Ducky, a VW Bus

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sneaks

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Hmph. Where do I start? The hardest part to a build thread I think is getting it started. Going to bring the project up to date using the stuff I posted over on another forum for VWs to save time and work. Been lurking here for a few years, read a lot of thread (awesome stories and ideas, thank you). Made many road trips to camp spots over the years when the kids were still in school. At the time it was a series of RAM trucks, dog and kids in the back seat, coolers, cabin tent, and everything else in the bed. NY, MD, VA, FL, but our favorite place to go was Lancaster and York counties in PA. I love my Mopars, I've had several RAMs, a Dakota, YJ, XJ, WJ, ZJ, an Eagle sedan, etc. I thought I'd probably do something with one of my RAMs or possibly the Libby or Nitro.

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Though, I've always had a soft spot in my heart for VWs, probably because that is what I grew up with. We had VWs as family cars until they stopped being air cooled. Around 2005, I decided I needed one in my life and picked of a '68 Beetle, which I turned into an Emory baja 'tribute' (Gary Emory is considered the father of the VW Baja Bug), using this as the guide:

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As you might notice in that last pic, circa 2009, there's a few buses in the background. Those came about after some excursions with a few friends and realizing that I really like Buses more. The main influence being the "party pickle" pulling the Sammie out of the drink that belonged to a buddy of mine. This spot is an old Superfund and current landfill location. I now shudder to think what was in that water :( 

[size=small]So I picked up the blue & white '79 in the baja pic in 2009 along with a '70 Westy. The Westy is a different tale for another time. The blue &white bus I bought as a non-runner for $500, the keychain that came with it had a rubber duck with an afro so it got named Aphroducky. It was painted with house paint over spots of 2" thick bondo from a crappy accident repair. I'm not a purist, nor do I really like having a vehicle that can't be used as it is intended because it is too nice, soooooo, I dove in to get the 2.0l FI motor running, the electrics back in shape, and the body respectable. I was moving a nice, happy pace. Funny how life has a way of tossing a wrench into things when you say "nice, happy pace." Within two days I had lunched the transmission in my truck and my son hydrolocked the motor in our shared ZJ. Hammer time!! Whipped the bus into shape quick with a scuff and squirt of TSC paint, got the BFGs off the Party Pickle that was being parted out, and used it as my daily for a year from 2012 to 2013


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Parked Ducky in the spring of 2013 to replace the exhaust and a few other things, since I had gotten a new truck. Parked for a few months became a few years . The summer of 2018 it needed to be moved from where it was sitting so I dragged it up to my place in Maine to ponder what to do next. Right about the same time the better half and I were returning from the annual family gathering in NY, passing through beautiful, rural VT. She said to me that it would be nice if I could take a break that wasn't a family thing and her and I go for a weekend here and there, and she wouldn't be hurt if that meant crawling through some small New England towns and camping for a few days. She then asked how hard would it be to turn "that ugly yellow thing" into "one of those camper VW things?" Ahhhh, I have a plan now :)
 

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So, upon returning home I started working on Ducky, fixing new rust spots, cleaning it up, stripping out the interior, going through the suspension, brakes, and fuel system. [size=small]That got cut short when Mother Nature decided that we really needed winter to start the first week of October...
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And it sat in the snow all winter as I planned out the attack. I have no garage so the work stopped and [size=small]I collected parts and ideas over the very long winter. My volunteer job was hectic so for most of the spring I didn't have a lot of free time, plus we still had snow on the ground in places until early May. Finally, weather broke and so did me schedule so I got back at it. Replaced fan, fuel pump, did complete brake overhaul, tune up, lube, indexed the torsion bars for a little lift, [size=small]Replaced 2 CVs plus the boots while under there. God, that job SUCKS. Might as well plan on burning whatever you are wearing when done cuz that crap ain't nevah coming out [/size][/size]

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Minor setback. Full pump installed, fired it up and it ran.

Speaking of fire...

A wire going from my VR into the main harness and up to the dash light melted down. Normally, inconvenient, but when the hot, melted insulation drops into a puddle of brake clean, things get a little toasty :(. Fortunately an extinguisher is always close so damage minor, was isolated to the wire, plug, and a few hoses underneath.

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So the next day I needed an easy win. Out with these:

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and in with these, got them at the dump, I'm assuming out of a domestic conversion van.

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Cleaned up and painted the dash top, rebuilt wiper system while in there with new bushing, cleaned motor. 

