First topic message reminder :

Latest addition to my pool of Aircooled VWs:

Matching Numbers All Around;
Current Missionary School Van;
November 1968 (Model year: 1969) Early RHD T2 Bay Window Walkthrough Microbus with Sliding Door on Left.
1600cc M-240 (Low Compression) 44BHP Matching Motor

Needs a ground up restoration but worth every penny its bought for.

Bought it for a Polish friend's Tour of Pakistan! The Polish friend named it as "Missionare" (German: means Messenger) for its life long service to humanity.



This is tell tale of Missionare's acquisition, 700KM journey back home and the restoration. Stay tuned as we embark on an exciting ride deep into the Early Bay world to explore what it is like to restore a half living auto-marvel from the past. 

DISCLAIMER: The thread would be creepy slow as I have two other projects running in parallel to this (a 65 Bug & a 79 Safari), so plz be patient but be assured that it would be another restoration cookbook, though this time on the subject of Early Bays.

Update on History of Missionare - July 16, 2013

*04 Documented Previous Owners
*1st Registration Date: March 04, 1969
*2nd Registration Date: January 01, 1975

1st Owner - Unknown as of yet (Owned from: March 04, 1969 To: December 31, 1974)
2nd Owner - Syed Rahat Ali Kirmani (Owned from: January 01, 1975 To: April 13, 2004)
3rd Owner - Syed Mohammad Zakaria (Owned from: April 13, 2004 To: April 13, 2010)
4th Owner - Amjad Yousaf (Owned from: April 13, 2010 To: June 16, 2013)
5th Owner - Yours Truly (Owned Since: June 16, 2013 To: Date)

3 hrs back bending servicing and a lot of elbow grease and this is the result:

Some of the immediately required parts are now dispatched.

The above pic shows two ignition switch locations on Missionare, one (on the left, the igniton housing) location was where an out of order universal ignition switch was installed and the other (on the right, the cut up dash hole at the round corner of dash) where another working order universal ignition switch was installed.

Had to be corrected. The "L" profile early bay ignition switches are hard to come by and can be as costly as US$175 in some cases. I picked up a clean housing with "L" profile ignition with matching key installed for US$25 with Joel/Kentucky along with the parts shown in the above post.

Had picked up the correct Walkthrough Seat Backs and Passenger side Seat Tracks from Jeff/USA as seen below;




He had a few other left over parts from the same 68 walkthrough laying around, which were also picked along with the above parts and are now shipped. The Gas door, the headlights pair, and the reverse lights pair

Its been over 10 days that Missionare is parked with all the wiring mess removed and waiting for the stock looms to be hooked up and make it possible for the bus to enjoy the voltage through its original looms. All these days because of scorching heat even deep into the late nights.

Spent a couple of hours yesterday to do the basics to close the unhooked wiring looms. The parking lights were first to light up.

Just won this dash cluster on eBay. But I am only looking to use the console. The gauges/clocks would be used from the original console which is broke in upper left corner trim.

Will get to the details later but here are the pictures of the parts that I was able to source locally.

reezvaan wrote:

Once I was bored of all the cleaning/lubrication of the front end, I shifted to Wheels and spent sometime with them too where I installed hubcap rivets and stock domed hubcaps from my stash to reform the look on them

The Wolfsburg West Hubcap Rivets/Clips Installation using the custom made hubcap rivets/clips installation tool that I got made when I was restoring wheels on Patina back in 2011.


On a second thought, I have removed the fresh spray from the recently repainted white wheels to help maintain the character of the bus. So all 5 wheels now have the same old powder coat finish again.

While I was at cleaning the interiors, starting from the front inner nose panel in the front cabin, here is what I found:

The Original M-240 (Low Compression) Motor Tag that goes on the rear two bolts that hold the generator/alternator pedestal in place on the block! Has seen better days but its still a rare find.

Missionare came without all but one driver's side top walkthrough seat pad. Which too is all worn out though is retained by its original fitting strips and hardware.




With passenger seat bulkhead now sourced from Jeff/USA, Missionare now needed a good useable walkthrough seats pads set which was located and bid for on eBay. Just won this one a while ago:


Once the seat back and this trim is installed, here is how the walkthrough seats should look.

