If you have an affection for vintage vehicles, the iconic Volkswagen Kombi is sure to bring joy to your heart. These nostalgic buses have roamed the lively streets and beaches of Brazil, symbolizing adventure, freedom, and a distinct cultural importance. More transporters (known as Kombis in Brazil) were manufactured at the São Bernardo plant than anywhere else globally, including West Germany. The last Kombi was produced in Brazil in 2013. Production was halted when modern safety standards could not be met due to the driver's position over the front wheels, which did not provide an adequate "crumple zone" for modern crash protection standards..Restoring these charming machines is more than just a hobby; it’s an art form requiring dedication, expertise and diligence.. Here’s an inside look at how we at Reborn Customs and Classics work to revive these cherished Kombis with standards that meet American expectations.
Step-by-Step Restoration Process
Our restoration journey starts by acquiring buses from various locations across Brazil, within reasonable distances from São Paulo. Unlike common car models, vintage VW buses are often elusive treasures, hidden away in garages, abandoned in backyards, or used as parts vehicles in junkyards. For example, we recently found a 1997 Kombi "Clipper" that we transported to São Paulo from a small town in the interior, where it had been used as a school bus on dirt roads throughout its life. Its outdated air-cooled engine no longer met the school district's evolving standards, which preferred later model Kombis with water-cooled, more powerful engines. Although it was well-maintained and in excellent condition, it was outdated for continued use as a school bus. Minimal metal repair, the ideal candidate.
When we identify a potential candidate, we evaluate its history and potential. School buses are involved in fewer accidents and are routinely maintained by motor pools to ensure they are dependable daily vehicles, responsible for transporting children to school. These make excellent candidates for restoration and modification, reducing the time to completion.
After locating a vehicle, the initial inspection before purchase is crucial. We find our projects on platforms such as Facebook, OLX, Mercado Livre, and through word of mouth at car shows and VW gatherings. Emerson, our shop chief at Reobote Customs, performs a thorough evaluation of the bus's condition by inspecting the engine, bodywork, interior, and chassis while reviewing photos and then, contacting the owner prior to the in-person inspection. The distance required to visit the car is also considered in the decision process, as traveling great distances increases the risk of wasting time to find quality project candidates.
Nevertheless, the most crucial aspect is the on-site inspection and documentation verification. It's vital to ensure that the engine and chassis numbers match the registered documents. Exporting a bus requires accurate documentation and original matching serial numbers. Many "Frankenstein" builds face high taxes upon import as "kit cars." Vehicles assembled with engines on different chassis not original to the bus or its year are difficult to document and title. We avoid these types of cars entirely, as the effort often isn't worth the time needed to navigate the regulations.
Each detail plays a role in the decision-making process. In a recent project, we identified over 100 different issues, including rust spots, dents, and mechanical failures. The bus roof is frequently the main concern. A damaged roof is difficult to repair and expensive to replace since it is a single stamped component. This comprehensive inspection serves as our guide for restoration. Missing any detail can result in wasted time and money, possibly rendering the car unprofitable to restore promptly and economically.
Once the decision is made to purchase the vehicle, transporting it to the shop over long distances can be an issue for cost vs. miles. Cars sourced in tiny towns, far away from São Paulo, can be great "barn finds," but getting them towed takes time and money. Documentation can be tricky without a clear understanding of Brazilian law regarding motor vehicles. An experienced shop chief like Emerson, experienced in titling and registering autos, is critical to a successful, legal purchase for rebuild and export.
Once the car arrives, the subsequent step involves disassembling and assessing parts for restoration or replacement. We treat the process like a puzzle, carefully dismantling the vehicle to evaluate each component. With all parts sorted, the chassis stripped, and the engine removed, we can precisely determine what requires repair, restoration, or replacement. In a recent project with a 1974 Kombi, we found that 60%-70% of its original parts could be refurbished, maintaining authenticity. However, if a part is excessively worn or lacks structural integrity, like a bent frame, it must be replaced. Our reputation, and sometimes the buyer's safety, are at stake.
After disassembly, our attention shifts to metal body restoration, tackling the prevalent issue of rust. Our expert craftsmen utilize top-quality materials to mend or replace rusted sections, bringing the bodywork back to its original state with minimal bondo. In extreme cases, up to 30% of the body might need replacement. Certain structural door elements and frame support parts for the cabin's superstructure must be entirely fabricated anew. Previous accidents we discover in a project car become evident during teardown, demanding time, money, and space in the metal repair bay. Some cars have been in metal rehabilitation for over a year and a half.
Simultaneously, we tackle the "mechanics phase", which involves overhauling the engine and rebuilding the transmission and suspension, while working on the body and preparing it for painting. We replace worn-out components and ensure everything meets our high-performance criteria. Whenever possible, we use OEM (Original Equipment Manufacturer) parts to maintain the vehicle's authenticity. Statistics indicate that cars equipped with OEM parts have a 20% higher chance of longevity compared to those using aftermarket components. OEM parts can be difficult to find for very old cars. Newer project candidates are easier to repair but less valuable. Older cars hold more value but are harder to repair due to the scarcity of parts, whether original or not.
