Received an update from the shop. Front inner panel and passenger door are fitted up. Starting to look like a bus again.

Just a quick update. The shop has just taken delivery of the front panels for the bus. We decided to go for an all-in-one front sub-panel instead of separate panels as not only is it assembled on a jig and so should hopefully be nice and square, but it will also save a heap of time compared to assembling the individual panels on the bus.

Building an early replica has been a bit of a challenge in some areas. The Late 50's cars have a pretty good availability for trim and parts as most parts are now remanufactured. The early cars however have a number of differences from those late parts which means that in many cases, to be correct the late parts cannot be used. One such case is the Porsche scripts.

The trip to this years Speedweek actually started seven years ago back in 2009; the first time that I visited Lake Gairdner. Myself and a mate had tried to get out there a few years before in 2007, but rain and bad track conditions had meant that the event was cancelled in both 2007 and 2008. In 2009 we rented a cottage in Kimba and commuted the 2 hours or so out to the lake every day. From the first moment on the lake I was hooked, it's completely inspiring to be there, stuck in the middle of nowhere, in one of the most surreal places you'll ever visit. Real grass roots stuff, not a corporate cash cow, but blokes like you and me, making stuff in their sheds that they drag from wherever on a journey that includes two or three hours over unsealed roads. Even as a spectator the commitment required to get there is immense.

Its been a quiet couple of months, the oval went onto the back burner whilst we led up to the xmas break - its a really busy time for me at work and with the bit of time that i did get off over the xmas break I found myself building a pond int he back garden. Not that I'm complaining as the garden was missing a little tranquility, the pond provides a great place to sit and contemplate whilst having a cuppa...

The 1600 single port build that I have been working on is using a Mikuni carburetor. These are normally found on Harley Davidsons and are fitted with filter covers. Whilst there's a lot of different bling style jewelry air filter cover available (Harley owners generally seem to be some of the worst for bling) this was no good for the 1600S/P build. What I really wanted was a nice velocity stack to finish things off. 

If you read my last post - 'Hydraulic clutch slave' which was about fitting a hydraulic clutch to a Porsche 915 gearbox you might have thought that it was a good solution to an otherwise difficult issue to solve. Well that is what I thought until I tried to fit everything together. What I actually found was that the slave cylinder that I used was too long and meant that it fouled on the clutch assembly when the engine was installed in the gearbox. With limited time to buy and fit another shorter unit I decided to look at converting the old pull style 915 clutch release to a traditional push style.

The one part of the oval project that has given me the the most challenges is the 915 gearbox conversion. Most people that opt to go down the Porsche 5 speed route use the much easier to fit 901 gearbox from the Porsche 914 / 912. Whilst not as strong as the later 915 box it shares the VW mountings, uses a cable pull style clutch and is much simpler to install. I opted to go with the 915 as the 901 was not suitable for the power of the big Type 4 that I had planned to hook up to it, plus I did not like the dogleg shift pattern of the 901.

I recently attended a local SATA meeting. The SATA (or South Australian Timing Association as they are also known) are a small group of racers who have got together to promote and create South Australian land speed racing events. They have successfully held a few test and tune days both at Tailem Bend and at Waikerie Airstrip and have planned another next month. The next Test and Tune event is on November 8th at Waikerie. Only three weeks away.

Whilst there is absolutely no way that I will get the engine finished in time, there is a chance that I could get the car finished and install another engine in it. at least this would allow me to do a shakedown and make sure that the gearbox is working properly.

Whilst we were making the pop top we did take the time to make up some patterns for the front seats and cut out the material but that was as far as we got. Having not done any form of upholstery before trying to figure out the best way of doing things was pretty hard. Google is pretty good, but even after finding some good videos online there were some details that they just glossed over. In the end the covers just got left and no more was done.

