovery tools

Tools on the back of the front seats (driver's seat and bench for 2 passengers - bench is only removed for photo):
short and long CB radio antennas, compressed air spiral hose, compressed air connections on the left and right connected to an ARB CKMA12 compressor below the driver's seat in the spare wheel corner (in sand, the tire pressure must be drastically reduced and then increased again on solid paths), collapsible coarse saw, axe, tire inflation gauge, large telescopic spade. And in and on the spare wheel in the middle: tow bar, wheel wrench and static tow rope in blue bag, including 5 t jack, folder with instructions and circuit diagrams, first aid kit.

roof rack

Mounted on the roof rack: additional water canister, big polished military aluminum box for spare parts and recovery accessories (e.g. elastic off-road recovery belt or petrol canister etc) with 70 Wp solar panel, 2x traction aid / recovery boards, white bag with awning and poles (not mounted at this photo).

... and much more as extra oil cooler behind the front axle, Monroe Ride-Leveler to increase ground clearance, second battery, snow chains, ...

filmset in a salt/sand desert in Tunisia, Africa: planet Tatooine home of young Luke Skywalker

gravel serpentines at the Stol mountain in the Alps of Slovenia

at the Sahara in Morocco, Africa

and sometimes the best help are friends traveling with you in such a powdery sand of the Sahara :

Wish you good and safe off road travels always,
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Rolf-Stephan Badura
1970 VW Karmann-Ghia Coupe
1979 VW Bus L camper conversion
1982 Eriba Pan travel trailer
2017 VW CrossPolo
HAZET classic tools collection

[Shonandb]

With the new front tires I had some rubbing during sharp turns and going over speed bumps so I resized my jack points and fenders to open things up a bit for more clearance. No more rubbing and am happy with the results.

Before

After

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76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
Click to view image

[notchboy]

The price of cool.
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[Earl Bay]

[quote="[email protected]"]

To this:

Care to share how you're running the wiring for your KC's?
I'm thinking about replacing my Hella high beams on the bumper with fog lights and moving the high beams onto the roof rack

[Shonandb]

Thoughts on upgrading my steering and possibly adding an electric motor front wheel drive unit with a locker for off roading.

I need to take a few days to a week over the holidays to either refurbish my front beam on my 76 Westy or consider building a customized rack & pinion steering project that would bolt on and be reversable.

There is a company in Europe that is making a kit to bolt on a more modern rack & pinion steering unit kit but I've been thinking about using a front wheel drive & steering rack from a VW Tiguan or similar and modify it to fit and then mount and make up drive shafts/CVs to connect to an electric motor and something like a Prius or Smatcar smaller battery pack.

The benefits would be a more modern steering and suspension and have the ability to mount and set up an Electric motor and drive unit that would be synced with the rear wheels through real time sensors and have some sort of locking electronic mechanism to lock the front axles for offroading or disengage when driving on pavement.

I'm thinking about only using it for offroad applications at speeds under 20 mph and only engaged when/if needed to get through challenging terrain. Range would not be a concern as I would only use it when needed.

Has anyone looked into this outside the Syncro crowd as they have a working unit but it works with the existing front suspension and axles of a Syncro? Any thoughts or comments would be appreciated.

I am ambitious and have a knack for making things work and my Bus is already far from stock so please keep the comments constructive. Mechanical and electrical challenges, including electronics are all solvable for me within a reasonable budget.

Thanks.
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76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
Click to view image

[Convoy]

Circling back on a previous post. Has anyone installed the adjustable coil-overs (rear bug application) on the front of a bus set at the lowest setting? What did that lowest setting/spring rate net you in ride and overall height? Looking for a slightly firmer ride with a 3/4"- 1" overall height increase.

Update: possible use of the gowesty Fox 2.0 may meet my needs.
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1974 Westfalia
2.2 Subie
Benco 002

[Convoy]

I have since installed Gabriel Hyjacker 49307 on the front of my 74 Westfalia with reported results. Since not many have installed these on the front and many have speculated varying results.. I'm reporting my findings for those that may be interested.

why common airshocks v. lift spindles.

1. Cost
2. Provides a mild front lift/level
3. Increased ride support
4. Reduce front end "diving" when hard braking.
5. Increase front end approach angles
5. Aesthetically able to maintain stock rear ride height
6. No lift in rear maintains stock CV angles
7. Increased cornering ability
8. Less front end sway
9. Ease of replacement

Disclaimer; Results may vary.

Parts:
Gabriel Hyjacker 49307
7/16-20 Schrader Valve Adapters
Loctite 545
Air LOL

Baseline is stock suspension, with the exception of older bilstein shocks and newer set of 27" general grabbers on stock wheels. When I would ride in front at 230lbs the bus would sag 5/8".

Current front ride height. 29.5" unloaded.

Comparison (stock Bilstein length to Gabriel Hyjacker)

Installed before and after

Valves

Side profile

I played with the PSI. Between 40-45 seems to be the best.

New ride unloaded at 30"+

Hope this helps.

BTW I did consider lift spindles though I only wanted to gain a small amount of lift and maintain rear ride height.
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1974 Westfalia
2.2 Subie
Benco 002

[virusdoc]

[Convoy]

Shrader Valves are from Fritz Custom Products. No leaks! I even went as far as submerging the entire shock pressurized at ~50 PSI in a 5-gallon bucket of water. No leaks no reported bubbles.
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1974 Westfalia
2.2 Subie
Benco 002