When you've an original ‪#‎Karachi‬ vehicle registration book in this state in your hands, you know its one of those joyful times when you officially become owner of a vehicle (read 'another' VW)!

The passenger side CVs looked better since the CV boots on them are still good and look to have been recently replaced but the CV boots on the driver side axle were all torn up and the CVs were all caked including the flanges. There was a constant grinding noise that one could hear clearly once Missionare was on the move. All this is straight forward SHOT CV Joints situation. I do not have replacement CV Joints with me at the moment to fit the early bay, VW part # 211 501 331A. So there remained no choice but to remove the CV Joints and to get them repaired until brand new/NOS CV Joints could be located and brought in from abroad.

So this night, I embarked on the removal of the Driver Side Axles to examine and refresh the CV Joints as well as replacement of the CV Boots that I had picked up from Lahore Autos when I was in Lahore bringing the bus home after it was bought.

Here are a few shots after removal and rough clean up of the CV Joints to examine their true condition. Plz note that both the CV Joints are a mismatch. the Transmission side CV Joint is year correct LOBRO and bears 211 501 331A dated 2/68 while the wheel side CV Joint is LOBRO but bears 211 501 331B dated 12/73. Both needs replacement but the later one is rather in far gone a state. Unfortunately, there is no choice at the moment but to get them both welded/ground/repaired.

LOBRO 211 501 331A - Dated: 2/68


LOBRO 211 501 331B - Dated 12/73


Shot CV Boots


Cleaned up flanges



In the morning these are going for a refresh while I work on the passenger side axle removal now.

As shared on Elk's thread when I was servicing CV Joints on Elk, these two valuable write ups on this job would help you any day;

1. Tom's VW Pages -  CV Joint Maintenance
2. type2.com - CV Joints Maintenance

Have had a busy day with the CV Refresh. Not the end though that I would have preferred but then got a lot of distance covered. Its always better to be patient with these small but important jobs than to rush into finish, especially when one is dealing with the drive terrain on the vintage VWs.

First the complete dis-assembly pics:



Dropped of the CV Joints with the best in the trade shop here in Multan for the repairs which they would return in the morning, all welded/grounded and polished. With that done, went on to buying the new CV Bolts as there were only 5 correct Allen head screws that were on rest of them all were hex bolts of different specifications.

Also, went on to get the CV Bolt holding strips fabricated which again were missing, with only one present that was used as a template to fabricate the required 5 plates. Pics of the plates and Allen screws to follow later in the day when there is light to click a few neat shots.

Next up was cleaning the drive shafts, oxidising them and painting them back to black. Here is a pic after it was all done:


Cleaned the flanges so that they are all set to receive the refreshed CV Joints+shafts. It was then when the nightmare appeared too. A broke screw in the transmission flange on the passenger side.




This screw will have to be removed before the CV Joints /shafts are installed. Mole Grips commonly known as wise grip should do it (I hope) else will have to weld a nut to the broke head to remove it. Will try mole grips in the daylight later today to see if that works. Fingers crossed.

Fished out my ABUNDANT supply of LIQUI-MOLY CV Grease from stash to do the CV lbrication once they arrive in the morning, all repaired and prep'd.

Missionare does have a Turn Signal Switch which works perfectly but then its from a later year thus isn't a perfect fit on the steering column. Have been looking for the correct one which is extremely difficult to find and if its available its pricey as hell. Today an Indonesian friend posted a NOS SWF Turn Signal Switch for early bay (correct for Missionare year) on FB and I was quick to buy it out. Here is what it looks like:

As far as the documented early bay windows of the country are concerned, I dont personally remember any more than two early T2a. One is Missionare and the other known was sold quite a few month ago from Lahore to Rawalpindi and then within the year from Rawalpindi to an unknown location. I have been eyeing on that one for quite some time now and have been watching closely for every & the frequent resales it has gone through because before Missionare, it was the only known surviving T2a to me.  

Those who hang around keeping an eye on VWs for sale in the country would know it for sure. Here is how it looked until recently before it was sold to RWP.


It bears KHI registration # CE-8566 and is a 1970 model. Here is its Excise Verification from GOS Online Verification System.


