South Hill Customs

Custom Stickers

noreply@blogger.com (Joe Masperi) — Mon, 16 Jan 2023 04:43:00 +0000

I recently got acquainted with a digital artist who created some renderings of Wilson the '67 VW bus for T-shirts and stickers, and then got a few stickers made up for the kids at the cruise nights and car shows from Sticker Mule.

VW Bus Fog Lights

noreply@blogger.com (Joe Masperi) — Sun, 13 Nov 2022 13:05:00 +0000

Over the past few weeks, I've been looking for a set of amber fog lights for the bus. Some were just not the right size/shape, and others just way too expensive. I finally found a pair that I liked, so I started the project by heading out to the marine hardware store to pick up some wire, ends and a nice little fuse block. I ran a new 6 GA wire from the battery up to the front and mounted the fuse block under the dash. I created a new switch panel from some scrap steel and painted it the bus color. I also added switches for the fuel pump, new electric defroster and also the fog lights. I ran a Bosch relay for the fog lights, so it required two separate feeds from the new fuse block; one for the switch and one for the heavier load for the relay/fog lights. I also picked up some glow-in-the-dark labels for the new panel too.

VW Bus Tent

noreply@blogger.com (Joe Masperi) — Mon, 19 Sep 2022 11:32:00 +0000

I made some modifications to the frame of the side tent for the VW bus, because the original design was just too big at 8 foot wide. I decided to scale it back to a more stock size of about 6 1/2 feet wide. So after cutting the pole again, I laid out the Sunbrella material and started sewing it up. Some tassels and a bit of parachute cord, and then I had it all done.

Now I needed to make a duffle bag to store and transport the tent in, so I found this very big top-loading duffle bag and used beeswax to water-proof it. First, you melt the wax and then brush it on the material. Once it is covered with wax, you melt it into the material with the heat gun. It really works well!

Ready for the Summer!

noreply@blogger.com (Joe Masperi) — Sun, 17 Jul 2022 21:27:00 +0000

Now I am ready for a little bit of summer bus fun! I have the interior ready with my lantern, beach bag & tunes (even got a hidden Bluetooth speaker in my candle on the table). I started creating a side canopy too. I have the frame, and the material is stitched up, I just need to make the final pieces after I determine what size I want it to be.

Bus Brakes

noreply@blogger.com (Joe Masperi) — Sat, 16 Jul 2022 21:25:00 +0000

The bus brakes were recently rebuilt, but they didn't work well. What would you expect from 55 year old manual drum brakes. I cut the front drums at the machine shop, and basically replaced all the shoes and rear drums. Thinking I had everything adjusted, I took the bus to the Hot Rods and Harleys show in Rahway exactly one year after I purchased the bus. I got there just fine, but lost the brakes on the way home, and ran through two red lights. The master cylinder was shot.

I purchased a new front disc brake conversion kit, and after the install I have awesome stopping power now (for a VW bus that is).

VW Bus Radio

noreply@blogger.com (Joe Masperi) — Sat, 16 Jul 2022 21:16:00 +0000

The radio was gone when I got the bus, and someone had opened up the dash a bit for a newer unit. I bought a radio delete plate, but could not install it correctly because the new hole was too big. I decided to flip the plate over and install it on the front, (it looks better than an ugly hole) and then create a new iPad dash holder from some scrap metal I had hanging around. This just hangs on to the dash vents, so you can remove it without any tools, and the iPad's magnet likes to cling to it nicely. I found a cool app for navigation and tunes, and now I have modern dash that isn't a permanent modification.

Vintage Weather Station

noreply@blogger.com (Joe Masperi) — Sat, 16 Jul 2022 21:11:00 +0000

The bus came with this vintage Airguide thermometer and humidity gauge in the door panel, but I did not want to put it back there once I made new panels. I thought that I could make a gauge pod for it, and then add magnets to the back so that I could move it around. I found an old tin can, drilled some vent holes in it, JB welded the magnet to the back and painted it the interior pearl white. It currently lives above the passenger visor area, and works great.

