Bespoke Early Bay Westy

Specifications Sheet (list)
  • Model
    • 1972 Original Volkswagen Westfalia (back dated to full early bay)
    • Bespoke'd (opens in new window = NW)

  • Exterior
    • All bodywork done by Owner
    • NOS, OEM and aftermarket metal used
    • all butt-welded & fiberglassed
    • all seam sealed behind (and painted)
    • 1” front custom tubs with shock tower mini-tubs (towers extended for air suspension)
    • Passenger bulkhead removed and OEM style tubing used to finish
    • Passenger seat swivel adapted
    • Late Bay inspection hatch grafted in, but moved forward 3” for better rear engine access
    • Shaved antenna
    • Late Bay Westy top adapted.
    • Early Bay opening enlarged
    • Lower front mounts fabricated into body
    • Tail light swap to Early Bay style with German metal.  Ultra-bright 4” LED tail/turn/brake setup fabricated behind stock lenses
    • Inspection panel fabricated for gas gauge sender (using stock VW metal)
    • Rear upper 3-point seat belt mounts welded in
    • Replacement metal
      • 75% of the nose (including inner lower panel and lower windshield lip)
      • Drivers side B pillar and main panel (removed OEM Westy openings - plug, vents, etc)
      • Both dog legs and inner front splash panels
      • 25% of front floor pan
      • Rear apron and Battery tray
      • Inner engine Bay (driver side) for AC setup
      • Rear passenger and drivers rockers (front)
      • 5 spots on cargo floor
      • All 4 rear seat belt mounts (2 front and 2 rear)
      • Early Deluxe trim added (but not drilled & clipped on.  Used 3M adhesive instead)
      • Custom trailer hitch fabricated / frenched into rear bumper & supports
    • Paint
      • All Paint done by owner in home double garage.  (1st paint job ever)
      • Colours used: VW Pastel White (L90d) and VW Mango Green (L346)
      • Interior Paint
        • 3 coats of DTM Epoxy Primer – tinted white
        • 2 coats of single stage Pastel White
      • Dash
        • 2 coats of DTM Epoxy Primer – tinted white
        • 2 coats of Mango Green base
        • 2 coats of clear
      • Exterior Paint
        • 3 coats of DTM Epoxy primer - Grey
        • 1 coat of Sealer
        • 3 coats of Pastel White base
        • 3 coats of Mango Green base
        • 5 coats of clear
      • Westy top
        • 2 coats of DTM Epoxy Primer – tinted white
        • 2 coats of Pastel White base
        • 2 coats of clear   
      • Wet sand and Polished
      • Whole body starting at 800 grit, 1000, then 1200 (by hand)
      • 1500 then 3000 using 3M DA pads with foam interference pad
      • Polished / buffed using 3-pad polisher setup / compound, then wax / buff
  • Engine
  • 2056cc Type 4 - Aluminum block (CB Series)
  • Pressed in oil gallies removed, tapped and replaced with stainless hex screws
  • German OEM 71mm crank with standard+1 sized Real German Bearings
  • German OEM rods/bolts with standard+1 sized Real German Bearings; balanced
  • 2L German rods, modified and balanced for better cylinder cooling
  • Porsche 914 2L Cam and solid lifters
  • 96mm hypereutectic pistons (balanced with pin and clips)
  • Cast iron 96mm cylinders
  • Porsche 914 2L Heads
    • real 3 stud with modified plug angle
    • rebuilt with 42mm intake and 36mm exhaust valves
    • high rev bugpack T1 single springs, Chromoly retainers/keepers
    • one breather added per head for engine ventilation
    • heavy duty 10mm valve adjusters
    • solid spacer conversion (not spring spacers)
  • Dual Weber 44mm IDF carbs – rebuilt (W/K&Ns).  Jetted by the late Peter Beltgens.  Vacuum port added for SVDA.
  • Hexbar linkage with additional return springs added per carb and one, dual spring mounted in middle.  Crisp throttle.
  • Heavy Duty Fuel pump on vibration isolating mounts with Holley Fuel Pressure Regulator with Fuel pressure gauge
  • SVDA (Single Vacuum, Dual Advance) distributor with Pertronix, OEM rotor, plug wires, Bosch blue coil
  • Full engine breather setup (crank case, each head, high quality oil breather lines)
  • Full OEM cooling tin and seals.  2L 914 heads required modifying the cylinder head tins to account for the increased plug angle
  • T1 thermostat modified to replace T4 thermostat (runs slightly cooler; opens ~10 degrees sooner)
  • Heavy duty 30mm oil pump (T1) modified to fit T4; Oil pressure gauge mounted on block
  • Oil cooler sandwich plate added to stock cooler with high temp lines and high temp line sleeves
  • 72 row External oil cooler with thermostatically controlled fan and  additional thermostat to bypass oil cooler when cold out
  • End play set at 0.0045”, compression set at 8.1:1 and 20-50w oil used with high zinc additive
  • 100% complete, desirable 72-74 stock exhaust (NOS muffler, OEM VW heat exchangers, control boxes, dumps) 
  • 105AMP alternator adapted to stock mounts.  Single wire, dual-cool setup.  Dual Charge relay used to charge AUX battery.  Twice the stock alternator output!
