Milly the 1979 Westfalia Berlin Deluxe Bay Window Camper Van

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My daughter loves the rust bus:-

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Got my new seat, very good quality, I need to modify it now so it fits.



Got my new Genuine German Bosch Coil today.

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Called in to see Tudor today. He's got all of my bits ready for the final clean, its surprising how clean everything is looking. Most of the parts could be passed off for new.
I think he's starting the build tonight, after Mike has fly cut the heads & put the new guides in, at the same time he's putting new studs in:-

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Yesterday I drove a lovely Bay window double cab pick up down to Carmarthen town centre to help promote the Volksfest Wales show first weekend in August, we had a fantastic response & the weather stayed dry.

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Called in to See Tudor Morgan today to drop off my pick up pipe, you can see its much longer than the old one-



This is the baffle plate that is usually missing from type 4 engines:-



This side of the case is now all ready to go, just needs a last clean:-



Tudor noticed this crack in 1 of the cylinders so its scrap & he'll use a different one.:-



Tudor has been busy on the engine all weekend, it turns out the Porsche case has been previously machined for oversize bearings & he has bought standard size bearings to suit the crank. He's decided to use the 412 case instead, so its a bit of a set back, the pick up pipe set him back as well so did the cracked cylinder. Its a good job he's checking everything so thoroughly. Its much better to find it now than latter.
The heads are ready so are the cylinders & pistons & they look really good.

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Tudor wasn't happy with my intake pipe seals, the rubber inside is starting to perish & could pull in air, I bought a 300mm long 35mm id silicone hose spec:-
Max Working Pressure 5 Bar (70psi)
Hose Temp range -50°C(-58°F) to 170°C(338°F)
Wall Thickness 4.5mm
Construction 4 Ply Polyester Silicone.

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The case is now ready for its final clean & then reassembly:-

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We have a visitor for the next week, its a very early bay prototype lol.
It's a genuine 42K miles 21 window Samba:-



I'm wiring in an electric hook up & a leisure battery. I'm also going to check over the wiring, the front fog lights don't work, neither do the brake lights. I'm also fitting an alternator instead of the dynamo. Come the winter Tudor will be rebuilding the engine. Its still got the original engine & its never been rebuilt. It still runs nice but Jonathan wants to make sure it is good for years to come.

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Tudor Morgan has now had some success with the engine & everything is now going to plan, things are moving on now. Crank all built up with gears, mains and new big ends, conrods free falling correctly.
Crank shaft and cam shaft (with new bearings) fitted to lower half of
case.
Cases sealed both sides and brought together, fitted with windage plate and all bolts torqued to the spec.
Its now just fit the barrels & pistons, the heads, ancillaries & tinware.
I can see light at the end of the tunnel.

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This is my drive before we left for Dubs at the castle:-

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Bought myself a centre seat from Bluebird Customs. It will need some modification as I only have one bulkhead but I'm sure I can work something out.



More pictures of our weekend at Dubs at the Castle:-

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