VW Bus Curtains

noreply@blogger.com (Joe Masperi) — Sat, 16 Jul 2022 21:04:00 +0000

I needed to make curtain rods for the bus, because there was no way I was paying the prices people were asking for original ones. I found a photo of one, and then used that to make a template/buck so that I could bend up some aluminum flat bars. Other than burning my hands a bit, I was pretty pleased. Remember kids, just because it isn't red anymore, doesn't' man it isn't still hot.

I also bought a new Singer sewing machine and re-learned how to sew. I hadn't touched one since 8th grade... and was like "what is a bobbin or a presser foot". It didn't take too long to make some curtains for the new rods, and some ties to hold them back.

One-Eyed Duck

noreply@blogger.com (Joe Masperi) — Thu, 10 Mar 2022 23:56:00 +0000

Got the one-eyed duck installed with new wiper arms and blades with the new safari wiper shaft disconnectors so that I can open the windows.

VW Bus Dining Table

noreply@blogger.com (Joe Masperi) — Sun, 06 Mar 2022 20:08:00 +0000

The dining table came with the bus, but I needed to c lean it up, restore the hardware, and figure out how to mount it to the wall. The hinges were the easy part, and with the help of Mr. King and his new saw, we ripped a nice piece of poplar for the mounting flange, gave it some round-over/router work, sanded it and then a couple coats of poly. I spent most of today fabricating a little bracket our of some scrap metal to clip the table to the wall when it is folded down.

Jalousie Windows

noreply@blogger.com (Joe Masperi) — Sun, 06 Mar 2022 14:19:00 +0000

The side jalousie windows needed some attention, and a few replacement pieces of glass. Unfortunately, the glass is a special order item, and not easily obtained. My local glass guy screwed up the order twice, and I am still waiting on the last 4 pieces for the final window. As for the rest of the materials, I followed some good instructions on this YouTube video here

and then bought the weather-stripping from Vintage Trailer Gaskets. I realized after I received the box that I over-ordered ( I bought FEET when I need Inches), but they graciously let me return what I didn't need.

I also couldn't find the original screens, so I built my own with Home Depot parts.

Bus Front Seats

noreply@blogger.com (Joe Masperi) — Sun, 06 Mar 2022 14:10:00 +0000

I special ordered the new foam and front seat covers from Sewfine a few moths ago, because they needed to source the Westy blue plaid material from Germany and then make the covers for the '67 buckets. I also asked for the side to be done in blue instead of the stock avocado-green.

The seats were stripped down and frames cleaned up, and I even needed to rebuild a spring on the driver's side. A quick coat of black paint and new burlap wrap under the new foam, and then I pulled the new covers on to the seats (my hands are still sore a week later).

Bus Rear Seats

noreply@blogger.com (Joe Masperi) — Sun, 06 Mar 2022 13:59:00 +0000

The rear seats were already covered in the nice blue/green Westy plaid, but I needed to pull the old Formica panels off that were chipping and looks pretty crappy. The heat gun made the removal of the Formica a lot easier. I then sourced a Mohawk Sawyer Blonde vinyl floor material that I special ordered Home Depot to recover the seat bases, but first I needed to fill the hole from the electric box in the jump seat. I feel the floor matches pretty well. The wood on the back and bottom side got 3 coats of poly, and the hardware and badge got a cleanup and reinstalled as well.

Bus Flooring and Paneling

noreply@blogger.com (Joe Masperi) — Sun, 06 Mar 2022 13:45:00 +0000

I decided that he floor was going to be a vinyl plank floor for comfort and easy cleanup. I also elected to replace all the wall paneling, because some of it was really beat up. After using the old pieces for templates, I cut all new wood and gave it 3 coats of satin poly to protect it. I didn't clean up the old screws, as I thought they added character too.

