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Wed Mar 28, 2012 1:02 pm

Changed out the master cylinder after two cups of fluid leaked into the tunnel. While doing the swap I relocated the reservoir to the left inner fender well to clear radio wiring. Next I fabricated a bracket to install a micro switch forward of the brake pedal so my brake lights come on a lot sooner.

Thu Mar 29, 2012 9:48 pm

3/29 - We were able to apply POR-15 to entire chassis, front beam, and floor plans. We pretty much spent the day painting the chassis, making an acid solution to clean all the chassis and suspension bolts, as well as brake parts and spindles.

Next week, we should have all the ball joints, tie rod ends, bushings, brake lines, master cylinder, steering box installed as well as front beam to chassis. POR-15 is some badass stuff. Expensive though. But I see the value in it. Looks better than rubberized undercoating.

Sat Mar 31, 2012 9:13 pm

Replaced rear brakes and wheel cylinders. Also replaced rear axle seals. Started on front suspension rebuild.

Sat Mar 31, 2012 9:51 pm

Put in a good used battery. Changed the oil, plugs, plug wires, points, and added fresh gasoline and it cranked right up. First time in 10+ years this car has run!! Drove it around the yard, slowly without brakes.

Tue Apr 03, 2012 8:16 pm

bought and towed home a 1963 :D :D

Wed Apr 04, 2012 8:52 am

Tore motor down to short block. Needs rings, dang! Put in soundproofing on floor and in rear cubby hole. cleaned, lubed and put door handles/latches and lock assemblies back in the doors. Dragged stock motor out of a pile of stuff to set it back up.

Thu Apr 05, 2012 11:01 am

In addition to switching to full synthetic oil a few days ago, I adjusted the valves, swapped out a questionable clamp on a breather line, adjusted the toe-in, pulled and checked the spark plugs, ordered new points and condenser from O'Rilleys, and installed a fuel cut-off valve.

The valves were all virtually identical at .003, so no unusual wear on any one part. I just reset them to .004 and was good to go.
The alignment was off more than expected, a good half inch of toe in! I'm amazed at how comfortable it is now going over bumps. I took it for a test drive in the country and went over some RR tracks at 50mph... made me want to go back and do it again at 70 ;)
I checked the plugs because there was a significant power loss the day before. Started it up and the exhaust from cyl 1 was not heating up. Plug one was finger tight and fuel fouled. My fault... I've been shy on proper plug torque. #4 was also finger tight, but not fouled. Runs much better when it hits on all four...
The VW shop has points and condensers laying around, but I thought I'd order through a local store just to let 'em know we're still out there :lol:
The fuel cut off valve was to address an ocassional issue with fuel inside the pump percolating and forcing fuel past the carb float valve. It also gives me a way to empty the fuel bowl neatly when swapping jets.

Paul

Fri Apr 06, 2012 9:24 am

Got the Title, tag and insurance and took it for its first drive. Its a little low but I will raise it next week and then lower the rear to match. This is Ghia #4 for me but the first one I have actually been able to drive.

Fri Apr 06, 2012 8:45 pm

I must say I've waited too long for this day. I bought my first car a 66 Ghia in 1983. Today I pulled it out of storage and evicted a family of Oposums. Gonna be an interesting build starting out like this. Can't wait to post pics.

Sat Apr 07, 2012 2:18 pm

Got the horn working,and replaced the rubber seals around the defrost/fresh air vent.

Sat Apr 07, 2012 2:19 pm

Almost forgot yesterday figured 32.77 MPG.

Sun Apr 08, 2012 7:51 am

Over the winter........

The engine started acting up and was only able to drive the Ghia a couple of times in 2011. :cry:
I made a decision to rebuild. Was told by the PO that is was a 1641cc. It was actually a 1600. Now it's a 1641. Added a new alternator and few other engine accessories..... My UPS guy Eric just dropped of a MST Billet Alternator Stand. Sharp!!
Never being satisfied with leaving things alone I played around and made a few “improvements”….. Playing with the Ghia is definitely therapy for me
Repro Bambus under dash shelf.
A Shift Knob with a Karmann Ghia side badge embedded into it.
Added an Oil Temp. and Oil Pressure gauge to keep track better track of how the engine is behaving. I cold not bear to cut holes in the dash or add a pod because I felt it would detract from the original look. I decided run my wires from the engine to a female socket that I mounted to the rear seat bench crossmember. I ran a 6ft harness to the gauge set. I just plug it in while driving and when get to a show I just unplug and toss it behind the seat storage area.
Repainted the cooling tins from a silver "Hammered" finish to a charcoal grey. Still keeping the "hammered" look.
I thought it was cool how the Porsche 356's used a leather "belt" to keep the spare tire in place. I found some black leather strap from an equine supply and fashioned a rather good looking leather belt to hold the spare in place. I will post some pics up soon.
Now its just time to detail and get out and drive 8)

Sun Apr 08, 2012 8:37 am

Hey Kingkarmann cant wait to see the pics of what ya did and glad you didnt cut up that beautiful dash....!

Sun Apr 08, 2012 10:11 am

The body has been completely worked over, cut out all rust and welded in new sheetmetal, replaced floor pans, POR-15ed entire chassis, front and rear suspension. Complete new front end parts, ball joints, tie rod ends, steering damper, urethane buhings, etc. Master cylinder, brake lines, pads, etc. Still waiting for sway bars to come in. Couldn't get pics to show up properly rotated.

Sun Apr 08, 2012 3:38 pm

kingkarmann wrote: Playing with the Ghia is definitely therapy for me
Glad I'm not the only one! :wink:

Paul

Tue Apr 10, 2012 6:18 am

Had the car about 10 years and never got a chance to work on it. So last week I stripped and gutted the car. Removed the engine and took to have it crushed glass blasted. Hopefully it will go to the the repair guy this week to get new floor pans replaced and some new L& R Quarter panels and rocker panels. Then it will be primed and I''ll start doing the body work. It's not in great shape but better than some I've seen!!!

Tue Apr 10, 2012 8:06 am

Quote: So last week I stripped and gutted the car. Removed the engine and took to have it crushed...

anyone else's heart stop while reading up to this point?

Tue Apr 10, 2012 8:22 am

Paint :D

Tue Apr 10, 2012 9:41 am

Your...
crimson ghost wrote: Paint :D
looks great, and so does the rest of the car!

Paul

Tue Apr 10, 2012 10:19 am

Tore down front suspension, sent out steering knuckles for new kingpins, replaced tierod ends, and checked out steering dampner (OK)! Started to get things organized for floorpan replacement