I’ve actually had the old VW bus for almost a year now. High time for an update here, what else do I have this blog for!
The short version: I repainted the cargo area floor and learned a lot about painting in the process – conveniently on a component that would be covered up again anyway. I broke a spark plug, which was a truly avoidable and very expensive mistake. And: The bus now has a bed, so my wife, dog, and I could spend the night in it for the first time. I also initiated a T3 regulars’ table in Mainz.
New paint for old sheet metal
The floor panel of the VW bus was scratched from years of use and a bit rusty in some places. Although there was a wooden panel on the floor, because it rested directly on the wood, the wear was apparently still significant. So I researched how to combat rust on vehicles and paint. I came across the “Lackstore” YouTube channel, a German online retailer for paints and painting tools of all kinds. On the channel, professionals explain how to repair paint damage even with simple tools. I was also able to get information there on rust converters, primers, and all the other layers that paint can consist of, right down to the grit of the required sandpaper. The most important tip of all, of course: use a protective mask.
Armed with this information, I sanded down all the areas that didn’t look optimal, and removed any rust underneath. Then rust converter, primer layers, paint, and clear coat – all, of course, with the appropriate waiting times in between. Because it was an interior paint job (an inside job, if you will), I was able to do it outdoors.
To prevent the floor from looking like it did before in a few years, I consulted my trusted hardware store and found “anti-droning tape,” an adhesive tape made of bitumen material specifically designed to absorb vibrations. I glued small strips of it over the raised seams of the floor before putting the floor panel back in place. I must say, I am very happy with the result!
Learning curve, a steep one
Perhaps the most important lesson I’ve learned since buying the Bulli: spark plugs must be tightened very gently, preferably only by hand. In my defense: I even informed myself beforehand about the correct torque for tightening, but then I made a mistake with the decimal point on the torque wrench. The spark plug broke off, a part of it rattled into the cylinder, another part got stuck in the thread, and I had the rest hanging in the torque wrench. At least I knew that I absolutely couldn’t start the car then, so now I also know the towing service of my automobile club. Then the next mistake: the choice of workshop. A VW dealership has no idea how to repair a classic VW and charges almost four times as much for such a repair as a more capable independent workshop. Two recommendations and another tow (this time at my own expensive expense) later, I finally arrived at a workshop that had a specialist for old VWs on staff and, for an acceptable price, not only disassembled the cylinder head and removed the broken plug but also gave me some really helpful tips – especially that I should get replacement cylinder heads because a complete engine overhaul would be due in the foreseeable future. Since the car is almost at 200,000 km on the clock, that’s probably fair.
The total cost of this learning experience was about €2000. As I said – an expensive mistake that would have been truly avoidable. At least I now have a really good workshop up my sleeve for the future. I have also since acquired cylinder heads, a reconditioned used part and a new one. Cost: approx. €1200 in total.
The first question from a fellow regulars’ table member when I told him about my entry into Bulli life was: “Do you have money?” I can understand how he came to that.
Other T3 friends
Speaking of regulars’ table. Through the great Bulliforum, a German VW bus forum, I found a few more crazy people nearby and gathered them for a regular meeting in a little restaurant. So far, there are only three of us, but I’ve already learned a lot there. Apart from that, it’s always nice to be able to exchange ideas with like-minded people.
So much for the current status of the Bulli project! Next up is the heater in the cargo area – it’s leaking coolant, which can, of course, also become problematic for the engine. Fortunately, you can get heat exchangers from third-party manufacturers (VW, unfortunately, doesn’t sell any parts for old cars of their making, unlike Mercedes and BMW), so I ordered one to replace the part. That should solve the problem. Also, a common recommendation in the community is to screw sheets around the radiator that direct more air through it. When these buses were new, cardboard parts took over this function. Those have, of course, dissolved since then, so metal replacements are the way to go. I will, of course, report!