VW Bus Fog Lights

Over the past few weeks, I've been looking for a set of amber fog lights for the bus. Some were just not the right size/shape, and others just way too expensive. I finally found a pair that I liked, so I started the project by heading out to the marine hardware store to pick up some wire, ends and a nice little fuse block. I ran a new 6 GA wire from the battery up to the front and mounted the fuse block under the dash. I created a new switch panel from some scrap steel and painted it the bus color. I also added switches for the fuel pump, new electric defroster and also the fog lights. I ran a Bosch relay for the fog lights, so it required two separate feeds from the new fuse block; one for the switch and one for the heavier load for the relay/fog lights. I also picked up some glow-in-the-dark labels for the new panel too.

VW Bus Tent

 

I made some modifications to the frame of the side tent for the VW bus, because the original design was just too big at 8 foot wide. I decided to scale it back to a more stock size of about 6 1/2 feet wide. So after cutting the pole again, I laid out the Sunbrella material and started sewing it up. Some tassels and a bit of parachute cord, and then I had it all done.

Now I needed to make a duffle bag to store and transport the tent in, so I found this very big top-loading duffle bag and used beeswax to water-proof it. First, you melt the wax and then brush it on the material. Once it is covered with wax, you melt it into the material with the heat gun. It really works well!

Ready for the Summer!

 

Now I am ready for a little bit of summer bus fun! I have the interior ready with my lantern, beach bag & tunes (even got a hidden Bluetooth speaker in my candle on the table). I started creating a side canopy too. I have the frame, and the material is stitched up, I just need to make the final pieces after I determine what size I want it to be.

Bus Brakes

The bus brakes were recently rebuilt, but they didn't work well. What would you expect from 55 year old manual drum brakes. I cut the front drums at the machine shop, and basically replaced all the shoes and rear drums. Thinking I had everything adjusted, I took the bus to the Hot Rods and Harleys show in Rahway exactly one year after I purchased the bus. I got there just fine, but lost the brakes on the way home, and ran through two red lights. The master cylinder was shot.

I purchased a new front disc brake conversion kit, and after the install I have awesome stopping power now (for a VW bus that is).

VW Bus Radio

 The radio was gone when I got the bus, and someone had opened up the dash a bit for a newer unit. I bought a radio delete plate, but could not install it correctly because the new hole was too big. I decided to flip the plate over and install it on the front, (it looks better than an ugly hole) and then create a new iPad dash holder from some scrap metal I had hanging around. This just hangs on to the dash vents, so you can remove it without any tools, and the iPad's magnet likes to cling to it nicely. I found a cool app for navigation and tunes, and now I have modern dash that isn't a permanent modification.

Vintage Weather Station

The bus came with this vintage Airguide thermometer and humidity gauge in the door panel, but I did not want to put it back there once I made new panels. I thought that I could make a gauge pod for it, and then add magnets to the back so that I could move it around. I found an old tin can, drilled some vent holes in it, JB welded the magnet to the back and painted it the interior pearl white. It currently lives above the passenger visor area, and works great.

VW Bus Curtains

I needed to make curtain rods for the bus, because there was no way I was paying the prices people were asking for original ones. I found a photo of one, and then used that to make a template/buck so that I could bend up some aluminum flat bars. Other than burning my hands a bit, I was pretty pleased. Remember kids, just because it isn't red anymore, doesn't' man it isn't still hot.

I also bought a new Singer sewing machine and re-learned how to sew. I hadn't touched one since 8th grade... and was like "what is a bobbin or a presser foot". It didn't take too long to make some curtains for the new rods, and some ties to hold them back.

One-Eyed Duck

Got the one-eyed duck installed with new wiper arms and blades with the new safari wiper shaft disconnectors so that I can open the windows.

VW Bus Dining Table

The dining table came with the bus, but I needed to c lean it up, restore the hardware, and figure out how to mount it to the wall. The hinges were the easy part, and with the help of Mr. King and his new saw, we ripped a nice piece of poplar for the mounting flange, gave it some round-over/router work, sanded it and then a couple coats of poly. I spent most of today fabricating a little bracket our of some scrap metal to clip the table to the wall when it is folded down.

Jalousie Windows

The side jalousie windows needed some attention, and a few replacement pieces of glass. Unfortunately, the glass is a special order item, and not easily obtained. My local glass guy screwed up the order twice, and I am still waiting on the last 4 pieces for the final window. As for the rest of the materials, I followed some good instructions on this YouTube video here

and then bought the weather-stripping from Vintage Trailer Gaskets. I realized after I received the box that I over-ordered ( I bought FEET when I need Inches), but they graciously let me return what I didn't need.

I also couldn't find the original screens, so I built my own with Home Depot parts.