Speedweek 2016 is at the end of February which is not really too far away. Whilst there's not too much to do on the Oval there's still heaps when I take into account how little time I actually get to concentrate on one project. In addition to Speedweek it looks like the SATA are putting together a speed trial at Waikerie. This will be open to SATA members and SATA / SCTA compatible cars and bikes. This is great news and is exactly what I was hoping for except that the meet is to be held on November 18th which leaves just a shade over a month to get everything together. Now of course I'm not going to kid myself that I can make it happen, but if I put another engine in that I happen to have already built and laying around the garage I recon I might be in with a chance of at least doing some shakedown testing on the car itself.

During the school holidays I wanted to get something achieved on the bus, so I decided to tackle the broken engine lid hinge mounts. Took a little longer than I had expected but it came up not too bad. 

A few pics showing the damage and areas in need of repair...

If you follow my blog or have read my previous article DIY Safari frames you're probably aware that I have been trying to roll a curve in aluminium extrusion so that I can make up my own rear safari window for the Lowlight. 

Last week the fruits of my labor ended up splitting the aluminium but after doing some pondering this week I realised that the extruded profile was not being supported correctly. The dies that I had made left the edge of the aluminium un-supported which resulted in the profile splitting.

There's a bit of a rust issue with the tailgate on the lowlight which is also causing a bit of a leak and water to get into the bus. The rust is on the bottom of the window under the window rubber so to repair it the rear glass will need to come out. Whilst pondering the best way to fix it I had a great idea - why not replace the rear window with an opening 'safari' window. This way I could make the repair to the rust at my leisure rather than having to get it done in a hurry.

Its been a fair while since I've had the time to sit down and put a progress report together, in fact the last post I made was back in January. This is mostly due to being flat out working on the car getting it ready for Speedweek. Well Speedweek has come and gone and despite putting in the hard yards in I did not get to compete. I had set myself the goal of getting everything together with engine in and running by no later than the end of February. I figured that this way I would still be able to do some tuning and get out to the lake with a relatively good chance of making it through the week with no major dramas. Unfortunately,  I did not get it together by the deadline. I was very close and could have pushed to get it done but this was the exact situation I sought to avoid when I set myself the February deadline. There's nothing like a rushed build to promote silly mistakes and expensive failures.

A little while ago I repaired the damaged part of the dash for the wiper switch on my '63 Bus.

Overall very happy with the end result, still needs a bit of work but its no problems.

I will let the pics do the talking!

I've been pretty busy over the past few weeks trying to get the shell and running gear finished so that I can make a start on building the engine. The body is pretty straight and only needs a few small patches welded in but having cut out the rear floor (for a variety of reasons) I needed to make up some interior panelling. After some deliberation I decided to go with aluminium panelling simply as it is easier to work with and requires no finishing. I had originally wanted to make the panelling and door trims out of reclaimed corrugated fence panels - the stuff you would typically see on a 100 year old Aussie property - just like the stuff I replaced on my house a few years back and retained for exactly this purpose but decided that the time that it would take to iron out the corrugations was time I did not have so aluminium won the day.

With Christmas out of the way I managed to sneak out in the garage and spend a day finishing off the window surrounds and moon disk fitment.

Progress over the past week has been a little slower than I had hoped. I've still managed to get stuff done but work has been massively busy so by the time I get home I've not felt up to much. But whilst my actual progress might not have been as good as I would have liked the ordered parts have been arriving at a steady rate, its almost like Christmas has come early

After last weekends progress and also receiving my 74mm DPR crank in the post this week I was amped to get back out into the man cave and spend a little more spanner time on the oval. The DPR crank is an awesome bit of work. It's a stock 36hp crank that is welded and offset ground to give the extra stroke. It also has counterweights added and is heat treated to stress relieve the crank after the welding process. The end result is a very affordable 74mm crank.

A short time ago I posted about changing direction with the oval and entering into the K36 class of the 36hp challenge with a blown 36hp engine. Since that time I've been carefully planning the build and collecting the necessary parts.

