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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Tue Mar 24, 2015 12:54 am Post subject: |
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djway3474 wrote: |
Originals were heat seamed (melted lines) and not sewn |
Didn't know that but did suspect they'd been recovered at least once before.
There's nothing quite like having original parts in front of you to work from but thankfully there are enough images out there to make a reasonably accurate representation of how they should look |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Tue Mar 24, 2015 11:04 am Post subject: |
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Nice idea but the old ones are now long gone. Going to start on door cards this weekend. 1000mm x 600mm is enough per card |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Thu Mar 26, 2015 9:47 am Post subject: |
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Been looking for a while Darrel and nothing is out there (here in the UK). Got a possible lead but the chap isn't very forthcoming about sending me his Paypal address or telling me if they're new or used. Maybe over the weekend he get in touch.
Meanwhile I unveiled the engine yesterday from the sheet it's been under for 20+ years. When I got the car in the States it was registered as a 1200cc. Once back home I discovered it was actually a 1300cc and drove it that way for 12 months. Then I pulled it all apart and rebuilt the top end with new 1500cc barrels and pistons and a pair of new heads. It only ran a couple of times and never left the driveway but thankfully but all seemed good with the rebuild.
With all good intentions of getting on with the full car restoration I pulled the motor and it's been there ever since and turned by hand a couple of times each year.
The sheet metalwork is now covered in surface rust so it's time to sort that out.
An hours work saw it back to basics and the various parts are off to get media blasted and powder coated this weekend.
Last edited by Karmann_65 on Wed Jul 26, 2017 4:48 pm; edited 1 time in total |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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swavananda Samba Member
Joined: February 14, 2009 Posts: 889 Location: Can o' Scruz
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Posted: Thu Mar 26, 2015 11:17 am Post subject: |
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c21darrel wrote: |
The deflector plate... (under generator stand)... i dont think that is the correct orientation.
Fuel pump block, Electric fuel pump? |
I concur via bentley's. Proper
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Thu Mar 26, 2015 12:01 pm Post subject: |
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swavananda wrote: |
c21darrel wrote: |
The deflector plate... (under generator stand)... i dont think that is the correct orientation.
Fuel pump block, Electric fuel pump? |
I concur via bentley's |
I see the deflector plate fitted wrong. Easy fix.
But the plugged oil galleys are where exactly?
Yes it did have an electric fuel pump but I'm gonna refit it with new mechanical one. A standard engine shouldn't need anything more. |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Mon Apr 13, 2015 11:25 pm Post subject: |
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Got the tinware back from powdercoating and generally it all looks good. There were a few minor parts that needed touching up (where they'd been hung on wire) but they were easy enough to blend out with a squirt of black satin spray.
The interior is now with the upholsterer for stripping down.
Last edited by Karmann_65 on Wed Jul 26, 2017 4:53 pm; edited 1 time in total |
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Tue Apr 21, 2015 11:32 pm Post subject: |
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So now the seats are stripped down is there anything I should know before they go for media blast and powder coat? Should I mask off the runners or dismantle the locking lever mechanisms first?
The rear seat looks in good condition except the first laminate of ply. The frames are solid but I'm tempted to swap out the middle panels.
The panels that fit behind the front seats will need replacing too and the clips are a little bent of of shape but that shouldn't be too much of a problem.
Last edited by Karmann_65 on Wed Jul 26, 2017 4:59 pm; edited 1 time in total |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Mon Apr 27, 2015 3:55 am Post subject: |
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Made new insert panels from 6mm ply using the old ones as templates. Stapled and glued them into position.
A couple of the little bent tabs on the metal clips broke while taking them off. I wanted to use them again on new hardboard backs but guess once again that I'll have to make something to do the job.
One interior handle came off no problem but the threads on the other were spinning round while loosening. Maybe some strong glue could set it back in place but I don't fancy it's chances of staying there. This handle is broke anyway. Bends in the middle like a broken leg.
Just something else to track down. I believe they were similar on some Beetles so fingers crossed I'll find a used one. These are going to be recovered also which kind of rules out the cost of buying new.
It's all good fun! Just wish parts were easier to find over here in the UK. Alas, used spares are either hoarded away or sold for fortunes.
Last edited by Karmann_65 on Wed Jul 26, 2017 5:05 pm; edited 1 time in total |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Mon Apr 27, 2015 1:36 pm Post subject: |
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Cheers Darrel. Definately got the longer Ghia handles but with no upholstory yet I could use whatever I find a pair of first and drill off accordingly. |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Tue Apr 28, 2015 11:55 pm Post subject: |
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You've talked me into doing a repair Darrel. If these handles are bespoke to the Ghia then it's best to fix them up if at all possible.
So, I've cut back the rubber around the mounting thread, beaten the plate back into shape and tack welded the thread into place. To cure the break mid handle I've performed surgery with a Titanium tube right through the middle.
Before...
During surgery...
After...
Another part saved and off for re-covering.
Next job is to sort out the bare door cards I bought. They're a bit big and the pre-cut holes don't line up with those on the doors of the old cards. I'm guessing this is down to the offset on the metal mounting clips. What's more concerning is the big round hole for the door lever handle overlaps where the rectangular hole should be, leaving a very odd shape that needs to be part filled again. So now I'm thinking of making all new cards using both the old and new cards as guides to get the best fit overall.
Last edited by Karmann_65 on Wed Jul 26, 2017 5:07 pm; edited 1 time in total |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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Karmann_65 Samba Member
Joined: April 17, 2009 Posts: 534 Location: Lancashire, UK
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Posted: Wed Apr 29, 2015 12:35 pm Post subject: |
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These are the new cards against the old ones I took off (covered in sticky plastic for water proofing)....
Same for the rears which don't look too bad....
When sat one over the other the lever holes don't line up. If I cut the rectangle to match the old panel then there will still be an extra half round hole missing. And that's going to cause a problem re-upholstering.
Last edited by Karmann_65 on Wed Jul 26, 2017 5:19 pm; edited 1 time in total |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8206 Location: San Dimas
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