  • Air Conditioning
    • Custom Coldmasters Inc setup
    • Compressor: SD508 Sanden type 2a groove 12v on custom fabricated, adjustable mount
    • Condenser: Parallel flow 14x20in  (18mm core depth) 4 rails aluminum
    • Condenser Fan: 12" diameter 12 volts 80w 6 amp reversible 4 Mounting Brackets included
    • Evaporator: cm-432-000 12 volts, with mount and drain hose. 32 pass 4 way aluminum coil temp. air flow: dual 3 speed fans, 13,700btu capacity 359 cfm (real)
    • Vents: 4 additional OEM VW Bay window dash vents added and 6' of 2.5" ducting used
    • Expansion valve: fujikoki 1.5 ton
    • Hoses: Parker #6 #8 #10 w/fitting and high pressure hydraulic crimps
    • Filter drier: 2.5 x 7.5 in 3/8 mio x 3/8mio w/ 1/4 cp roi.  w/ pressure switch calsonic oem
    • Belt: 15477 Continental Belt
    • Pulley: Princess Auto 5" weld-on style pulley, Modified to fit T4 hub between fan and hub (OEM spacer removed)
    • Controls mounted in custom centre console
    • Vents: 4 VW Bay Window vents colour-matched to interior

  • Transaxle
    • 091 six-rib conversion (late bay high-geared transaxle)
    • Modified input shaft and shift rod for install in Early Bay
    • 228mm flywheel (machined) and OEM SACHS clutch
    • 100mm x 32mm German CV joints and boots
    • Shortened and welded shift linkage (with new bushings) – modified for 1” raised beam
    • Redline MT-90 GL-4 gear oil

  • Chassis and Suspension
    • Suspension
      • All suspension work done by Owner
      • Air suspension front and rear (Front / Back / Side / Side adjustable 4-valve setup)
        • Front
          • Adjustable 4” narrowed beam with extended shock towers, tubes raised 1” (more suspension travel), running torsion leaves
          • Monroe Air Sleeve Front Suspension - MA803, modified bushings and upgraded fittings to 1/4” lines (come with 1/8” lines)
          • Front upper shock towers extended 2” and welded with gussets and bracing
          • Front lower shock mounts extended 1” and welded with gussets and bracing
          • Lowered spindles w/new ball joints
        • Rear
          • Adjustable Autohaus Spring Plates (from the UK)
          • 3.5" horseshoe drop plates (fully TIG welded with 1/4" plate thickness)
          • Rear CONITECH 2-ply double convoluted 2600 (lbs) air bags - single 1/2" port reduced to 3/8"
          • Additional Monroe Air Sleeve Rear Shocks - MA824
          • Thick steel, custom-made lower air bag brackets (5.5") welded and braced on modified trailing arms,
          • Upper air bag brackets on welded brackets bolted to frame with 8 x 3.5" Grade 8 bolts, Welded brace connects two mounts for structural rigidity
          • Modified rear torsion arm spring perches to allow easier wheel removal (with adjustable spring plates)
        • Air Management
          • Relayed, on-board Viair 350C (Chrome) air compressor on vibration isolators
          • 90PSI on / 120PSI off pressure switch,
          • 3 Gal steel air tank with water trap,
          • Dual check and drain valve on tank and under body with tank gauge mounted in cabin.
          • High pressure paddle type valves,
          • Anodized distribution manifold (1 x 1/2” inlet to 4 x 1/4” outlets)
          • Lines: Front: 1/4" lines; Tank gauge:  1/4"; Rear: 3/8 for 95% -1/4" to valves; Tank to manifold: 1/2”
          • Fittings: PTC (Push to connect), brass and DOT compression fittings used.
          • Two Universal dual needle, back-lit black-faced 2" gauges with chrome rings
    • Chassis and Brakes
      • All chassis work done by Owner
      • Wide5 bolt pattern conversion
      • Late Bay Power Disc brakes (larger) up front with wide5 steel adapters
      • Early Bay wide5 Drum brakes in rear setup (to tuck wider wheels)
      • pressure bled at 4psi with correct DOT4 fluid
      • 1” Front beam raise (extensive fabrication to make this work: shift rod, heater plumbing, etc)
      • 3.5" Monster-Notch welded into rear frame with additional bracing
      • Oil cooler (w/fan), Air Conditioning Filter / Condenser (w/fan) and Air Compressor all mounted above frame rails for suspension clearance
      • Zinc painted and Undercoated
    • Wheels
      • Note: this crossover Bay came with 5x112 wheels and has been converted to 5x205 for the ‘Early look’
      • 5.5" wide Aluminum 15" wheels Sprint Stars Black with Polished spokes (3-1/2” Backspace) –
      • Chrome centre cap and lugs
      • Tires
        • Front: top rated P185/55R15 Yokohama AVID TRZ tires
        • Rear: top rated P185/65R15 Yokohama AVID TRZ tires
  • Interior
  • All work done by Owner with exception of:
  • Sewing the front and rear seat covers
  • Sewing front door, sliding door and kick panels
  • Done by Jordan at ‘Styles’ in Victoria, BC
  • Designed over 2 years.  Interior design also matched to our family for camping.  (Seating / sleeping arrangements)
  • Fully insulated / sound deadened
  • Dash
    • Extensively modified dash
    • Padding removed and holes welded up.
