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The push against entropy
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sputnick60
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PostPosted: Tue Oct 20, 2015 10:58 pm    Post subject: Reply with quote

c21darrel wrote:
Quote:
It runs like a clock.


So you could hear it ticking? Check valve adjustment. Wink


Smartypants! Laughing

I should say it runs like clockwork.
http://idioms.thefreedictionary.com/run+like+clockwork

Nicholas Cool
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PostPosted: Sat Oct 24, 2015 4:15 am    Post subject: Reply with quote

More progress today.

Engine poised for the lift.
Image may have been reduced in size. Click image to view fullscreen.


Lift done and bolts tightened
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This is all I'm going to get done until December because tomorrow I fly off to Switzerland once more and this time for a month. Work continues to get in the way of this project but at least now I have the engine in the car. I have on order the Vintage speed hi flow exhaust but this will be the Ghia specific prototype that tucks up under the car a bit better than the standard unit. I'm looking forward to that but should it get delayed, there's the fit out around the engine and the roof to get all done.

Plenty of work waiting to get done before Xmas.

Nicholas
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PostPosted: Sat Oct 24, 2015 4:19 am    Post subject: Reply with quote

The car looks great and work/life does seem to get in the way of getting things done. I like the car color, what color is it ?
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PostPosted: Sat Oct 24, 2015 4:37 am    Post subject: Reply with quote

CiderGuy wrote:
what color is it ?


I'm glad you like the colour. Its a late 50's Glazurit colour Bernina L431. There's more info on the third page of this thread.

Nicholas
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PostPosted: Sun Jan 03, 2016 7:04 am    Post subject: Re: The push against entropy Reply with quote

Back to work on the cabrio top. This time I've started with another headliner.

Here is the first step, gluing a strip of perforated dots onto the back of the front bow. I used just a few stapes to position this.
Image may have been reduced in size. Click image to view fullscreen.

the only bit you see of this the back edge of the header which is just below the mechanism here below.
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This shows the edge with the strip folded over and glued
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Keeping the centre line was easiest with a string pinned between the tack bow and header bow. The headliner, the padding liner and the padding itself were all marked with centre lines too. It's just a matter of lining things up after that.
Image may have been reduced in size. Click image to view fullscreen.


The metal cover for the header bow has a small screw hole that positions the "ears" of the headliner side pieces. I had trouble with this using that last headliner which precipitated this restart. So to make sure the position is correct and final I placed the cover in position, still with its old fabric, then screwed the ears in position. Already things are looking better here.
Image may have been reduced in size. Click image to view fullscreen.


There is a loop of fabric where the top and the sides of the head liner join. This loop gets sewn to a support line between the bows but if you pull too hard it can tear the vinyl fabric. I put a string in the loop so later the sewn line can load up against the string and not cut the vinyl.....
Image may have been reduced in size. Click image to view fullscreen.

Possibly its overkill......
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....but I don't want to revisit this task for yet a third time.
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There are these cheap clothes pegs that are plentiful and just perfect for grabbing the intermediate bow. You can see I've already made up the elastic pull-back pieces a step ahead of time. I figured it would easier to cut and glue the fabric with the slot already done.
Image may have been reduced in size. Click image to view fullscreen.


I used a strip of White GAF tape to hold the leading edge of the headliner in position. The Bentley guide suggests lots of tacks but there is more control with the tape. Another benefit of the tape is that it lessens the chance of cutting through the vinyl with the staples which I put over the top of the GAF tape. I have an air stapler and although it is regulated pressure, sometimes when I press too hard, the bolt strikes into the work. I've learned to hold the tool on the work with light pressure and let it kick back a little so it doesn't drive the staples too far.

The wiggly line is the cut line for the Box knife. I took the photo before I fixed up the line. It was a straight cut after I redrew the line, but alas no photographic proof exits. A small 1cm strip of GAF tape remains in the slot after the excess is cut.
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This shows the reinforcement sewn into the headliner loops. This pulls tension across the headliner and removes wrinkles and sags in the three centre parts of the headliner.
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And here it is looking way better than the last one.
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At this stage I've caught back up to the earlier progress. From here I step ahead. Now, I've never done this before so I have no idea of what I'm doing. I'm just reading the Bentley manuals. There are two versions as well. One is for the Lowlight styles (A83) and the other is for something a little later that 1960 (A83-A) but as it turns out in '66 there is again slight variations and with these modern "kits", its more variation on a theme. It's all very confusing and I'm taking about four times longer to get things done than I probably should. I'm being very cautious to not stuff this up.

