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1969 Karman Ghia Build (UK)
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carl4x4
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PostPosted: Mon Mar 31, 2014 2:03 pm    Post subject: Reply with quote

Lot's of small jobs getting done over the last few weeks, The biggest was the gearshift bush which took a good afternoon to complete. Been concentrating on the engine wiring, starter, gauge senders, fuel system, ignition timing etc.

New bush & Vintagespeed 356 shifter:

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New re-routed wiring to the starter from battery relocated to under rear seat:

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New Spax adjustable shocks fitted to match the rates of the Red9 front ones:

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Aluminium Sill plates fitted, to hide the main front/rear loom

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And perhaps the biggest pain in the ar$e job which was haiving to re-do the front flexi brake pipe mountings. Rolling Eyes I went to bleed the air from the brakes and noticed the flexi lines were under strain. So out came the fuel tank (again!) empty the brake system, move the brackets, get some new hard lines made up to 25mm longer, fit those, (if only I'd tested at full lock the first time Rolling Eyes )

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carl4x4
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PostPosted: Thu Apr 03, 2014 2:16 pm    Post subject: Reply with quote

When I was looking for something else in the garage last night I stumbled across these Carello fog/driving lamps I bought at an autojumble a while ago and forgot about. Only paid a couple of £ for them and stored them away without much thought.

Anyway I Googled them this morning and found that not only are they the right age for the car, they were used on old Lancias, Maserati's, but more importantly are the same type as fitted to Herbie, in Herbie goes to Monte Carlo (ok so perhaps this model has a slightly different lens)

Anyway I mocked one up tonight on the car with a temporary bracket, the lens needs cleaning inside & out but I think it suits the car and it's nice they are period correct and didn't cost me an arm & a leg! Smile

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Last edited by carl4x4 on Thu Apr 03, 2014 3:13 pm; edited 1 time in total
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mountainkowboy
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PostPosted: Thu Apr 03, 2014 3:07 pm    Post subject: Reply with quote

NICE! Would love to find a set for mine.
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PostPosted: Fri Apr 04, 2014 5:09 am    Post subject: Reply with quote

Very illuminating. I like them
Nicholas
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c21darrel
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PostPosted: Fri Apr 04, 2014 11:03 am    Post subject: Reply with quote

I like the shifter AND the lights. Might like the lights even more if you painted the lenses yellow Smile
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carl4x4
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PostPosted: Fri Apr 04, 2014 2:33 pm    Post subject: Reply with quote

c21darrel wrote:
I like the shifter AND the lights. Might like the lights even more if you painted the lenses yellow Smile


Funny you should say that, I had considered re-coating the lens yellow
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FRNKNSTNGHIA
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PostPosted: Fri Apr 25, 2014 3:58 pm    Post subject: Reply with quote

carl4x4 wrote:
c21darrel wrote:
I like the shifter AND the lights. Might like the lights even more if you painted the lenses yellow Smile


Funny you should say that, I had considered re-coating the lens yellow


did you trial fit them on the inner bumper. Between the over riders?
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carl4x4
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PostPosted: Fri Apr 25, 2014 4:14 pm    Post subject: Reply with quote

FRNKNSTNGHIA wrote:
carl4x4 wrote:
c21darrel wrote:
I like the shifter AND the lights. Might like the lights even more if you painted the lenses yellow Smile


Funny you should say that, I had considered re-coating the lens yellow


did you trial fit them on the inner bumper. Between the over riders?


Yes I did, not sure I liked it though...

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carl4x4
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PostPosted: Sat Apr 26, 2014 12:37 pm    Post subject: Reply with quote

I'm now at the stage where I definitely am getting pi$$ed off doing wiring. Spent another 6 hours on it today and a similar amount during the week. I know I am getting somewhere but there's not much to show for it when you do wiring! Crying or Very sad
This will teach me to completely re-wire the car plus change all the instruments to 914 ones, change the horns & switch, convert washers to electric, plus change from Generator to Alternator, and move the battery under the rear seat all at the same time.

I must have been mad, all that on a UK car that no proper wiring diagram exists (not that it would have been much use looking at the list above!)

Laughing Laughing
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carl4x4
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PostPosted: Sat May 10, 2014 2:18 pm    Post subject: Reply with quote

Been spending a lot of evenings on the Ghia recently with quite a lot of progress.

