Trev's Westy
I bought my '74 Westfalia from California in Summer '04 and after much red
tape, faxes, phone calls etc the van arrived in Dublin port in September
'04, was unloaded from the container and driven home. On the way home I
filled the tank but upon arrival it became evident that the tank had developed
a serious leak. I don't know if it was the flavour of the Irish petrol that
finally broke through the last little bit of metal sealing the tank or just
an unfortunate coincidence but either way it dropped the contents of the
tank and remained where it stopped until I could pull the tank and get it
sealed. I had never sat in a VW bus before this and knew nothing about how
they worked but with the help of the nice folk on www.type2ireland.org
I got the tank out, sealed up and back in. Unfortunately it wasn't until
February 2005 before I could actually get insurance to drive it. In the
interim I set to locating and collecting the bits of the Westfalia original
equipment that were missing after 30 years and researching the optional
accessories available at the time of manufacture. Between Westfalia equipment,
VW factory accessories and VW dealer accessories the van has been reinstated
to as close to original as possible with a couple of concessions to modernity
but all in the name of practicality.
The van came with a thick sheaf of paperwork with both the VW and Westfalia
manuals, receipts for parts and work done to the van and even a notebook
from somewhere back in the '70s recording fuel consumption on a weekly basis!
From the receipts, I could see that the van had received a lot of attention
in recent years, with bills for the replacement of the stock carbs with
Weber 34ICTs, installation of an external oil cooler and mechanical maintenance
work including shocks and brakes.
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These are the pics I received before authorising purchase
of the van in Northern California.
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And after it was bought for me
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The last pic of the van on US soil!
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The first pic of the van on Irish soil, leaving the
shipping agents' yard.
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Finally home, safe and sound.
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Exploring my new van!
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Catching the contents of the tank as it ebbed away...
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Original Westfalia equipment:
After 30 years in the hands of a string of owners in the US, some of the
original Westfalia equipment the van left the factory with had gone by the
wayside. While all the original cabinets, sink, cool box, rock'n'roll bed
and all the original upholstery and carpets were still there and in great
condition, the removable things like the cab area hammock, the Westy stool
and the storage box that goes between the front seats were all missing.
Scouring www.thesamba.com, Ebay and
other sources turned up most of the bits and pieces, I found the stool and
storage box in the USA and the hammock from a nice lady in Wales. Once found
and delivered, the stool and storage box had to be reupholstered in the
orange plaid fabric to match the rest of the interior. This was my first
foray into the world of upholstery ;-)
The original spare wheel for this model Westfalia was a collapsible tyre on a standard bus rim. However, the collapsible tyre had been replaced by a full size tyre and fixed to the front of the van on a home-brewed aluminium bracket. Luckily, the previous owners hadn't drilled the front panel to fit the spare there so I didn't have to weld up any holes. After searching for an original collapsible spare wheel from a Westy turned up nothing I had to do a spot of lateral thinking to find the correct style tyre. I knew that some Porsches also had collapsible spare tyres as space-savers but as far as I knew, only the Porsche 924 came from the factory with 14" wheels, like the van has. I found a 14" collapsible spare wheel from a 924 on www.ebay.de and transferred the tyre onto the spare van rim. Once that was sorted I could then reinstall it in the bottom of the sink cabinet where it belonged. Incidentally, the door of that cabinet actually comes clean off its hinges to get the spare out. At first I thought it was broken but once I got the wheel in there it made perfect sense! Since the collapsible spare had gone missing in the past, so too had the original equipment compressor used to inflate it. Another search of the usual online spots turned up nothing so I resorted to a cheap 12V compressor from Argos.
Other standard Westfalia equipment that was still with the van were the louvered windows on both sides, the flip-up dining table with slide-out leaf and the fly-screen for inside the tailgate. Little things like the cabinet handles, tap for the sink and knobs for the louvered windows were all replaced as the originals were either missing or broken.
The original orange pop-top canvas is still in the
van. It is rough in spots, namely the front panel where it has been trapped
in the latch before and the rear corners where it has been chewed a bit
by the hinge mechanisms. The fly screens were perished and made the canvas
look worse than it actually is so I trimmed those off. Getting rid of them
smartened up its appearance no end! I'm still between two minds whether
to replace it with an off-the shelf tan or yellow coloured replacement or
to hold out until I can locate a correct, orange one. Until then, it's in
serviceable condition and isn't a huge priority.