Here I've laid out the Hessian/Vinyl/Calico on the car using GAF tape to control the position. The red lines are the "slot" where staples can go in the bow, not miss and punch through the headliner.
Image may have been reduced in size. Click image to view fullscreen.


I'm using paper clips to hold the calico out of the way for the moment.
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The Bentley guide suggests a 1cm gap above the mid frame for the seam where the vinyl and calico join.
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This is along the rear bow ( the one above the window) where the Hessian/Vinyl/Calico and been stapled and cut.
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This is the same thing from the other side of the car but laying on top is the padding material I'm using. This is the rubberised coconut husk traditionally used in the cabriolet roof. I'm not a fan of foam rubber and I've never seen it last more than a few years. For this roof I'm planning endurance.
Image may have been reduced in size. Click image to view fullscreen.


The bits down the sides of the windows were done earlier but I didn't get around to sewing in the coconut husk which is inside the wrap of fabric. This is one of the variations in the guides. The Lowlight guide (A83) does this part before the Calico goes on where the later guide (A83-A) puts these on after the calico.
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This is the thread I'm using throughout the job. It is wax coated and very strong. It won't rot, least not until everything else has rotted.
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This shows the coconut padding sewn onto the Hessian/Vinyl/Calico so that it is pulled down in line with the front bow. Once again I've stapled through the GAF tape to add support for the rather flimsy hessian.

Image may have been reduced in size. Click image to view fullscreen.



I've run out of weekend. Tomorrow I return to work after the Xmas / New Year break. I'm thinking should take more breaks like this. I get so much more important work done. I'm happy to be forging ahead now and hopefully I can avoid any re-work.

Nicholas
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kiwighia68
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PostPosted: Sun Jan 03, 2016 11:02 am    Post subject: Re: The push against entropy Reply with quote

I always enjoy watching a master craftsman at work. My car is not a convertible, but I still found your last post fascinating, Nicholas. I also feel a lot better now that I now others have also had to take a step back and start some jobs from scratch again. (I have a few of those waiting for me.)

All the best for 2016, Nicholas. I hope to have the opportunity to shout you and Boris a beer when next I come across the ditch.
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PostPosted: Wed Jan 06, 2016 5:50 pm    Post subject: Re: The push against entropy Reply with quote

Nicholas, I too have enjoyed reading and watching you reconstruct your cabriolet. Outstanding work and thank you for the detailed pictures!

I noticed your choice of the coconut fiber inner core on your top - nice! Where did you come across this alternative to foam and I'd be curious to know if other K.G. convert owners have opted for this material and how its held up over time?

Is one sheet of this coconut fiber all that is required or do you have to double up to increase thickness? Flexibility to this material - does it hold up to the folding and compacting of the top? Can you tell us what comes after this fiber mat is fixed to the top mechanism? Is the exterior top the next piece in the sequence of materials that make up a Ghia cabriolet top?

Thank you and keep up the great work!
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PostPosted: Wed Jan 06, 2016 6:27 pm    Post subject: Re: The push against entropy Reply with quote

Hi Brad,

I got the material from Germany. It was expensive, 90 Euro a sheet and even more to ship Australia.

https://www.vintagecarparts.de/artikel.php?set_artnr=VHPYARD

It comes in 1 metre x 2 metre x 2cm sheets which is thick enough to do the job and seems more dense than the original material. I think that the original stuff has molted over the years and may have started off just like this stuff.

I know of a commercial upholsterer near my home and I plan to ask him if he knows where to get the same stuff locally.. but its summer holidays now and he's gone surfing (or fishing). I'll let you know when he comes back.

It goes together from bottom up....

Headliner: a) staple to front bow. b) staple to rear bow (one above the window). c) Glue to intermediate and main bow ( keep the seam underneath straight). d) sew to support line on either side. You'll do the insides and back section later after the top piece goes on.

Hessian/Vinyl/Calico wrap sheet: This wraps over the coconut padding. a) staple to Header bow. b) staple to rear bow. c) cut off excess at front and rear.

