A T2 project with a bad start
This VW T2b project came to us from the area north of Dortmund. The plan was to restore a Transporter and convert it into a window bus. The vehicle was a 1978 model, had the 1.6-liter boxer engine, and arrived with boxes full of parts that the owner had already purchased.
This is precisely where the problem began. Many parts were duplicated, completely unusable, or not intended for the VW T2. Such incorrect purchases initially seem like a "stockpile," but quickly become a burden in the workshop. Every part has to be checked, identified, sorted out, or replaced. This wastes time, creates confusion, and doesn't solve any of the actual bodywork problems.
VW T2b bodywork with total economic loss
The original body was completely rusted through. In addition, there was accident damage to the front. From an economic standpoint, this vehicle was a total loss. Underestimating rust on a VW T2 is one of the most expensive mistakes you can make. The bus has large surface areas, many cavities, and load-bearing components that are crucial for stability, doors, sliding door, front, roof, and window openings.
Critical areas on the VW T2 include the sills, jack points, floor, crossmembers, wheel arches, front panel, window frames, roof gutters, rear sections, battery boxes, and the connections of axle and suspension components. If rust is present in all these areas, even a good parts supply will only help to a limited extent. You can buy a lot of parts for a T2, but you can't simply talk your way out of poor condition.
Replacement bodywork against better advice
We found a replacement body for a window bus near the Austrian border at a reasonable price. From our perspective, that would have been the better solution. However, after inspecting it himself, the owner opted for a different body, located approximately 700 kilometers from our location.
This second body shell also proved problematic. Many parts were missing, and the sheet metal was in poor condition. This not only made transport more complicated, but also significantly increased the cost of the planned restoration and conversion into a passenger van. In the end, the restoration costs skyrocketed to a level that could have been avoided with a properly planned project from the outset.
Allegedly overhauled engine, but not working
The engine had supposedly already been overhauled by a "professional." However, our findings contradicted this. It wouldn't start, gaskets were missing, screws weren't tightened, and several other issues indicated that the engine overhaul hadn't been completed. We did not start the engine. We documented its defective condition; final commissioning was not part of our work.
This is another classic mistake when buying old vehicles and parts. "Reconditioned" is not a technical condition, but initially just a claim. Without an invoice, documentation, measurements, photos, and verifiable work steps, a supposedly rebuilt engine is nothing more than a risk sitting in the trunk.
Completely restored, but not put into operation
The VW T2b was completely restored and converted into a van with windows, but it was never put into service. Work included the body, spare body shell, paint, chassis, brakes, axles, electrics, interior, glazing, and all areas necessary for the van conversion. The color was applied according to the owner's wishes.
It's important to note the caveat: "completed" here doesn't mean fully tested and ready to drive. Without the engine running, such a bus isn't technically finalized. This distinction needs to be clearly stated, otherwise a false impression could arise.
VW T2 buying advice instead of buying parts on suspicion
This project is a prime example of how you can burn money buying a classic car and rushing into parts purchases. A VW Bus has a certain charm, parts are readily available, and the scene is large. Nevertheless, a poorly maintained T2 body remains expensive. This is especially true when you also have incorrect parts, shoddy preparatory work, accident damage, and an unclear engine condition.
The advice is simple and firm: If you don't know what to look for in a VW T2 body, spare parts, and mechanical components, don't buy one on a hunch. Take someone with you who knows these vehicles. Inspect the body, frame areas, window openings, sliding door, underbody, front end, engine, and documentation before you pay.
In most cases, the supposedly cheap bus isn't cheap at all. It's just the beginning of a very expensive restoration.