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Didn't get back to it for a few months, fast foward to Sept. Had a VW buddy from NH make the trip over in his Westy to deliver some parts, help out, and just hang out. He got me motivated to get back at it before the weather turns. Again. 

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[size=small]Still ugly. Nice soot mark, huh?[/size]

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so time for a big push. I can do a lot of things in the wet and cold, paint ain’t one of them. That week was supposed to be a small window of nice warm and dry so I got the windows pulled and it primed.

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So the next day sanded out a couple of runs, hooked back up the HF HVLP gun and my little pancake compressor, and on went color. The day after that [size=small]was a holiday so I put the windows back in, made the decision to go with body-matched hub caps instead of naked lugs, added the lights up front, and a 5k winch (it won't move the bus but it will help clear debris). Finally all one shade, looks ok from 20 feet (ok, 20 yards...), and if it gets scratched or dinged, IDGAF. The body has more than one old battle scar, not be bothered to cut out and put in new metal just to bang it up again. This has been from day one planned to be USED not garaged, trailered, or stared at as art. Nope. It’s a vehicle and vehicle it will, that means going in harms way and I don’t have the energy to worry about dents, dings, and branch pinstripes. All that being said, for being shot in my driveway, in Maine, in September, with a cheap HF gun and ancient pancake compressor, I’m satisfied. Disregard the windshield, it’s cracked and junk so I set it in so save masking time.[/size]

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The next weekend was a work weekend so I was on call. The weather was pretty decent so I hammered out a lot of the honey-do yard list plus got some time to do a few things on this project. Was mostly trimming trees so they don’t come down on the roof when snow hits and making one last mower pass on the yard. Since I was productive with house stuff, I took a few to install 3-point retractable (stock VW belts are non-retractable and hell, 40 years old). Safety first!!

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I picked projects that would be easy to leave for a few hours in case my pager went off. Dug into the long forgotten memories of middle school home ec. classes and made curtains today. Didn’t take as long as I thought it would, pleased with the results for $7.00 + tax (I gotta move back to NH...), a free sewing machine, and a few hours worth of my Sunday.

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Was near a Home Depot this week (closest is about an hour away) and made a run through to get stuff for the interior. Had yesterday kinda off so dove in (on call). Created an extended platform to bring the deck out from 36” to 6’. We are both 5’3” so this should be a good “lay down” length. It gives me about 22 cu ft of storage under there. [size=small]Then built up a sideboard. This covers the old spare tire well and will be where the electrics will run and possibly a 5kw diesel heater. Not sure how much cold weather camping we will do but VWs aren’t known for killer heat so might go that route just cuz... [size=small]Cut and fit the carpeting in the back. Once I get the wiring run I’ll tack it down on the sideboard. [size=small]Built a small kitchen shelf unit. My jig saw died so couldn’t cut hole for sink or do the plumbing. Yes, that’s a microwave... [size=small]I’ll probably poly the wood that isn’t covered by carpet. I have my isolator kit and fuse panel, gotta pick up house battery so can wire it up. Looking at a 100w solar set up, might be the next purchase - that or a portapotty. Maybe both[/size][/size][/size][/size]

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Yesterday was a crap day, never broke 40F, rained all day, a few flurries as it got dark. NOT READY FOR WINTER! Grrr. Today - as we know Mother Nature is bipolar - it hit almost 70, was overcast but dry. Windshield still hasn't arrived, ran to the hardware store (~30 miles away) and on the way back, hit a detour for a road race. This is rural Maine, when they say "ya caint get theyuh from heyuh," they mean it. What should have been a 90 minute jaunt ended up a little over 4 hours, the "detour" took me miles in the opposite direction before hitting a road I could use to get back home. Fun times. That left me with less time than I had hoped for the day, but I did get something accomplished. I had started the rack in the spring (recycled twin bed frame rails and some 1x3s) then abandoned it to finish up more pressing things. Today, it got its place in the sun (clouds?). I deliberately left the center open to discourage my automatic tendency to over-pack, over-load everything. Figured if I limited my space, I might be more mindful of what I bring along (says the guy with a microwave in the cabin...).

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Almost caught up to the present. Did some perimeter lighting and other outside wiring tasks.

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Then this past Sunday (4/26/2020) spent from sun up to sundown working on stuff inside - carpeted seat pedestals, wired up 2m radio (CB install this weekend I hope), cut out storage doors, wired up shore power, added a few switches for interior electrics, outlets, inverter, sink, sprayer, front carpet, kick panels, and repurposed a discarded laptop desk arm for a nifty multiposition utility table. There! Caught up!