Rubberised Coconut: Cut to length to fit between front and rear bows. Cut to width to fit between the seams of the vinyl and calico. a) sew to wrap sheet at the header bow so it pulls the padding down level with the front bow top edge with loop stitches 15 to 20 mm apart b) sew to the sides of the wrap with similar loop stitches. Stitches go through the "lip" where the calico and vinyl join. c) sew to the wrap sheet along the rear bow just like done at the front bow. For a), b) and c) trim off excess padding as required.

Use a sharp pair of scissors (get a new set?) Use new blades in your box knife.

This is as far as I've got. Actually I haven't done the last item c) as yet.

I bought two sheets of the coconut husk and I'm glad I did. When cutting to size I copied dimensions from the foam sheet that came with the kit. That was a mistake because that was too short between the header and rear bow. I had to cut it out again. But making mistakes with the Coconut padding is not really a problem because it glues back together really firmly with the same contact adhesive used elsewhere in the roof. You do a "butt weld" and once the glue cures is very solid.

If anyone has advise please go ahead and post in this thread.

Nicholas
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PostPosted: Tue Mar 08, 2016 2:13 pm    Post subject: Re: The push against entropy Reply with quote

Nicholas,
How nice to see your work.
I think We are at the same point in our project. seeing the same situation with the headliner I wonder if you had the same. Problems with the edges of the rear bow . My headliner seems to be a bit short there also. I needed to sew the sides to the roof part a bit to get it al nice and even.

did you order the kit from convertible specialties ?

I wanted to go with the Bentley style beading strip and staple the rear sides of the headliner to the strip.
after installing the outer top I can then install the headliner material around the window to the beading with needle and thread.

keep up with good work and the sharing of the proces.

Peter
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PostPosted: Tue Mar 08, 2016 8:07 pm    Post subject: Re: The push against entropy Reply with quote

petergun wrote:
did you order the kit from convertible specialties ?

Not directly but through HOG. Mind you, Mike took a lot of effort to help sort this out. But to his surprise Convertible Specialties have since not revised their patterns despite having in their hands my original head lining to copy. Further, when they returned the OG headliner, one side had been cut out of it and they kept it. I wouldn't mind that if they had used it as a reference and updated the patterns.
That both Mike and I acting with good intentions to benefit of the wider Ghia community and also a small specialist business would have whole exercise deem pointless when that same supplier continue with a defective product.
I'm speechless.
Sure, I did get a head liner that worked for me, but nobody else will.
Nicholas
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PostPosted: Sun Apr 10, 2016 8:36 am    Post subject: Re: The push against entropy Reply with quote

I'm talking 'bout my generator.
Just because it's somewhat round.
(Channeling my inner Pete Townsend)
Image may have been reduced in size. Click image to view fullscreen.

Before I commit to it being reliable, even though I've fitted new bearings and brushes to it, I want a final test spin on the bench to prove it will function.

"DF" is connected to the Gen case (D-) with a jumper wire and the Voltmeter goes between D+ and the Gen case (D-)

The drill does 1500 rpm and according to Bentley it should make "about 6 volts".
The meter shows this one does more than that. A good Australian built Bosch!

Do this test for only a few seconds or risk burning out the field coils.

Later I'll do the same test with the generator mounted in the car with the battery and regulator in circuit to verify the complete charging system works OK.

At the moment I'm having to workout a way to get the battery cover and clamping strap to play nice together. The battery fits under the VW OEM metal cover but is too tall for the strap to get over. Sad . I'm going to make an extension tube to effectively lengthen the bolt behind the battery. Fiddly stuff.

Then the battery terminals are right out on the edge of the case so I need to to deal with the terminal clamps to make sure they don't short out on the battery cover with such little clearance. I think some judiciously place tar board will help there. More fiddly stuff

At least I'm good working with electricity.

Nicholas.
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PostPosted: Sun May 01, 2016 8:37 am    Post subject: Re: The push against entropy Reply with quote

With the generator sorted I focused on finishing the wiring in the engine bay. One of the things that's been a bother is finding a battery that fits under any one of the several VW OEM battery covers i've restored. I have a 12 Volt and 6 volts covers from Beetles, Type3's and Kombis and I figured lots of options would make it easy. After several failed attempts I eventually found a DIN 53 battery that provided a reasonable fit, would work with the tie down strap and not short circuit the terminals.
Image may have been reduced in size. Click image to view fullscreen.