But as compared to Missionare, bearing KHI plates too, Registration # CB-8667 it fails to qualify as the country's oldest Bay window. Because thats where Missionare wins;


Here is Missionare's GOS Online Verification data:


So this data does make Missionare the oldest known Bay window of the country, upto my knowledge.

If any of you does know about any early bay windows still surviving and not yet documented, please do point me in its direction and lets find out which one is the oldest surviving T2a of the country.

I have been repeatedly asked by VW friends if I was going to restore Missionare ground up. My answer has always been "YES" but not just yet. Like Patina, I like Missionare's overall battered character lot better than a shiny/blemish free finish. Only deviation from Patina's plan is fixing the undercarriage with new sheet metal imported from abroad and to minimize the panel beating as much as possible, while increasing the amount of welding at the same time.

Missionare is probably the only existing Sign Written Bay Window too. Bearing a school signs which it has served previously. Sign written buses have always been my favourite. Not to mention that battered look that Missionare bears along with the sign writing.

The sign writing "Progressive Public School - New Khanpur" was rather freshly done and gave a contrasting character to the battered / rusty look. It was discussed and debated among few VW friends and finally it was decided to "age" it to match the overall character of the bus.

Since I don't plan to redo the paint job just yet, on Missionare, it looked only inevitable to age the sign writing to match the overall character.



Finished product coming soon, stay tuned.

reezvaan wrote:

Have had a busy day with the CV Refresh. Not the end though that I would have preferred but then got a lot of distance covered. Its always better to be patient with these small but important jobs than to rush into finish, especially when one is dealing with the drive terrain on the vintage VWs.

First the complete dis-assembly pics:



Dropped of the CV Joints with the best in the trade shop here in Multan for the repairs which they would return in the morning, all welded/grounded and polished. With that done, went on to buying the new CV Bolts as there were only 5 correct Allen head screws that were on rest of them all were hex bolts of different specifications.

Also, went on to get the CV Bolt holding strips fabricated which again were missing, with only one present that was used as a template to fabricate the required 5 plates. Pics of the plates and Allen screws to follow later in the day when there is light to click a few neat shots.

Next up was cleaning the drive shafts, oxidising them and painting them back to black. Here is a pic after it was all done:


Cleaned the flanges so that they are all set to receive the refreshed CV Joints+shafts. It was then when the nightmare appeared too. A broke screw in the transmission flange on the passenger side.




This screw will have to be removed before the CV Joints /shafts are installed. Mole Grips commonly known as wise grip should do it (I hope) else will have to weld a nut to the broke head to remove it. Will try mole grips in the daylight later today to see if that works. Fingers crossed.

Fished out my ABUNDANT supply of LIQUI-MOLY CV Grease from stash to do the CV lbrication once they arrive in the morning, all repaired and prep'd.

Pics of fabricated plates as well as Allen screws as promised above:


The broke screw too is now sorted. Mole grips did the trick.



Also plugged in the dust caps in the rear backing plates on both sides

The Repair shop returned the repaired CV Joints today, all welded, grounded and polished. After inspection, all of the 04 CV Joints were cleaned and assembled thoroughly and then one of the two shafts was readied with new Brazilian CV Boots that I picked up from Lahore Autos/LHR, to be mounted on Missionare. Second one couldn't be assembled/installed because of the fact that unlike I had thought that only two CV Boots on Missionare were torn, all four were found torn. And since I just had a pair of the new CV Boots so there was no way both axle shafts could be made ready for an install.

Will hunt out the CV boots tomorrow locally if I could find any to do the other shaft otherwise missionare is now grounded until some CV boot kits are brought in from abroad.

Here are some pictures from the readying of one of the two axle/drive shafts and its installation:

reezvaan wrote:

The Repair shop returned the repaired CV Joints today, all welded, grounded and polished. After inspection, all of the 04 CV Joints were cleaned and assembled thoroughly and then one of the two shafts was readied with new Brazilian CV Boots that I picked up from Lahore Autos/LHR, to be mounted on Missionare. Second one couldn't be assembled/installed because of the fact that unlike I had thought that only two CV Boots on Missionare were torn, all four were found torn. And since I just had a pair of the new CV Boots so there was no way both axle shafts could be made ready for an install.