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Had a few hours free yesterday, so despite the crappy winds that were blowing, I got a little more done.

Pump for sink installed, like that the sprayer can reach out the window for a quick hose-off.

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Got the CB installed, according to the date code is the same age as the bus :)

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Wired up house battery, not impressed with the fuse blocks, ordered different ones. These don't hold the cables well at all :(.

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Did some interior lighting

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Very cool!

If you are interested, I know someone who has two VW's he is trying to sell. The engines are in great shape, bodies trashed, both run. Lots of spare parts. Located in western Colorado. If you are interested, let me know here and we can get in touch.
 
WOW, sneaks -- this is great!

Thanks for all these posts, and keep 'em coming.

I am in awe of your talent and dedication to this van -- but look! You've brought it back after all these years.

Way ta go

Johnny
 
Thanks for the positive feedback, I'm having a lot of fun doing this and getting excited to putting the bus to use. I've gotten a lot of good ideas from others on this forum, the general "personality" of CRVL is much more relaxed and more inline with my thinking compared to some other sites. I appreciate people who do things outside of the box and that doesn't require cashing in the 401k to buy a cell phone mount :). I get a lot of satisfaction from "yeh, I could buy the 'right' thing from someone, but hey, I put this together for 1/10th of the price and it works." 

Yesterday was another nice day up here in northern Maine so took advantage of the nice weather to finish up this phase of the interior so I can move on back to mechanicals now that the ground is dry and solid. Working outside does have its struggles but you work with what you got :) . I hit the counter with some poly urethane (got on clearance for $3 a quart, go me!). It’s old a barn board taken from 19th building we tore down in the back yard a few years ago because of insurance reasons. It soaked up the first 4 coats fast before it finally took a gloss on the fifth one. I love the color that came through. Hit the new wood too, though with less dramatic results.

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Finished hanging curtains on the "kitchen" to hide the lower shelves and sorted out how to hang the privacy curtains. Really wanted those to just block prying eyes and don't mind that they don't reach to the ceiling. I can put them up and down in seconds and they store under the passenger seat. I love my little table a lot more than I thought I would :).

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Put stock seats back in, the others were super comfy but I struggled to reach the pedals (I’m 5’ 2”), plus the factory seats just feel “right.” Part of using a bus is the experience. You cannot be in a hurry, it won't let you :). Also mounted cup holders while in there, another dump find :).

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Joe Cool...

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I owned lots of VWs over the years probably over 300 air cooled ones and a few watercooled. The newer Japanese 4 cylinder fuel injected engines are just so much better than the old VWs especially now the quality control is so poor especially on engine parts or sky high price wise. I still smile every time I remember one of my friends coming by to admire my newest rebuilt engine and the first words out of his mouth were "Oh wow, I could of have had a V8." LOL!!! Nice job on the bus.
 
God, I HATE brake work. Not sure if it is the smell and texture brake fluid or the grime or the rust or danger if you f*** up or all of it combined, but next to packing CVs, brakes are my least favorite task. But, they had to be done so that wast the weekend's project. It went smoothly. Got the calipers rebuilt And painted with minimal fuss, pads loaded, new hard and soft lines installed, rears adjusted, parking brake adjusted, and all lines bled. Glad it is behind me.

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[font=Verdana, Arial, Helvetica, sans-serif]Got the dash back together, some 12v outlets hooked up, cell mount, second extinguisher mounted (one behind seat, one front of bed), bed reinforced as there was one spot That’s was flexing. Kick panels in, auxiliary backup light wired up, and the old cassette AM/FM back in, just in case want to listen to radio. Waiting delivery of some exhaust parts and some interior stuff, hopefully by Friday so end of week can get a muffler on it and start tuning it up.[/font]

[font=Verdana, Arial, Helvetica, sans-serif]Yes, my dash is filthy. .[/font]

[font=Verdana, Arial, Helvetica, sans-serif]The cell mount I’m using for my old phone for music (have a JBL Charge Bluetooth speaker, still gotta figures place for that) and backup camera viewer. I’ve got an old router that I’m converting to 12v, will mount another old iPhone in back window running WebCam+. Been testing it in the house and works, I know Chinese backup cam systems are cheap, but this was for fun.

