Had some time for my '58 low light today

[d5626]

FYI, I've used those panhalves and you're going to need to address the pedal stop area on the new pan halves to match the original ones. Its not flat, no nut insert on underside. Almost easier to cut section off old pan and weld into new than mess with flattening/drilling welding nut underneath to correct position. Hate to see you catch this after getting the pan into finished state ie painted/powder coated.

[Porschedave]

Hi d5626

Thanks for the advice. I was aware that I was going to have to make those mods to this pan including the jack points. I cut the old jack points off the old pan and will weld them to this one as well locating the pedal stop area. And I need to repair and weld the seat tracks in place. More work to do yet ...

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[Porschedave]

Hi Folks

Today I finished the repair of the slightly (LOL) damaged and rusty seat rails, make a new cross member and welded the whole thing in place. Here is my setup to make sure things stay aligned:

And then the driver's side in place.The copper color is weld through primer so that there will be no raw metal.

And finally both seats in place.

And I can even sit in them and make zoom zoom noises.

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[c21darrel]

Nice.
Cool recessed area for your lift!!

Try to keep the zoom zoom to a minimum til you have your brakes
_________________
GhiaBuild
http://www.thesamba.com/vw/forum/viewtopic.php?t=481184
1967 DC build
https://www.thesamba.com/vw/forum/viewtopic.php?t=693583&highlight=67+dc
Stop dead photo links! Post your photos to The Samba Gallery!

[bobnorman]

[Porschedave]

Hi Foks

Today I brought the shell home so I am ready to tackle the restoration of the body now that the pan is done.

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[Porschedave]

Hi
I got to work on the car today, beginning at the right front corner. It is kind of a mess, with rot around the headlight bucket and inside the fender where the cool air flows.

I removed a section of the fender to make access easier.

The fresh air tube was shot,

I cut the tube away and some of the poor metal around the tube,

and then a cardboard template to make the new metal piece with the tube inserted

and I removed a rusty section and made a replacement piece just behind the headlight.

Tomorrow I'll start welding the replacement pieces in. All in all, not a bad day.

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[oldbusboy]

Looking good Dave. Look forward to your progress!

Trevor
_________________
1968 porsche

[kgj]

Hi, nice work and thanks for sharing.
Can I request a few more photos as you tackle this please?
I'm doing similar work on my '58 (CJ from South Africa) on the left hand side fender.
Keep up the good work.
Best regards.
_________________
1958 coupe

[Mellow Yellow 74]

[Porschedave]

Hi

We're having something like 50mm of rain today - talk about the wet coast!! But the garage is relatively warm so I spent the day staying dry working on the right front air intake. What a pain. It was difficult to make the piece that flows are from the nostril. But I've managed to make a piece and managed to get it to fit.

And I've finished the pieces for the front of the box as well.

By this time tomorrow it will all be welded into place and I can have a closer look at replacing the front fender and headlight bucket.

Cheers.

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[kiwighia68]

I went through much the same processes replacing my fresh air boxes and tubes on my '68 Ghia. My only regret is that I didn't paint the insides of those parts before spot welding them to the frame.

Paint and cavity wax while the access is good, is the lesson I learned.
_________________
Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015

[Porschedave]

Hi kiwighia68

Yes, I agree. I've painted the insides of all of the metal and the original material as well.

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[Porschedave]

Good morning

Yesterday I completed the repair to the right-front air duct and am now ready to fit the replacement fender piece and the newly purchased lower fender part that I got from Danny Gabard. I used an etch primer over the new parts to reduce rust. And I noted that the replacement headlight buckets need a bit of modification to match the original - like removing the tabs for the newer light fixture and plugging one hole.

The fit of the replacement parts is not too bad so I am hopeful that in another day or two of work the fender will look quite finished.

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[Porschedave]

Hi
Before I weld the new section I looked carefully and sure enough there was factory lead in the panel. I used a torch to gently heat and melt this stuff out of the way so that I can go ahead and weld the panel to the fender section. I think that working with this lead was pretty unhealthy and I was careful not to breathe any fumes.

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[bobnorman]

If it's the factory applied material it was pewter, not lead. I'm guessing it would be slightly less toxic.
_________________
Air does not freeze. Air does not boil.

http://www.thesamba.com/vw/forum/viewtopic.php?t=289807

[Porschedave]

Hey

Today's progress was to tack the new pieces into place and they fit very nicely.

Tomorrow I'll finish weld these completely, add a headlight bucket and then move onto the next section - the engine compartment!!

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[Inchpincher61]

The car is looking more and more like a Ghia again. The engine compartment is a section where I will have a lot of work too so I am curious for the coming progress and pictures o course!

Really ambitious project! Keep us up to date.

[Porschedave]

Howdy Folks
Today I started the work on the engine compartment. This will be complex because not only do I need to work on the engine tin but also the fender supporting brackets, the rear valence and of course the rear fender area. And all of these are interconnected. Here's shot of the compartment and you can see that it is somewhat sad. It seems this car was bumped from behind at some point.

Trevor gave me a chunk from a wreck of a lowlight,

So, I removed the essential piece that I need:

and then media blasted it and matched it up with a battery tray piece I bought from Danny at Gab-Fab. It's a perfect fit.

And I made a few of the supporting pieces that I'll need.

Not bad progress today.

Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139

[Inchpincher61]

Dave,

this is a really complicated area because some many pieces come together. I did almost the same on my Ghia yesterday (removed the engine bay) but with the damage on the driver side.

Your preparations look good especially the rescued and blasted middle section, well done! I also have imported a battery tray from danny and I am really satisfied with it as well. I think there is no better reproduction on the market at the moment. So looks good so far...keep on going!