The doors were especially fun to make with their nice bend, which I was able to do with a hot, wet towel and some pressure, and then screwed it to the bus.

Sound Deadening & Insulation

noreply@blogger.com (Joe Masperi) — Sun, 06 Mar 2022 13:38:00 +0000

The new panels needed to be quiet and insulated, so I used some butyl-based foil matt and insulation to quiet everything. I can barely hear it running now from the inside!

Bus Nose

noreply@blogger.com (Joe Masperi) — Sun, 06 Mar 2022 13:31:00 +0000

I didn't realize how much of the bus nose was rusted until I started poking around, and so I cut off most of the lower nose and support area, and got to work.

I even welded up the holes from the old spare tire carrier that was removed a long time ago, but tried not to take away the dents, dings and small imperfections that the nose had which I feel give it such character.

Bus Floors

noreply@blogger.com (Joe Masperi) — Sun, 06 Mar 2022 13:21:00 +0000

It's been a while since I updated the blog, but I've been so busy with work and some bus progress. The rust is all gone (except for the patina-surface.. which is staying). I replaced all the rusty floor sections, side panels and even some extensive nose work.

The front floor area also needed repair, along with the driver's side dog-leg.

The final result was worth all the work... although it is a shame I am coving it all up with flooring.

That dog-leg is probably the nicest paint on the entire vehicle LOL.

Left Side

noreply@blogger.com (Joe Masperi) — Tue, 05 Oct 2021 22:58:00 +0000

The left side of the bus was in the same condition, needing floor braces, outriggers, inner and outer rockers and the floor replaced. Here is the rough weld of the outside without any grinding yet. There was a lot of braces and patches that needed to be done on this side too.

Right Side Done

noreply@blogger.com (Joe Masperi) — Mon, 04 Oct 2021 22:58:00 +0000

After a bit more grinding and bodywork, the right side of the bus is rust-free. I am trying to remove the rust and leave as much character to the body as I can... which means dents and paint chips are not being removed. I sprayed the paint for now just to prevent the rust from attacking the bare metal, but I want to blend it in better once I get the other side done.

The bottom of the cargo doors were replaced both inner and outer. I'm not going to go crazy grinding up the welds, it will be all covered up with door panels.

One Floor Done

noreply@blogger.com (Joe Masperi) — Tue, 03 Aug 2021 01:41:00 +0000

It may not look like much, but it was a lot of work to get that right side floor done. The hardest part was figuring out where it once was before it rusted away and left me very little to work with. New floor braces, new outriggers, new jack points, new quarter panel, new inner rocker, new outer rocker and of course a new floor patch panel. I forgot to mention the dozen small patches that had to be made up to connect them all together. My wife asked if I was having fun yet... I think that I am!

Outriggers

noreply@blogger.com (Joe Masperi) — Wed, 21 Jul 2021 21:00:00 +0000

The structure under the sides of the floor (and the floor of the bus itself) needed most of the rust repair. I luckily had the outriggers, frame supports, inner rockers and floor patches to get the job done. I did pick up some extra panels from Wolfsburg West to make it a little quicker too.

Plasma Cutter

noreply@blogger.com (Joe Masperi) — Tue, 20 Jul 2021 21:00:00 +0000

I always wanted a plasma cutter to speed up the metal work, and was this ever a good investment! I picked up the Eastwood Versa Cut 20 Plasma Cutter, and I love it.

'67 VW Tin Top Camper

noreply@blogger.com (Joe Masperi) — Tue, 20 Jul 2021 01:44:00 +0000

I have been busy working on the latest project, an 11 window, 1967 Volkswagen walkthru split window tin top camper bus (that's a mouthful). The bus is originally from Nebraska, and a previous owner bought it in Colorado, and traveled the US with it - and even lived out of it in Mexico for over a year! It came partially disassembled, but included most of the repair panels it needed to put it back together. It has a blue/green '74 Westfalia camper interior and jalousie camper windows. The motor clutch and transmission are new, it is lowered and has a bunch of new parts. My goal is to get all the rust repaired, most of which is underneath the floors and in the outrigger areas, and to keep it original for now.