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Flip-up table
(NB: not a pic of my van) |
Cool-box cabinet (near) and sink cabinet (far)
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R'n'R bed and rear side cabinet
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Westy stool had to be reupholstered to match
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The front storage box
(NB: not a pic of my van) |
The cab hammock
(NB: not a pic of my van) |
Additional Westfalia equipment:
Once all the original equipment was reinstated to factory specification,
I started looking at other Westfalia models for useful additions to supplement
the stock equipment. The ones I decided were most suitable were the one-legged
cab table, the late Westy rear ceiling cabinet and the Westfalia Continental
2-burner hob. The hob and the top of the cab table were sourced from the
nice Welsh lady and the leg and brackets for the table from Westy
Frank in the UK. The ceiling cabinet was again found on www.thesamba.com
and shipped over to Ireland. Another useful addition was the Westfalia towbar.
This is the type that replaces the original bumper brackets and was sourced
from a hippy in Co. Clare. It needed a bit of work to one of the bumper
brackets to make it fit well. I also had to ditch the 4-into-1 aftermarket
exhaust the van came with in favour of a stock exhaust to get it to fit.
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Rear ceiling cabinet
(NB: not a pic of my van) |
The one-legged table in the cab
(NB: not a pic of my van) |
Fitting the Westfalia tow bar
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Towbar gets used towing my bug
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Genuine VW accessories:
Since the van is a US sourced model, it was upgraded with VW of America
(VWoA) dealer-fit bumper over-riders. These are pressed steel over riders
with thick rubber buffers attached. Unfortunately, of the 4, only 3 were
present with the van so I had to buy a pair to get the one I wanted at Vanfest
'05. With a quick rub and some fresh paint, they smartened up nicely.
All bay window vans have three "holes" in the stock dash binnacle. One for the fuel gauge and idiot lights, one for the speedo and a third one that is left blank in 99% of vans. This spot is reserved for the factory option VDO time clock. Since these weren't usually specified as extras when ordering a van back in the '70s they are a pretty rare accessory these days. I sourced mine from that nice Welsh lady (again!) but unfortunatley it needed to be reconditioned to get it to work. I happened across the solution by a stroke of luck. I pulled a VDO clock from an '80s Opel Ascona hoping to see if the mechanism was anything similar. As luck would have it, the mechanism from the Opel was almost identical to the VW one. The Opel mechanism needed only minor modification to fit the VW clock, it's amazing that almost 20 years later, VDO hadn't changed much of the mechanism! Another unusual feature of the dash binnacle is that teh coloured markings beside the heater and fresh air levers are illuminated and come on with the dash lights. These are dimmed with the dash lights from the headlight switch on the dash.
I think it was because it was a US market van and not destined for the European market that it came as standard with opening quarterlights in the cab doors and an opening quarterlight in the rear left window. More basic models had fixed quarterlights in the doors. The door ones especially are great when cruising, just open them a chink and you've got a great blast of cooling air :-) I broke the driver's side quarterlight one day after locking the doors with the keys in the ignition. I tried to jimmy the window open from outside but the latch was just too good and the glass shattered before the latch let go. D'oh!!
The window in the rear hatch is a heated window with factory-fitted demisting elements in it. The green illuminated knob on the right hand side of the dash controls the demister.
Another rare factory-fit option that I sourced for my van are the fresh air (or "ambulance") fans fitted to the air ducts in the cab. These were sourced from a friend in Cork and were fitted and wired up in about an hour. They're noisy buggers but ensure a good blast of air when the van is standing still or crawling in traffic. At speed they're no more useful than just opening the front fresh air vent but they're a nice accessory to have. Incidentally, they're called "ambulance" fans as they were standard equipment on factory ambulance converted bay window vans.
One small thing that mightn't be noticed straight away but is a very useful
accessory is the rear inner handle on the sliding door. Ordinarily it is
a white plastic handle and fixes to the inner rear end of the sliding door
by a special bracket. It was only fitted to Westfalia converted vans as
far as I know but after breaking two 30 year old handles I replaced the
plastic handle with a chromed steel one from a split-screen bus. The handle
helps to close the sliding door from inside the van as the front handle
is hard to reach with the fridge cabinet in the way.
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Ambulance fans in ducting covers
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Ambulance fans, switch and loom
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VWoA bumper overriders
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Bumper overriders fitted
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Deluxe dashboard clock (right)
(NB: not a pic of my van) |
I discovered there's more ways to open the quarterlights
than the factory intended!!
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Non-period accessories:
The few non-period accessories in the van are really concessions to comfort
or practicality and despite their presence in the van, they have been installed
without ruining anything or making any irreversible modifications. The stereo
hole in the dash had been opened up to accept the modern DIN sized stereo
head unit by a previous owner but luckily the rubber of the padded dash
hasn't been butchered. The head unit that came in the van was pretty dated
and wasn't working very well. I found a replacement in the form of a VW/Blaupunkt
Gamma head unit from a '98 mk4 Golf. It operates through a pair of 6x9 speakers
mounted in the cab kick panels. These have been cut to fit but it's not
like they couldn't be replaced with stock ones if originality was the priority.
