Continuing on from my March entry on insulating the roof, I'm now ready to start installing the birch ply headlining. I searched the Internet looking for company's that supplied the 'J' channel and the 3mm birch ply that I required and I was getting quotes of over £300. OK this was close to original as possible looking 'J' channel and the ply was pre cut and shaped, even so, at those prices I decided to look for an alternative solution.
|They are only spot welded in every few inches|
or so, so out came the small chisel and
|A nice sharp chisel and a swift blow from|
the hammer and the welds broke quite
easily. You can see in the above photo after
the tabs have been removed, it leaves a small
spot weld that will need to be ground off.
|Once all the tabs were removed, out came the|
trusty grinder to smooth off the remaining spot
welds until the whole surface was smooth.
|Not sure why Volkswagen thought it was |
necessary to put the spot welds closer together
over the sliding door. It just meant I had more
tabs to chisel off and more spot welds to grind
|The front panel over the cab is tricky as it has|
to be shaped around the visor mounts and it
is narrower at the front than the back. This is
a pain to create, luckily for me Zoe and Spike,
my good friends at The House of Dub
kindly lent me a template from an original
Westfalia. Even with the template it still took
me 5 hours to shape and sand my panel until
I was happy with the fit. This was mainly due
to my 'J' runners not being in the same
position as an original Westfalia.
|Once the cab section had been fitted, and the|
interior light had been wired up and fitted into
it's new location I used these plastic screw
caps just to hide the screw heads and make
things look nice and neat.
|Looking at the cab panel. I am very pleased|
with the end result.
|Once the cab panel was in, the ply seemed|
a little loose across the top of the windscreen
due to there being no support, so I put a
self tapper screw on each side, behind the
sun visors and again finished them off with
the same screw caps.