About 10 years ago, the following was done:

rebuilt RGB's with new bearings, circlips and steel plugs
new differential bearings in transaxle
new brass starter bushing in bellhousing
new fulcrum plates, daisies in transaxle
new nosecone and hockey stick on transaxle
new reverse switch on nose cone
new hardware, resealed transaxle
new front transaxle mount
new rear transaxle mounts
new spring plate to rgb bolts and washers
new rear Boge shocks
new rear lower shock bolts/washers/nuts
new upper engine compartment rubber seal
drained the gas tank, replaced the brass strainer inside
new bearing retainer seals
powder coated rear backing plates
new brake shoes, wheel cylinders, brake shoes, spring kit
new German teflon coated brake lines
new German rear rubber lines
bead blasted and painted rear drums
wire wheeled and painted rear shift rod, installed new rubber boot on each end
new shift rod coupler
new clutch cable
new throttle cable
new ebrake cables
modified type 1 throttle cable tube/sheath
repaired weak spot on front beam shock tower
degreased, wire wheeled, primed and painted front beam and trailing arms
replaced center pin bushing, reamed to 24mm (Thank you GA)
new left and right German tie rods
new German drag link
spindles rebuilt by Hazetguy, new forged kingpins from Wagenswest
new front wheel bearings and seals
repaired and powder coated front brake backing plates
new front brake hard and soft lines (German)
new steering stabilizer
new front brake shoes and spring kit
bead blasted and painted drums
new front boge shocks and upper mounting bolts
wire wheeled and painted beam mount bolts/washers
new throttle repair kit, replacing throttle cantilever, rod, and pin
wire wheeled and painted master cylinder clevis, pin and rod
new NOS ATE '67 only master cylinder
Master cylinder, wheel cylinders painted with Eastwood brake fluid resistant paint
powder coated wheels and mounted and balanced tires

New Wheels for Camaro

noreply@blogger.com (Joe Masperi) — Sun, 14 Feb 2021 00:58:00 +0000

The new Blaque Diamond BD-F25 wheels went on today without a hitch, and even though the weather was cold and roads are covered with snow and ice, I just had to go around the block once to test them out. I decided to go with the square setup, 20x9 all the way around... 5x120, 66.9 hub and a 35mm offset... they fit like factory with the 245s in the front and 275s in the back. Everyone was trying to get me to go bigger, like 20x11 in the rear, but I had new tires already, and there is always that tight clearance to worry about now that I have dropped the car with the new springs. I don't want to make any sacrifices with driving it just to get the biggest wheels on the block.

The Baer Decelarotor rotors and new brake pads were also a must have. Now, I do have the black G2 caliper paint and new silver Brembo decals, but the temp is still below freezing, so I'll have to wait until it warms up to finish that part... I can't wait.

Ceramic Coating New Wheels

noreply@blogger.com (Joe Masperi) — Sun, 14 Feb 2021 00:39:00 +0000

The new Blaque Diamond BD-F25 wheels arrived from Modified Concepts, and they looked great. Now I just needed to test fit them all to make sure the backspacing was perfect, and of course it was. So they took a trip over to ACE so that Peach could mount the tires, and I ordered my ceramic coating.

The Cquartz Dlux Wheel Ceramic Coating was the next step. Since the wheels were brand new, and super clean, it was a quick prep job and the installation of the product. I was mostly concerned with getting good coverage inside the wheel, and really hope that it keeps the brake dust and road grime off, and makes it easier to clean. I wore gloves and used the nice applicator that comes with the kit. It was a bit difficult to see while applying (like clearcoat in a bottle), but it was thick and left very little if any haze to wipe off. Next day they were very smooth and slick, I doubt anything could have stuck to them.

I still haven't figured out what to do with my old wheels yet, so I packed them up in the new wheel boxes for now.