Build thread - My (love it & hate it) hightop westy project

[xellex]

I had this small stainless steel part that I kept trying to remember where it went. So when it finally came to my mind, I quickly moved to the rear of the car:

I padded that hatch like it originally was. I don't quite understand it's function tho...

And done:

After making sure I had all the wiring needed in the front doors, I went on with the finishing touches:

Then I closed up every hole and padded the cracks around the speakers.

And that's the final result:

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[xellex]

After having all those 4 speakers installed, I badly wanted to hear them work, so I started working on the wiring.
It's basically original, or done with a few original add-ons, but the different part is that all the interior lights, radio, and all 12v plugs work on the aux battery, through their original fuses, in the original location on the panel.

Cleaned the dashboard and glued a bit of sound proofing on it.

I then realized It was best to install the brake and clutch master cylinders now. So I refurbished them. I trust them better than the new junk parts.

And the dashboard is in: Working radio! wohoo!

Glove box installed:

With a little mod:

And original working key:

All the lights working! Eaven the one on the light switch. I made it so it lights up when I put the key in the ignition.

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[xellex]

It was time to pull out the vanagon steering wheel I bought a few years back from the USA. These are extremely rare in Europe.

Unfortunately the horn button had 2 broken tabs, so I had to dismantle it completely. I combined parts from 2 steering wheels, but it came out perfect!

Tried installing the sliding door card, but realized the small plastic fixing parts don't fit. My old panel in the old sliding door was kept in place by self tapping screws, so I can't say what type was used when it was new...

From right to left: Original beige but too small diameter, original grey but it's too short, aftermarket beige but too short, generic grey/beige that I test fitted.
And it's the only one that fits!

So that's what I used:

Awning fully open for the first time ever!

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[Jake de Villiers]

Wow, that's a lot of work. I like your replacement door panels!
_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com

[xellex]

Yep, alot of work and alot of money. That's why my topic title has the "hate it" part

Back to my story, one day I found something interesting on Facebook. I guess fb is good for something...

I fully recommend these parts as my bus had a mouse nest inside the dashboard tubing back when I bought it.
And I'm sure this gap is where it reached inside...

I also replaced this part that I managed to break, with the 3d printed one:

And a small detail: A part that my car was missing: That plastic cover for the dashboard

I installed the original heated seats wiring and control, eventho I'm not sure I'm going to add heated seats for the moment.

And the fuse cover... Another part I was missing. I hope I can find a brown one in the future.

Originally I wanted to install that outside temperature display instead of the heated seats control knob, but the display light was too bright at night, so I moved it lower.

I installed the dashboard organizer which I reinforced on the rear, because it was rattling alot!

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[jimf909]

Nice work!

There's a light in the light switch?!? Now I have one more burnt out lamp to track down.
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- Jim

[xellex]

I got a good price for a compressor fridge that I was following for a lot of time, so I had to buy it. ( I think it was black friday or something).

And finished my 12v setup that basically replaces the westfalia buzzing black box.

I then moved to the outside, and installed the mud guards. Originally my camper didn't have them in the rear at all, and unfortunately I couldn't find OEM ones with the big white VW logo... But nevertheless, they are good quality.

The brackets are stainless steel which is very nice!

And on the front. The original ones were badly worn, so I replaced all 4 corners.

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[xellex]

[xellex]

Some time last year, I took a trip to a very special place.. A guy whom I became friends with has this yard full of t3's. He started collecting them back in the 90's and never stopped. He had around 300 of them at the peak. And he made a living out of selling parts, of course.

That's where I picked most of my syncro parts and I brought home the first batch that day. All that I could fit in my car

I was so excited that it didn't take me too long to install the first syncro parts. The locker panel, wiring and vacuum lines in the dashboard:

And a nice little setup in my living room:

The last thing I did back in 2020 was to buy a set of mercedes 16inch wheels, sandblast and powdercoat them. I had another set back in the day, but I repurposed them as winter wheels on my audi allroad. It's funny but they fit perfectly!

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[xellex]

And then my project came to a standstill for a long time, because of having a very big house/roof renovation work, and because of the winter season which lasted like forever. And after that, in spring there was so much rain and cold weather, I almost went into depression...
The bus waited for me paciently. I keep doing these large posts because I want to reach present time in my topic, and I'm nearly there.

So this year in may, I took my second trip to that special orchard full of t3's:

And got more parts. This time I didn't fit them all inside my car )

Back home, I started working again. I copied the mounting holes location for the gearbox, and made some plates that I could fit inside the rear crossmember through the existing holes:

Made a bracket for the vacuum reservoir

I installed the syncro specific trailer hook, with the wiring and plug:

And I finally was able to install the rear bumper too. Also in chrome version

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[dobryan]

That is great! Wonderful work.

I may be in Romania (Buzau area) with my euroBus in October. I'll know in a few weeks. Definitely would like to hook up with you.
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794

[xellex]

This is the new setup for the rear crossmember. Gearbox mounts bolted to the metal plates that I inserted. The driveshaft protection brackets bolted into the 2wd original nuts, and non structural small parts bolted to captive riveted nuts.

Vacuum reservoir bolted in place. I also ran the syncro specific wiring in place.

I then tried to give a shot at fixing the original plastic coolant lines. So this is what I came up with:
Broken:

Cleaned:

Made and inserted some brass fittings:

And riveted for safety:

I glued this rubber center floor mat because I just cant find anything better for now:

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[xellex]

[dobryan]

[xellex]

What countries are you planning to visit by bus this year? I actually did the trip to Amsterdam and back, with a stop to Croatia and Montenegro also. And it was beautiful. If all goes well, maybe I'll do a trip to European Bugin or Lebugshow next year depending on the situation...
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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[dobryan]

[xellex]

That would be nice!
Here are a few of my last weekends:
Hopefully soon riding the t3...

This year turned out great so far, excluding the awful rainy weather we had for a loooong time.
A trip to the Danube with a few close frieends:

A small bus meeting near Sibiu. The first edition.

The balkan bus meeting in Serbia. This was postponed from last year, and was held in smaller numbers, but still great!

And a trip to the Bulgarian seaside. Unfortunately ours is too crowded right now, with all the people searching for alternative tourism..

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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[xellex]

And going back to my story, I tried something I never did before in my life... My thinking was that if it turns out bad... at least it's my fault. If I give it to a professional and it turns out bad, I lose alot of money, and I would always regret my choice...
So I took one of those ISRI seats apart:

I had a spare original rear mattress with the correct fabric for my bus:

I cut patterns from the old seat covers:

I did all the stitching by hand. I do have a sewing machine in my house, but I'm not confident using it:

And it turned out like this: Pretty happy so far...

One piece down, 3 more to go.... It takes me ages to do this, but I think I'm on the right way!
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1973 GL 1303s, 1983 high top westfalia t3, 1989 mk1 golf cabriolet

[dobryan]

Wow! That looks great!
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794

[Jake de Villiers]

Wow, great job with the seat!!

And lots of variety at the VW meets - cool!
_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com