After recently going to look at a 356 coupe with the intention of buying it only to find out when I arrived at the sellers house that he had changed his mind I had a bit of a case of the 356 blues. I'd first seen this car about a year ago and passed it up. It was a RHD 'B' model missing its engine and fitted with VW front axles and gearbox, it also needed a fair amount of surgery to get it back to spec again - a perfect candidate for an outlaw build. Whilst the car was perfect at that time the price was not and so I decided to pass. Well that day had niggled at me for the past year and coupled with a change in financial circumstances I decided that I would go to buy the car only to find out that he had changed his mind. Ahh well. I guess it was not to be.

In my lasts blog post Slamfest Part 1 me and the Jimp had stripped down a bay beam and prepped a design for some new side plates ready to cut them out on my CNC plasma. Cutting out the plates was a slow affair as the cutting speed for the 10mm steel plate had to be set at about 300mm per minute, any faster and the quality of the cut suffered. The design was based on a 5 degree castor with the shock tower location moved upwards and backwards to allow for use of the stock shock.

Made a start on building a narrowed beam tonight. Plan is to build two beams - one for my bus and one for The Jimps.

A chance meeting has netted me with a bunch of 36 horse parts. I popped out to buy a number plate bracket for the Type 34 and ended up coming home with a bunch of 36 horse stuff. This has nudged me to change direction with my plans for speed week and look to build a 36hp power plant instead of the planned 50 horse - literally a change in heart. Having been an avid follower and support of the 36 Horsepower Challenge for a number of years its probably fitting that I enter at least once. So with a selection of 36HP parts now at my disposal it has given me a chance to take a look at whats possible with these early engines.

It's been a while since I did anything on the Oval. It's pretty much been left abandoned in the garage and used as a bit of a storage shed. I think that this is a necessary step in any restoration project, or at least thats what it seems like as all mine end up this way at one time or other. 

So after sitting for the past few years its time that the oval project was revisited once again - mostly as I've decided that I'm going to race at speed week next year.

Hi all, im a bit new to this so bare with me and be gentle.. here goes

Im in the middle of fitting electric windows to my T5 transporter which were kindly donated from a mk4 golf, so far ive managed to get each window working independently from two separate switches (one each door) but im pulling my hair out trying to fit a third switch to the drivers door to operate the passengers window, don't get me wrong im no idot but seam to be having one hell of a blonde moment and cant figure the wiring for the life of me. Heres a run down of what ive done so far...

Two relays one for up one for down

terminals 30 live out to motor for up and same on the other relay for down

Been getting a bit distracted by cyclops lights recently. Not that the bus is anywhere near ready for trinkets, still plenty of metalwork to do before its time to add jewellery. So completely sidetracked I decided to scratch that particular itch and have a go at making a cyclops light myself. My reasoning was that it would be good metal shaping practice, plus I had kinda figured out how to make it in my head and wanted to see if I could actually do it.

So, for nearly five years the lovely Lulabelle has been trundling round the festival circuit serving tea, cake and smiles... She is in desperate need of a 1200 gearbox that is compatible with reduction gears....I've had one on order for weeks and they've just rung to say they can't get one...

Can anyone help us? She's been struggling along but I know the original is on it's last legs and probably won't last very much longer...

If you know of anyone that might have one or could source one for us it would be so much appreciated...

Well its been a while since I added to this so here goes-

After getting the panel back from the blasters we continued  the work,now on the rotisserie..All pre 59 or so buses use an open long shift rod that is only supported at the front by a metal spring open to the elements so I decided to change the set up to the later style enclosed shift tube so the rod is supported by 2 plastic bushes.This was a hell of a lot of work as the hole in each I beam and the front and rear tophats had to be enlarged and the rigid tube bashed in.Before the shift rod was installed for the last time I filled the rod itself with grease,this acts as a vibration dampener and gives the gear shift a more solid feel.

This weekend I decided to finish off the plasma table so that I can get cracking on the supercharger kits. The plasma has been pretty much finished for the past few weeks but has been on hold waiting for some smaller nozzles. The previous tests that I carried out resulted in a lot of dross and a larger then normal kerf which I put down to the 60amp nozzle that I had fitted. I ordered some 40 amp nozzles which arrived late last week.

