Project Westfakia

[nmshaikh]

NOS BOSCH headlamps were fitted. The bus came with different style headlamps but since I was only interested in making it a reliable family vehicle I settled for the newer style H4 headlamps that really light up the road ahead.

[nmshaikh]

The next step in making of a Westfakia was the addition of a camper top. Westfalias have a couple of different styles of camper tops. The coachbuilder cut the roof of a regular Baywindow bus, reinforced the roof and added a pop top that could be lowered or raised when needed. Two adults can fit nicely in the space. I was not keen at all to chop the roof but still wanted the westfalia look so I had the original fibre glass pop top reproduced locally that sits on the roof. It does nothing more than improve the looks and in the summer keep the temperature inside down a little. The front section can be used to carry luggage like it is intended for ( however I have a feeling it would add to the drag, so maybe not unless absolutely necessary.) The guy who made the replica top did a great job and the top looks identical to the real one on BOB (the Big Orange Bus)

[nmshaikh]

The next important task was to make a working Z-bed. This is a seat that turns in to a bed or a bed that can be used as a seat depending on how you look at it. The main part of this set-up is the hinges that work the seat and back. There is nothing special about the hinges except the precision and good manufacturing so they move freely when transitioning between a bed and seat. I chose to buy the hinges from the US and get the rest made locally. These were trial fitted and tested. Once satisfied they were covered in Westfalia plaid fabric.

Here you see the hinges installed and the seat base fitted. It is lifted to tighten the screws but when it is complete it can be lifted to provide access to the storage space under the seat.

[nmshaikh]

The back is fitted to the hinge here. It looks more like a seat now

[nmshaikh]

the two slots that you see in the previous picture are for the finger hold when pulling the seat forward so it forms a bed.

[usman922]

great going MASHAA ALLAH!!

[AsadIshaque]

Following this thread and lovin every minute of it.......

Pl shed some light as to how the Bosch headlamps differ from what the bus had originally.......the lens seems to be of the early to mid seventies style.......not the variety which has 'H4' embossed on the lens....

[Xulfiqar]

NOS BOSCH headlamps were fitted. The bus came with different style headlamps but since I was only interested in making it a reliable family vehicle I settled for the newer style H4 headlamps that really light up the road ahead.

They seem LHD spec, the whisker is facing the right side of the vehicle.

[nmshaikh]

Following this thread and lovin every minute of it.......

Pl shed some light as to how the Bosch headlamps differ from what the bus had originally.......the lens seems to be of the early to mid seventies style.......not the variety which has 'H4' embossed on the lens....

The early (and the original to the bus) headlamps are the kind that have a reflector un attached to the glass and is adjusted by turned the screws thru the chrome ring..quite like the headlamps on the 71 bug. As the reflector is separate it is in most cases rusted and the quality of light that falls on the road is quite dismal. An option is to get them re-chromed but like most other parts that have been tried to be rechromed they turn up at best dull shiny (as opposed to mirror shiny)

[nmshaikh]

They seem LHD spec, the whisker is facing the right side of the vehicle.

Good observation. They are of the LHD variety but hardly a disadvantage as the secondary requirement on Pakistan roads is to have headlights that are respected by idiot drivers who would not dip their lights for oncoming vehicles unless they are threatened with temporary blindness. Add to the mix the higher level of fitting for these headlamps and these are quite intimidating. I usually drive on dipped lights but whenever I go high beams the offending drivers do notice.

[Xulfiqar]

going mad max are we?

[Xulfiqar]

The early (and the original to the bus) headlamps are the kind that have a reflector un attached to the glass and is adjusted by turned the screws thru the chrome ring..quite like the headlamps on the 71 bug. As the reflector is separate it is in most cases rusted and the quality of light that falls on the road is quite dismal. An option is to get them re-chromed but like most other parts that have been tried to be rechromed they turn up at best dull shiny (as opposed to mirror shiny)

for good chrome - find a place that does "hard chrome" - the cost is about 4 times the cost of normal nickel coating but worth every little paisa spent because it shines for decades like the original items. I have had some odd ball stuff coated like that one was a set of motorcycle fork stanchions that cost me Rs 7000/- in the year 2001 - the stanchions are the front shock legs, I could not find unscratched ones for my bike, the fresh coated and machined items were so incredible quality that even brand new OE stanchions for that bike were cheaper spec.