    • North American style dash side vents welded up to match euro-spec dash
    • Radio plate moved up (cut / welded)
    • 3 gauges added
    • Passengers side lower knob section: cut / welded / smoothed
    • 4 additional gauges added: Tach, oil Pressure, oil temp and Cylinder Head Temp (CHT)
    • Painted euro-spec dash
    • Upholstered dash pad and dash top (with speaker holes in stock pattern – widened for additional speakers)
    • Colour-matched defrost vent covers
    • UK chrome trim rings for speedo cluster gauges and dash vents
    • Switched 12v outlet flush-mounted on dash top
  • Cabinets / Flooring
    • Flooring: Commercial-grade Japanese maple laminate on top of 3/8”, foam insulator and sound deadening.  Front carpet is sea grass (Sisal) custom cut and bound with matching vinyl.
    • Cabinets:
    • Ultra-lightweight 1/2” birch plywood used throughout (3/4” birch used for seats / beds)
    • KREGG system used to attach cabinets together
    • Full slide ball-bearing drawers
    • Euro push to lock latches
    • Colour-matched 1/2” T-molding
    • All custom-built cabinets
    • Recessed fire extinguisher – mounted by sliding door
    • Access cabinet to AC & electrical in walk-through
    • Upper switch panel houses over 100 feet of wiring to 12 switches and 10 fuses for the electrical management.  Built to maximize access, indirect lighting, and minimize risk of head banging
  • Seating mode
    • Roughly based on the 1984 Club Joker layout (L-shaped seating)
    • Front seats: PT Cruiser (recline), with arm rests and heated backs and bottoms (2 heat settings)
    • Passenger seat swivels to increase seating when parked / camping
    • Rear seat (/bed):  Top of the line dual layer deluxe foam used for seating (2” extra firm, 1” medium, bonded together)
    • Retractable, colour matched seat belts.  3-way front and rear.  3 point rear seat belts require quite a bit of modifications to install correctly and safely
    • Fully adjustable table of my own design and fabrication.  Table top doubles as top for stove / sink (same size)
  • Sleeping mode
    • Full width bed:widened 2” to 56” (larger than a Double)
    • Rear bed, custom cut/sewn.  Matching vinyl on all sides.  Carpet on bottom for sound deadening and air flow
    • Modified OEM VW Late Bay rock and Roll hinged unit
    • Storage under seats
    • Top of the line dual layer deluxe foam used for seating (2” extra firm, 1” medium, bonded together)
    • Upper bed:48” wide.
    • 4” air mattress (48” x 75”)
    • Tri-folding base folds out of way when not in use
    • Front OEM tan canvas hammock.  Weight tested to 95 lbs
  • Lighting
    • Dual LED adjustable light bars mounted to top of Westy pop top
    • 60” of 5050 LED strip under main switch panel (indirect lighting)
    • 40” of 5050 LED strip under head banger cabinet
    • 5050 LED’s controlled individually, or simultaneously by remote.  Colour changing / flashing/fading all by remote (mounted on left and right side of sliding door)
  • Hidden alarm system
  • Hidden fuel pump cutoff switch
  • Super bright 4” LED tail lights (Brake / Turn and Running)
  • LED backup lights
  • Sink / Stove / Fridge
    • Main sink / stove unit from a T25 Westy. 
    • Fold-down switch activates pump with dual check valves (instant water). 
    • 20 gallon on-board fresh water tank
    • 5 gallon mini refillable propane tank for stove and fridge
    • Fridge: 3-way T25 Westy fridge (late T25 with flame indicator and mini icebox)
  • Heating / Cooling
    • B2 gas heater rebuilt and adapted to work with Dual IDFs on a T4 (no room for a BN4)
    • Custom fabricated heat shield added between heater and IDF Carb.
    • Dual inlet and outlet gas line solenoid safety valves added
    • Remotely wired by dual relays (along with indicator LED)
    • Colour-matched high-output oscillating fan magnetically mounted in rear.  Remotely activated from rear seat / bed
    • Rear screen optional when hatch opened
    • Onboard fire extinguisher
    • Awning / Add-a-room:
    • Full length BusDepot awning (full length of bus), not the standard version.
    • Colour matched to canvas. 
    • All three wall individually removable.