With the long Easter weekend I managed to get a few extra hours in on the bus. Having already cut off the front panel and one dogleg, and made up an A-Pillar repair I decided to carry on with the front end and take a look at the dented front panel.

The front nose, like pretty much every other panel on the bus has suffered a bit of abuse and has taken a bit of a pounding. Not only is there current crash damage, but there are also some previous repairs that have rusted out and need to be repaired.

Spent some time today making up the repair panels for the bottom of the passenger side A pillar. Fortunately there was enough of the original left for me to take some measurements from. The repair panels are in three sections - two sections form the a pillar itself and another makes the bracket that attaches to the inner lower nose panel.

Managed to get out and do a bit more work on the bus today, decided to carry on sorting out the lower nose inner panel. The panel that I acquired unfortunately turned out to be for a left hand drive bus, which meant that to get it to fit I needed to swap over the mounting brackets. The reason for this is that the two chassis rails that it attaches to are not identical and so have slightly different profiles, this means that the mounting brackets are also slightly different.

With the cab floor on the '55 looking like it needs replacing I decided to see if I could avoid having to buy a full repair panel by using the floor from a front cut that I have stored for my 15 window project. I have the front cut to provide a dashboard and chassis member to convert the 15 to right hand drive but for some reason the cab floor is nearly perfect. Not what you would really expect on a bus that ended up getting chopped up. Unfortunately whoever chopped the floor section out did not really do a very good job, not only did they gas axe an inch off of the floor on every side, but they also managed to cut straight through the chassis member that I need for the RHD conversion. Phah.

So I decided to dig the floor section out from the back of the 15 and take a look.

Those of you who know me will also know that I sell supercharger kits under the moniker 'Joe Blow'. A while back I decided that to promote the kits I would put together a logo'd rat panel van - with nice Joe Blow powered motor. Orignally I was after a lowlight panel but somehow ended up with a '55 panel instead. So today I decided to start work on eliminating the tin worm. I recently cleared a load of projects from my schedule and so figuring the bus wasn't going to fix itself I decided to get stuck in.

Since building the engine and adding the supercharger the lowlight has been pretty reliable. There were some initial gremlins to overcome such as the vastly underpowered generator, but since swapping it out for an alternator things have been fine. Fine that is until the other day.

We had just stopped off at Hungry Jacks (or Burger King as us Poms call it) to grab some well deserved mango smoothies after a day out at the beach, the bus did not want to fire straight up, which I put down to the very hot weather but I managed to get it started and drove off back to home. We managed to get about 200 yards down the road when the bus just stopped.

So, my pan halves rocked up the other day, I was over the moon. I spent a couple of hours outside so that was great. Was cleaning up the tunnel a bit more and then I got a little carried away on the body.

I figured I best bring the Vdubber community up to speed with my current build.

A couple of months ago I came into the possession of Gretl. She was to be a ground up restoration and at the time of purchase, I race car on the weekends. Since then I have changed my mind.

G'day everyone,

My dad and I spotted a VW bug mostly covered over on a trailer coming home from Melbourne today. The guys who were towing the bug stopped for fuel so we stopped and I had a look and had a chat to the owner. He told me it was a 1978 VW "Champagne Edition" Karmann Cabrio. It was a very, very tidy car. Here is a pic I took of the bug...

It's been absolutely ages since I did anything for my VW's. I've been pretty busy developing the supercharger kits but have done nothing on any of my resto projects.

Inspired by the Peter Tommasini sheet metal forming course held in the Adelaide Hills that I recently attended I decided that it was long overdue to do something towards making progress on one of the projects. One thing that I have been doing since the course was sourcing some more tools. I've mostly already got everything that I need but am missing a good blocking hammer and a few other odds and ends. One thing that I have been meaning to make for a long time is some of these butt welding clamps.

G'day everyone,

We finished lowering our '70 type 3 Notch yesterday. The front has been lowered 2 splines and the rear has been lowered 1 spline.

It has been a great learning journey working on our 1970 Type 3 Notchback. We now have it Road Worthy ready for my dad and I to cruise around in, and also ready for when I get my Learners.