This has been tested with the electric drill spinning up the generator and the battery volts are seen to increase. I guess the regulator is a good one.

What's more exciting is the contents of this box that arrived this week from Vintage Speed in Taiwan.
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


This is one of the first five Vintage speed exhausts modified to fit further under the Ghia valance than the standard beetle unit. The concept is entirely from Boris Orazem of Vintage Vee Dub. He cut up a Beetle version to made the mock up which was sent to Vintage Speed for production development.

The major concerns were clearing the valance panel and the tin work under the crank pulley. The clearances are pretty tight, being down to a few millimetres which hopefully will be plenty to succeed.

This is the view of the rear with the Exhaust installed. It went in fairly easily even though there was no diagram showing the fit-up. I might have got it wrong and not really needed to buy an extra set of four 8mm x 35mm bolts and nuts that seemed to be missing from the pack.

Anyway it clears the bumper with room to spare.
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....And it just clears the valance on the right side.
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....And it just clears the valance on the left side.
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... And in clears the tinwork around the crank pulley.
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The clearances are indeed small but there is no actual contact with the body or tinwork. Once the car gets rolling, which is getting nearer, I'll find out if this actually works.

This is the view looking straight up the pipes so you can appreciate that at least the visual objective has been achieved.
Image may have been reduced in size. Click image to view fullscreen.


Nicholas
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PostPosted: Sun May 01, 2016 7:26 pm    Post subject: Re: The push against entropy Reply with quote

Wow, looks beautiful Nicholas, are you worried about heat transfer being so close to the sheet metal. I know my metal gets real hot, even the bumper gets hot. Will you make it to the Nationals??
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PostPosted: Sun May 01, 2016 11:03 pm    Post subject: Re: The push against entropy Reply with quote

Rich62ghia wrote:
Are you worried about heat transfer being so close to the sheet metal. I know my metal gets real hot, even the bumper gets hot. Will you make it to the Nationals??

I'm not particularly worried about that. The valance is right down the bottom and if really necessary I might consider bending the edge so those corners nearest the muffler have slightly more space. But there is plenty of radiated heat to make that sort of thing pointless. I figure its best to keep moving and let airflow cool things as much as possible.
Rich62ghia wrote:
Will you make it to the Nationals??

I'll make it to the nationals. The car won't. It's booked at the upholsterers to finish the roof. My target completion is week 2 of July to coincide with the car's actual 50th birthday.
Nicholas
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PostPosted: Wed May 04, 2016 7:35 am    Post subject: Re: The push against entropy Reply with quote

Brakes!
I wasn't happy with the way I did the original brake fluid reservoir and the "T" piece to feed both circuits of the new 4 wheel disc brakes set up. So I revised it with this set up.
Image may have been reduced in size. Click image to view fullscreen.


The brake fluid reservoir which fits on top of the MC is part No: 211 611 313 5 from an early 70's bus. This is fed from the original single circuit bottle behind the spare wheel.

I will need to re-make a new hard line from the M/C to the front RHS wheel so it clears the fluid entry point a bit better and allows the bottle to sit straight. Not a big deal.

I thought about the other way of doing this with the Volvo reservoir but didn't like the risk of contaminating the fluid every time a top-up was needed. We'll see if this works any better.

I just need to get someone over and help bleed the brakes and then its time to put the fuel tank in place.

Nicholas
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PostPosted: Sun May 08, 2016 5:06 am    Post subject: Re: The push against entropy Reply with quote

Started the motor in the car for the first time. Now that's a milestone in this project


Link


Tomorrow it goes to the upholsterer to complete the roof.

Nicholas
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PostPosted: Sat Jul 02, 2016 5:11 am    Post subject: Re: The push against entropy Reply with quote

I went over to vist John at Pro-Stitch to inspect the progress he's been making.
He's redone much of the padding work I had done, not so much that my work was wrong but more because the dimensions of the liner was incorrect. Also the white cailco supplied looked bad and really should have been Black so it doesn't stand out so much between the head liner and roof. It was faster and ultimately better to do it all over again.
Image may have been reduced in size. Click image to view fullscreen.

this shows the new padding with its edges closer to the frame and windows.
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Looking from inside at the parcel shelf and how the headliner is joined to the rear panel.That's a Dino, 911 and a Mini in the back ground.
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Same thing but looking accross the car a bit more.
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Looking down from outside the car, a view you normally wouldn't get because the outer fabric would be in the way. There are not many photos on the samba of this part of the cabrio top, Probably becasue it is tucked up and out of the way, or badly damaged.
Image may have been reduced in size. Click image to view fullscreen.