Will hunt out the CV boots tomorrow locally if I could find any to do the other shaft otherwise missionare is now grounded until some CV boot kits are brought in from abroad.

Good news on the CV Boots, four of them were located today with a VW contact. He will be shipping all four tomorrow morning and those would be arriving in on Saturday so hopefully, the Missionare would be back on its feet on Sunday after I install the other/passenger side Drive Shaft.

reezvaan wrote:

Just picked up this nice pair of OG Trim year correct RHD Front Walkthrough Seats for Missionare on Ebay:


They are still in factory trim just kind of dirty otherwise perfect.

reezvaan wrote:

Missionare came without all but one driver's side top walkthrough seat pad. Which too is all worn out though is retained by its original fitting strips and hardware.

With passenger seat bulkhead now sourced from Jeff/USA, Missionare now needed a good useable walkthrough seats pads set which was located and bid for on eBay. Just won this one a while ago:


Once the seat back and this trim is installed, here is how the walkthrough seats should look.

Both these items, RHD early bay front walkthrough seats as well as walkthrough seat bulkhead trim are now shipped!

Tony was kind to send the seats and with seats, the radio block off plate as well as hundreds of VW magazines from his collection as a gift.

Little something for the heating and making the front cabin look more complete.

Sliding door with mechanisms and catches and roller was already sorted and held for shipping with Nick due to the fact that we couldn't locate a nice pair of interior and exterior sliding door handles. Thanks to Nick's consistent search, we now have, thus the whole thing can now be shipped to be fitted to Missionare.

I am afraid I have been wrong about the interior on Missionare more than once. Initially, while making the purchase decision I had thought that the interior on the Missionare was original except the front passenger seat, which turned out wrong because only the Driver's seat was original to Missionare while all else seats were from Toyota Hi-Ace.

Secondly, I had thought that Missionare was 7 Seater (2,2,3) arrangement but as it turned out, while I was working on cleaning the cargo floor, Missionare has all seat mounting plates intact which prove it to be an 8 seater (2,3,3). A little research on the RHD models confirmed it.


I am the "bone stock" type, cant stand the alterations and non-stock items. So had to hunt for the correct interior, all of it. OG Trim RHD Walkthrough seats were won on eBay for a hefty USD 230 as has been previously shared and are now shipped as well. That done, the RHD full width middle seat (flip option on left) and the rear bench seat remained to be hunted. Rear Bench Seat (full width) is all the same on all the bays so it was rather easily available but then had to fish out a year correct seat which took quite a bit of weeks. Anyway, the correct rear full width bench seat still in OG Trim was found and bought and is now awaiting shipping. Here is what it looks like;



As can be seen. the trim is not in excellent condition but then it still is OG and have the lower kick panel as well as the top rear trim. So I am thinking it will do for now.

Once done with the front and the rear seats, the RHD Only Full Width Middle Seat with the Flip option on the Left remained in shadow. Talked to quite a few VW buddies in UK, because thats where you could expect to find a RHD specific seat and eventually one was located in Birmingham, was in good shape except that it had a tear on the flip seat upper corner. Nonetheless it was picked up and is now awaiting to be carried to me. Here is how it looks;


So we are all done with the original seats, finally!

After both the Toyota Hi-Ace seats were removed from Missionare's cargo area, it was stripped of the shattered mat and there was a hell of gunk that broke loose. There was so much caked dirt that the cargo floor pressings were totally flattened and it looked as if the floor was a flat sheet metal with no pressings.

First had to scratch the caked dirt and then automated grinder mounted wheel brush was used to clean off the chipping paint from the cargo area, bringing the floor to bare metal which looked surprisingly very solid for a KHI car. All seat mounting/anchor points are still solid too!

Once the cargo floor was cleaned, I used Grey Primer rattle cans to cover it up. Here are a couple of pics from the Primer spray.



The 2nd pic shows the area of the cargo floor covered by one rattle can of Grey Primer. Grey Primer coating is an interim coating until the time when Missionare goes for an inside/out sand blasting, to safeguard the bare metal from rusting.

I do have a few BEFORE pictures of the cargo floor but not with me at the moment. I would upload those later.