Following mechanical work, we give the interior our special award winning touch. We totally restore and in most cases, improve the interiors. This interior restoration process has been our hallmark for our receiving awards at car shows. Seats, the dashboard, and all interior components are cleaned and refurbished or replaced with period-correct materials. During restoration, we source fabric from a number of quality local suppliers who specialize in classic styles, staying true to the Kombi’s heritage. If we can't do the high quality work ourselves, we job it out to professionals who are craftsmen in their field.
The final significant step is painting. We have collaborated with Skylack Paints of Brazil to utilize the latest paint formulas and application protocols for applying fresh coats over repaired metal. This not only enhances aesthetic appeal but also offers protection against the elements. In a recent restoration, we painted a Kombi in "sea-foam green," which is reminiscent but not identical to its original color, giving it the unique personality associated with road trips and adventures. Eye-catching colors aren't always new. Stock colors, accurate for the period of the original build, hold substantial value for certain customers. We are always mindful that "taste is subjective." A 1960 Samba in Canary Yellow probably isn't suitable, much less desirable, to most discerning and knowledgeable buyers.
In the end, our ultimate quality check ensures that every part functions perfectly and can be maintained with regular care. Each Kombi must meet our stringent visual and structural criteria before hitting the road again. Every Kombi is distinct...and our good reputation is vital for future sales and for upholding our role as dependable and skilled restorers of the VW car legacy. We create Kombis we would want to own ourselves..Simple.
Preserving Automotive History
Restoring classic Volkswagen vehicles like the Kombi bus or Single Cab isn't solely about getting them back on the road. These buses represent a significant part of our culture, embodying a time when simplicity and exploration were paramount. Each Kombi tells a story, whether it’s about family vacations or cross-country adventures. These have become cultural icons in Brazil and the U.S. and have been utilized in a myriad of ways.
In Brazil, Kombis have served various purposes such as delivering flowers, functioning as beer trucks, coffee bars, ambulances, fire trucks, school buses, food trucks, and police vans. They are utilized in Samba parades as speaker vehicles and by vegetable vendors announcing the sale of their goods on streets in both rural and urban areas.
Our restorations contribute to preserving automotive history in Brazil. Nostalgia runs deep; many individuals reminisce about childhood trips taken in a Kombi. By breathing new life into these vehicles, we keep memories alive and honor a rich heritage that connects generations.
Transformative Before-and-After Showcases
Our work is showcased through impactful before-and-after images. We share photos of our recent projects at various stages—before, during, and after—on our website. The transformation is not just visual; it reflects the hard work and dedication we invest in each restoration project. For example, many of our builds involve Kombis that seemed destined for the junkyard, which we restore with modern safety features while preserving their original charm. Once finished, they are almost unrecognizable from their initial state. We take pride in that transformation. "Junk to treasure." Unappreciated effort until you see the "before" and "after" photos and understand the value of good restorative metal work followed by quality finishing...
Our Unique Process in Brazil
Discovering and refurbishing vintage VW buses in Brazil is an adventure that leads our shop chief through the rural countryside and the lively markets of big cities. Each discovery can be a gem if you know how to identify what is salvageable and what is beyond repair. Our satisfaction comes from reviving a historical piece that has influenced the culture of this nation and others worldwide.
Our team consists of dedicated enthusiasts committed to the art of restoration. It's crucial to train and inspire the next generation of car crafters and restorers, ensuring these vehicles remain in our collective memory and don't become mere relics of the past. We mentor and employ selected young apprentices to develop their skills, enabling them to eventually work confidently alongside our experienced mechanics. We take pride in our craftsmanship, ensuring these vehicles continue their legacies into the future. Furthermore, we foster a community of vintage Volkswagen enthusiasts by participating in car shows and VW cultural events. We enjoy sharing our passion for automotive history with others and our process to make them "reborn" from the junkyard.
A Journey of Automotive Love
Restoring vintage Volkswagen vehicles, especially the cherished Kombi, involves more than just mechanical work. It’s about rekindling history, culture, and the adventurous spirit. Our meticulous restoration process demonstrates our commitment to reviving each Kombi, honoring its distinct story. Our shop is challenging the notion that only subpar restorations come from Brazil. Many exports to the U.S. are often crafted in private garages with amateur skills. Not in ours.
We construct our vehicles according to American shop standards. We utilize specialized shops when necessary to ensure our buyers receive the highest quality in every aspect and stage of the build. If we cannot execute something well, we will hire someone who can and whose livelihood depends on it.
Preserving these classics means keeping pieces of Brazilian heritage alive. Whether you fondly remember your family adventures in a Kombi or appreciate automotive beauty, our passion for restoration resonates with every enthusiast, in the U.S. or Brazil..
"Air-cooled, old school." It's not about horsepower and chrome; it's the experience of "getting there" and the journey that will make these buses memorable over the years.
Embark on this journey of automotive passion with us, and you might find the ideal Kombi ready for your own adventure! Surf Kombis, campers, and Single Cab Cycle Haulers... these familiar shapes have been revived from the brink of excessive age and road wear for future generations to appreciate.
Everyone has a story about a Volkswagen... Our narrative honors the legacy and memory of the renowned, iconic VW transporter. We offer Dedicated and meticulous restorations, celebrating everything Volkswagen.
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