More of the same
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Looking inside the no-mans-land between the head liner towards the tack bow to show how the headliner is tacked to the rear over the back liner under the rear window.

Next week John will do the outer cover but he has to unpick the edging of the kit because the line along the window is incorrect. Lucky there is excess material that can be cut back before reapplying the edging.

There's been so much wrong with the supplied material in this project it almost isn't worth bothering with these pre-made kits...or you have to be satisfied with a lousy looking fit ... which of course I'm not.

Nicholas
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PostPosted: Sun Jul 17, 2016 1:36 am    Post subject: Re: The push against entropy Reply with quote

An update on work carried out by John at Prostitch.

Image may have been reduced in size. Click image to view fullscreen.

The Stayfast cover is pinned down and the chrome trim nailed in
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The Ghia is surrounded by Italian metal. Three Ferrari Dino in various states of rework. Good company I would say
Image may have been reduced in size. Click image to view fullscreen.

The roofline looks nice an taunt and the padding is smooth.
Image may have been reduced in size. Click image to view fullscreen.

Once more the taunt roof line. The curved stitch line where the side sections are applied to the Centre pieces is per the supplier. Really disappointing levels of precision with this particular supplier.
Image may have been reduced in size. Click image to view fullscreen.

If you look carefully at the bottom edge you can see how the beading and the top roll over below the lower chrome trim. It the sort of finishing touches I was completely unable to achieve , So I'm really glad to have given the task to John to complete.

Nicholas
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PostPosted: Sun Jul 17, 2016 9:16 am    Post subject: Re: The push against entropy Reply with quote

I was scared to death of that stock trim. It's still in my toolbox. I look at your top in utter amazement. Shocked What a beautiful build! Such attention to detail!

Having used a plastic bow at the bottom back (which I regret) there was no way I was going to be able to pound the built in nails of that soft lead like trim at the seam. And it's so skinny! I know my staples weren't that even and straight!

So I used a standard upholstery cover to match the haartz canvas. Not as clean and original, but it did cover my imperfect seam!

The House of Ghia was supposed to do my top - but after months of time, when we brought our camera gear to film the process with Mike - I noticed the top frame was still bent, and not closing properly on the drivers side. So I stopped the whole affair, shocked that it was even considered good enough to upholster the top. Took it home, and spent a week with torches and light bending to get the top to sit correctly. Then we did it ourselves.

As you know sputnick - my ghia is a patina driver, not a garage queen. So while I have a poorly fitting headliner from HoG too - and a few wrinkles in my hedgerow, I'm still super happy and it doesn't leak when driving in the rain. A bird can do a flyby on it, and it washes off, even with the tan.

The cats roof nesting on the other hand...... Rolling Eyes
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sputnick60
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PostPosted: Sat Jul 23, 2016 2:24 am    Post subject: Re: The push against entropy Reply with quote

Thanks bluedot. I reckon what you have done is consistent with the overall look of your car. I think its great.

Here is a photo of the way the rear windlace rolls under at the transition of the top. in the sunshine it is easier to take a better photo of that detail
Image may have been reduced in size. Click image to view fullscreen.

Today I picked up the car from John. Here is a picture of the car on the tilt carrier in the sunshine. It looks great, but I will need to raise the stance by maybe 30 or 40 mm all round, its too low to be properly drivable despite the killer looks.

Image may have been reduced in size. Click image to view fullscreen.

finally back in the garage
Image may have been reduced in size. Click image to view fullscreen.

I'll do the seatbelts and the door panels next. After that is the alignment of front wheels, ride height, headlights, brake testing, engineering certifications and finally registration.

I'm really digging the engine. After sitting idle for eight weeks I pumped the throttle a few times and cranked her. My foot was off the gas when I cranked her and she started first time. Its a willing engine, perfect!
Nicholas
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'65 Porsche 356C Coupe...
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