So. Spent today fitting the engine into the bus. Had a bunch of shits and bits to fix up like fixing up my dizzy, rewiring for the alternator, fitting a new exhaust, adding the electric fuel pump, running new fuel lines, cleaning red dust from everything. In fact it took most of the day just getting everything to the stage where I could fit the engine.

Hi all,as some of you know, I've been flat out doing a 57 panel patina monster for the last 18 months so I figure its time to share the highs and lows.So here goes..

The bus is a 1957 Dove Blue panel that was advertised on DSK in July 2011.It looked good,the usual rust,but for me it ticked the major box,ORIGINAL PAINT!! Turns out that the guy who was selling it had bought it from the first owner,he'd done nothing with it except drag it home so I like to think I'm the second owner or at least the second driver.

G'day everyone,

My family and I recently purchased two Type 3 Notchbacks, a 1968 and a 1970. They arrived by truck on the 4th of December.

If you are into Type 34 Karmann Ghia's, chances are that at some point you would have come across the name Mick Percy. If the name sounds familiar to you it's probably because you have spent some time over at Type34.com or as it's more commonly known The Type 34 Registry where Mick has been the resident webmaster for the past ten years. You might also know him from right here on VDubber.

The build of Mick's '65 Sunroof Type 34 spans some 18 years, two continents and several changes in direction.

Here's Mick to tell you a little more ...

If you've been following the build of the Ghia you may recall that I previously blogged about narrowing the IRS arms to help fix a tyre clearance issue that I have with the Ghia. Well having sourced another set of IRS A-arms some time back, this weekend I finally set about getting started.

One thing that really struck home on our recent interstate jaunt to ReVolks was how damn slow the bus is. I have often joked that when I toured around Europe (also in a 1600 bay window) you would have to go flat out down the hills just to be able make it up the next one. Well somehow the reality of driving a 1600 bus over very long distances  had managed to become little more than anecdotal humour. This is a bit of a shame, as had I remembered how painfully slow driving a1600 bus was I might have opted to build something a little larger. After all, as our cousins in the good ole yew ess of aye say... 'there's no substitute for cubic capacity', or is there? Faced with the reality of having to build another bigger engine I opted to take the easy way out. Forced induction!

It'd been a good many years since I've camped in a bus so I'd really been looking forward to ReVolks. For the non-Aussies here ReVolks is a VW show held in Geelong in Victoria - Some 700k's away from where we are in Adelaide. The mad rush to get the lowlight finished in such a short period of time was mostly so that we could take a bit of a holiday and take in the ReVolks show at the same time.

With the ReVolks trip looming and the interior in the bus it' time to get things finished off and start packing for the road trip. Everything at floor level is pretty much done, carpet is in, rock and roll seat is in, rear cargo area is carpeted, in fact the only things that havent been done are up in the roof.

The bus has been pretty good over the past week or so, it starts up on the button and apart from a little bit of a flat spot when cold is running pretty good. I readjusted the choke by aligning the (rather small) mark on the choke element housing with the mark on the carburettor, this has made a massive difference but there is still a bit of hesitation when pulling away. This disappears when warm so I'm guessing that I've still got a little tweaking to do.

Since getting the bus roadworthy I've spent the past week and a half cruising to work in it which has been pretty cool. It's great to have a veedub as a daily driver again and even cooler for it to be a bus. It's also given me a chance to iron out a few bugs and make a list of stuff that needs to be looked at.

One of the the things that found its way to pretty much the top of the list was a leaky fuel tank. Ironically when I was originally fitting the engine I looked at the bottom of the firewall tin and noticed that the foam seal looked a bit 'melted', I even thought to myself 'I bet that's due to a leaky fuel tank'. Well, guess what, I knew it! the darn thing leaks. Fortunately Volksfactory once again helped me out from their stash of stuff and provided me with a nice early style fuel tank (early bay tanks have a bolt in style fuel sender unit). I also picked up a few other bits and bobs as well, including a passenger window.