[nmshaikh]

My Westfakia needed to be tested on a long stretch of road and what better than drive to Lahore and back on the motorway. I was quite confident that the bus would not let me down (it had better not as I was taking my family along). A few days back I had bought a new set of tyres and had gotten all five wheels sanded and painted white so I was safe there as well.

I had the fuel tank cleaned out and coated inside before refitting when the engine was not in place. However i had not filled the tank to the brim. The long journey required a fill up but when the tank filled up there was fuel dripping like crazy from the tank. Upon investigation I found that the fuel was leaking thru the flexible connection between the fuel filler and the neck of the fuel tank. There was no time to get this fixed so I waited till the fuel in the flexible pipe leaked out completely and evaporated before re-starting the engine. As a precaution I carried the fire extinguisher and spare fuel can because i didn't want to refill the tank to the brim again before I get a chance to have it looked it.

After that initial hiccup the bus performed like a star! I noticed that the speedometer does not cross 50 miles (80 km) even when the bus is apparently going faster than that.

[Basharatu]

Nasir bhai, Excellent Restoration, very good color selection, the fabrication done is art work. Westfalia is looking really cool!

The next step in making of a Westfakia was the addition of a camper top. Westfalias have a couple of different styles of camper tops. The coachbuilder cut the roof of a regular Baywindow bus, reinforced the roof and added a pop top that could be lowered or raised when needed. Two adults can fit nicely in the space. I was not keen at all to chop the roof but still wanted the westfalia look so I had the original fibre glass pop top reproduced locally that sits on the roof. It does nothing more than improve the looks and in the summer keep the temperature inside down a little. The front section can be used to carry luggage like it is intended for ( however I have a feeling it would add to the drag, so maybe not unless absolutely necessary.) The guy who made the replica top did a great job and the top looks identical to the real one on BOB (the Big Orange Bus)

The next important task was to make a working Z-bed. This is a seat that turns in to a bed or a bed that can be used as a seat depending on how you look at it. The main part of this set-up is the hinges that work the seat and back. There is nothing special about the hinges except the precision and good manufacturing so they move freely when transitioning between a bed and seat. I chose to buy the hinges from the US and get the rest made locally. These were trial fitted and tested. Once satisfied they were covered in Westfalia plaid fabric.

Here you see the hinges installed and the seat base fitted. It is lifted to tighten the screws but when it is complete it can be lifted to provide access to the storage space under the seat.

the two slots that you see in the previous picture are for the finger hold when pulling the seat forward so it forms a bed.

[nmshaikh]

On the motorway, returning from Lahore.

[nmshaikh]

Nasir bhai, Excellent Restoration, very good color selection, the fabrication done is art work. Westfalia is looking really cool!

Good to hear from you 'Bash' I hope you are enjoying your stay in the US. Text me your number when you get a chance.

Thank you for your comments. The Westfakia behaved nicely on the motorway and even when we were stuck in bumper to bumper traffic for hours at end in Lahore. Now that all the children are in their teens I needed a bigger vehicle. Once i get to doing up the interior we'll have in there Bose speakers, a DVD player and an LCD screen for the passengers. This would be in addition to the regular Westfalia cabinetry. I think I'll add the curtains too for I noticed a lot of nosy people peeping thru the windows when the bus was parked. We need to do a fair amount of work still but at least we have a reliable VW bus! creature comforts would come in due course..

[hamza_xeg]

Awesome restoration bro

[nmshaikh]

Awesome restoration bro

Thank you. Its not done as yet. there is more to come.

[Quattro]

If you dont mind me asking
What do you expect the breakdown of the restoration cost might be
Body/paint
Interior
Engine
Front end
Brakes

I am just curious. Thanks

[usman922]

awesome... lovely bus... loving it!!