T2
Dirty overalls, smeary hands, and oil traces on the face. Here in the workshop, grinding, screwing, and assembling are taking place. Mike and Micha have set themselves a goal: The restoration of a 1976 VW Bus T2.
Micha
The desire to restore an old car had indeed been with me for a long time. The idea of reviving such a vehicle, carrying its own history, fascinated me. However, I lacked the financial means and the appropriate infrastructure for it. In a conversation with my friend Mike, I found out that we both dreamt of such a project. So, we began the search for a suitable vintage car. Right from the start, we were thinking of a VW Bus. The cute 'Hippie vans' are trendy, spare parts are excellent, and the internet is full of offers. Unfortunately, most of them are offered at massively overpriced rates. It took us several weeks to find a suitable offer. Just one week after the inspection, we could proudly call ourselves owners of a VW T2. However, there is still a lot, a lot of work to be done before the Bulli shines in new glory.
I completed my apprenticeship as an automotive mechatronics technician specializing in commercial vehicles. Therefore, craftsmanship is not unfamiliar to me, and I bring a lot of knowledge to this project. However, working on an old vehicle is something new for me. The most challenging aspect for me was deciding how certain things should be realized. Revising the engine itself posed a challenge, but we could consult specialized literature and the internet for clear guidelines. When it came to wiring and interior construction, it became more difficult. I found it challenging to find the optimal solution to a problem. It was also disheartening to realize, after completing the work, that the problem could have been solved much more easily
It was partially frustrating. Quite often, things didn't go as planned. It was common for us to leave at the end of the day without a clear understanding of what we had actually accomplished. We underestimated the aspect of time. Many tasks took longer than expected, and a lot of things didn't work out the way we wanted to. For instance, when assembling the individual engine components, we discovered that metal shavings had accumulated inside the engine block, and the bearing shells were worn. Consequently, we had to order additional parts and further disassemble the engine. In the end, it's all about patience. It's also crucial to learn from such setbacks instead of being hard on oneself. With the next engine we revise, we'll definitely start by completely disassembling the engine into its individual parts from the beginning, rather than taking shortcuts.
However, there were also moments of success, and the engine serves again as a good example. Every screw was loosened, many parts were replaced, seals were renewed, adjustments were made, and then came the moment of truth. After a few turns with the starter to circulate the oil, we connected the ignition. The first attempt to start resulted in initial sputtering, followed by some smoke from the exhaust, and finally, the engine roared to life, purring like it did on the first day! This definitely made our hearts race. The same sense of accomplishment accompanied us during the interior construction. With each additional step, the bus took on more and more shape. A self-installed radio, an LED lighting system, a practical folding bench, and a beautiful ceiling are just a few examples of many successful achievements.
The bus was handed over to us as a project vehicle, so all interior components – engine, transmission, bench seat, wiring harnesses, instruments, and covers – were dismantled and stored in crates. Consequently, we could quickly focus on the body. We had to replace some sheet metal parts, rework welding seams, and, above all, do a lot of sanding. Almost the entire first year of our project was spent bringing the body into an acceptable condition. The old paint had to be sanded, some dents knocked out, and repaired with filler. After searching for the right color for a long time, we handed our bus over to the painter.
In the meantime, we dedicated ourselves to the engine. Before we could order new parts, the engine had to be disassembled into its individual parts and cleaned. After obtaining the new components, it was time for assembly, sealing, and adjustment. When the bus came back from painting, we sealed the underbody with spray kit to provide optimal protection against stone chips. After that, we focused on checking the functionality of old interior components and replacing defective materials. Gradually, lights were installed, the engine and transmission were placed, the gearbox was assembled and adjusted. The entire braking system had to be overhauled, and wiring harnesses were pulled. In summary, it all sounds very self-explanatory and straightforward. However, until each component found its place and was properly adjusted, it took a lot of time and patience.
Our bus is a second-generation VW Transporter. It was built in 1976 and served as a fire truck in Germany. Below the rear, there is a 4-cylinder boxer engine with a displacement of 1.6 liters, producing a modest 50 horsepower, along with a 4-speed manual transmission.
After all the necessary components were installed, we were able to embark on a test drive. The bus was roadworthy, although the interior was still empty. It was time to tackle the interior. We had already made plans on how we wanted to design the interior of the Bulli. It was intended to become a camper—a livable vehicle with a bench that could be transformed into a bed. Equipped with cabinets, a cooler, dimmable LED lights, and charging ports for smartphones. However, we didn't want a permanently installed kitchen, shower, or toilet, as we considered the space too valuable for that. More and more additional cables were pulled into the vehicle body, switches connected, wood cut and painted or oiled, custom-cut carpets, insulation material applied, and sketches made for further work.