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[font=Verdana, Arial, Helvetica, sans-serif][size=small][font=Verdana, Arial, Helvetica, sans-serif]Pulled the right front tire off the rim to clean up the bead seat, had a slow leak. Glad I kept those spoons around, mounting a tire old school saved having to wait a month or more to get the job done.[/font]
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[font=Verdana, Arial, Helvetica, sans-serif][size=small][font=Verdana, Arial, Helvetica, sans-serif]I haven’t gotten my house battery yet but wanted to try out things I put on that circuit so a grabbed my ham power supply and hooked it up temporarily. I’m pleased with the results.[/font][/font][/size]

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Had a 1967 VW bus with the single reservoir master cylinder under the driver's floorboard. Towing it home behind my friends bus down the highway at 55 MPH with a chain I lost the brakes due to a slow leak. I remembered I had a container of brake fluid in the back so going up the long hill I ran to the back and got it filling it through the hole in the floor while driving and pumping the brakes. Got enough petal to get it stopped at the bottom of the hill without running into him but it was close to a disaster. Nothing like not knowing if the brakes will work while driving down the highway with your foot resting on the headlight bucket! LOL!!!
 
bullfrog said:
 Nothing like not knowing if the brakes will work while driving down the highway with your foot resting on the headlight bucket!  LOL!!!
Right?? When your feet are about a foot from your front license plate, things like brakes take on a whole new level of concern :)
 
I have always thought more people would use seatbelts if they just mounted a big spike in the center of the steering wheels as well to make it clear you are going to die if you don't!
 
[font=Roboto, -apple-system, BlinkMacSystemFont,]Had some time tonight after work to play around with some of the new stuff. So, this cheap ass solar panel from eBay wasn’t quite as described. Reached out to the seller, and though they responded quickly, they really didn’t know much about what they sell. Yeh, and English definitely wasn’t their first language, despite shipping out of California, responses came in around 2:30am and needed my Ingrish translator to figure out they didn’t understand my question. So it was listed as “100w solar panel with 2 USB plus 12v & battery clips.” Welp, it did come with a ciggy plug and some tinfoil alligator (more like tiny as hell salamander) clips... but... no place to attach them, lol. All there was on the junction box were 2 USB ports. They did revise the listing after I purchased to show output of 5.5v @ 1500ma. So I asked wtf? They were clueless and were going to “ask me our supply” which I took to mean “ask our supplier.” For $35, I told them forget it. Popped off the “junction box” and looked at what I was dealing with. Two nice tabs coming out of the panel with blocking diodes, connected to a PCB with that only had the USB ports and some ICs[/font]

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[font=Roboto, -apple-system, BlinkMacSystemFont,]Disconnected after the diodes, put it in the sun, connected my DMM to the diodes and BAM! 22v DC. Clipped on a couple of leads to a big resistor I have kicking around and got 8.3a in full sun 90 degrees to the panel. WOOT! Wired it up with a 20’ run of 10ga fine strand copper wire soldered to the diodes, wrapped in that expandable nylon wire sheathing, terminated with a SAE connector. Tested in the shade about 7:30 tonight and still got over 18v over the 20’ run of cable [/font]
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[font=Roboto, -apple-system, BlinkMacSystemFont,]I have a weatherproof passthrough SAE socket that will go on the back of the bus by the left tail light to feed into the solar controller. This weekend will install that, mount controller, set up the ammeter, etc. Even is this thing shits the bed in a year, worth it just for the education and I’ll have the groundwork in place for a better panel and controller.[/font]

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[font=Roboto, -apple-system, BlinkMacSystemFont,]Cost:[/font]
[font=Roboto, -apple-system, BlinkMacSystemFont,]Cheap ass panel - $35.99 shipped[/font]
[font=Roboto, -apple-system, BlinkMacSystemFont,]Cheap ass “50a” PWM controller - $12.29[/font]
[font=Roboto, -apple-system, BlinkMacSystemFont,]100’ 10ga fine copper strand wire - $17.48 (used half)[/font]
[font=Roboto, -apple-system, BlinkMacSystemFont,]SAE connectors - $13.79[/font]
[font=Roboto, -apple-system, BlinkMacSystemFont,]50’ nylon 0.5’ expandable sheathing (plus 50’ 0.25 roll for other stuff): $10.49[/font]
[font=Roboto, -apple-system, BlinkMacSystemFont,]Total - $90.04[/font]
[font=Roboto, -apple-system, BlinkMacSystemFont,]Playing around with something new - $ priceless.[/font]
 
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