The other non-period modification has been done to appear as period-correct as possible. I picked up a pair of mk2 Golf GTI front seats and recovered them to suit the van's upholstery. The plaid fabric I sourced from thesamba.com, it was salvaged from the roof bed cushions of another '74 Westy. The orange vinyl for the head rest and seat backs was found via a German retailer on ebay after a couple of months of fruitless searching. The piping is from a US supplier on ebay and was sold as welting for speaker cabinets (!). I unpicked all the stitching from the Golf seats, ironed the panels flat and used them as templates to cut out new fabric, then sewed the whole shebang together using my mum's sewing machine! The results are pretty good for an amateur attempt at upholstery and the seats look right at home, almost like a factory optional upgrade.
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Porsche 915 transmission
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Mk2 Golf GTI seat retrimmed to match van's upholstery
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While the van has never left me stranded by the side of the road (touch wood!) I have had to undertake some preventative maintenance along the way. Among these were service repairs like rear brake shoes, westy roof seals, rear screen seal, shift rod bush & linkage, new tyres, new rear shocks but by far the biggest job I undertook was the top-end rebuild of the engine in June 2007. The valves were constantly going out of adjustment over the course of a few months and needed constant adjusting, coupled with this there was an intermittent backfire through the carbs. I knew this couldn't go on forever without something drastic happening so I pulled the engine to investigate. Upon stripping the engine of all its tinware and removing the cylinder heads, it was obvious that all four of the exhaust valve seats were mashed into the head and weren't going to get any better! I bought 8 new valves from VW Eirespares in Co. Tipperary and a sent the heads off to High Precision Engineering in Co. Carlow for the rebuild. They machined out the old seats, fitted new seats which they supplied and rebuilt the heads with the new valves I provided. While the heads were away, I ordered a set of piston rings and a ring compressing tool from CIP1.com and fitted those and rehoned the cylinders with the help of my dad. Since I'd gone this far, I ordered a full type4 engine gasket set from GSF in Dublin along with all new plugs, filter and points and put the engine back together with new seals and serviced it in one go. Now that it's back in the van it's pulling strong and inspires confidence!
Aside from the mechanical maintenance I switched the LHD sealed beam US lamps to RHD H4 halogen lamps, swapped the MPH speedo for a KPH item, the fixed 3 point front seatbelts for inertia spool seatbelts and repainted dash top after the paint had flaked off.
The front panel of the van is the only panel on the van that had seen some repair work in the past. The story that came with the van was that one of the POs had an unfortunate meeting with a deer and the front panel received some remedial welding to the front left side and a repaint to this panel only. Over the years the new paint had flaked off so after a request for a van at RTE (Ireland's national TV station) I had some L20B Lichtorange paint mixed up into aerosols and resprayed the front panel. The results weren't half bad for the time but 2 years on it's not wearing too well. I will have to repaint the front panel again properly in the near future. After all that work, the van only appeared in the background of a couple of pics of minor celebrities in a TV magazine!
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The engine mid-rebuild
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Dash out for repainting, not a small job!
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Black faced KPH gauges and VDO clock
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freshly painted front panel at the photoshoot
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Future repairs/upgrades:
On the cards for future upgrades are an engine conversion to a watercooled
1.8l petrol VW Passat engine. I will use a www.KEP.com
adapter kit and aim to make the conversion as reversible as possible.
If I ever want to return the van to stock I want to be able to do
so without a bunch of welding and painting.
Another useful conversion I have been watching with interest has been the electric power assisted steering (EPAS) that the guys on www.vwkd.co.uk have been working on. The van's steering is very heavy with the stock steering box and I'd like to make it more user friendly.
Out & about:
The van sees regular use on T2I camp-outs, weekends away and
use as a workhorse on occasion too. I get out in the van whenever
possible, the freedom it gives is great. With the van I don't
need to plan ahead and book a hotel or B&B for a weekend
away, it's a mobile dressing room for beach trips, it's a tow
vehicle if I need to get one of my bugs somewhere, it's a show
vehicle at local classic car days, when I moved house it was
a delivery vehicle! I would highly recommend everyone buying
a bus! ;-D
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It's a dressing room at the beach...
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...it's a home from home at Vanfest
'05 with T2I...
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...it's a show vehicle at classic car
shows...
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...and it's a tow vehicle upon occasion
too!
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