Engine & rear of car wiring, fuel & plumbing is all complete now, just a vacuum advance pipe left to fit.

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Interior is now finished, treated myself to my favourite period steering wheel, a Momo Prototipo with quick release for added security. (this photo angle makes the seat base look bigger than it is!)

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And the wiring is now almost complete, just the main battery feed left to splice into the main loom under the rear seat, waiting on me buying some 7mm 50 amp wire to complete the job. The combination of being a RHD car with no published wiring diagram, plus changing to alternator, moving the battery location & fitting Porsche 914 dials has meant the wiring has taken what seems like ages to do. Brakes will hopefully get bled next weekend then the fuel tank can go back in (keeping it out for now just incase any of the new brake lines/junctions need tweaking)

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And for safety I also fitted a third brake light today inside the engine grill

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very unobtrusive when it's not on Smile
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motorhead364
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PostPosted: Sat May 10, 2014 3:18 pm    Post subject: Reply with quote

Very nice
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FRNKNSTNGHIA
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PostPosted: Sat May 10, 2014 6:01 pm    Post subject: Reply with quote

Nice ghia... Ours will be somewhat similar interior wise.. I will also be running the Momo Prototipo but in brushed aluminum, as well I will be running Porsche 356 Speedster gauges. I like your shifter, I have the 13" Empi for now but will upgrade to a Vintagespeed eventually... I like the 356 version you have...


What quick release did you use?
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ScottDoonan
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PostPosted: Sat May 10, 2014 11:29 pm    Post subject: Reply with quote

Very clean, nice work. Me likey a lot.....
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carl4x4
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PostPosted: Mon May 12, 2014 6:18 am    Post subject: Reply with quote

FRNKNSTNGHIA wrote:



What quick release did you use?


It's a snap-off quick release with a lock;

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carl4x4
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PostPosted: Sun May 18, 2014 1:55 am    Post subject: Reply with quote

It lives !

Spent a great day Saturday and managed to get the brakes all finished, bled, fuel tank back in, wiring finished, put some fuel in her, then managed to get the engine started Cool Cool

Took lots of attempts, my wise old Uncle was there to help me and he took 14 videos of failed attempts at starting before she sprung into life, timing was a challenge without points but we did it the crude way of timing to 0 degrees from the coil wire sparking on the alternator when at tdc to get it started. (then set it when running with a strobe light) Then we had a problem with not enough fuel until I raised the pressure on the fuel regulator.
Also managed to drive it up & down the drive so I know 1st & reverse work now Laughing

Running;

Link


One of the outakes...

Link

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carl4x4
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PostPosted: Thu May 22, 2014 11:49 am    Post subject: Reply with quote

Had a problem with the turn signal warning lights flashing only once then not at all. Found the answer here: http://www.thesamba.com/vw/forum/viewtopic.php?t=375700 the front bulbs were the wrong wattage.

Proves what a great resource TheSamba is Smile
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carl4x4
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PostPosted: Sat May 31, 2014 1:46 pm    Post subject: Reply with quote

Decided to polish up the old licence plates to see if they would come up to scratch, bit of metal polish on the letters and three coats of wax to bring up the background and the result was quite surprising !

Also cleaned up the driving lights and made some mounts that use the existing bumper bolts so I don't have to drill through the bumper

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carl4x4
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PostPosted: Thu Jun 05, 2014 9:43 am    Post subject: Reply with quote

Well the Ghia saw the light of day today with a visit to Novatech in Slough, nice guys who checked over the fuel system, sorted out the carbs & timing for me & have set it up & jetted it at the moment for running in. I'll go back after it's run in for another tune up & a more aggressive setup. But for now it's making 90bhp with a nice healthy 125lb ft torque that comes in quite low down the rev range which is useful. probably be closer to the magic 100 when it's loosened up Very Happy
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c21darrel
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PostPosted: Thu Jun 05, 2014 10:04 am    Post subject: Reply with quote

Congratulations!
Must be nice for you to be on the road. Low end is where its at for a street car. Much more useful powerband. I remember you are 76 stroke and 90.5's. What cam?
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carl4x4
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PostPosted: Fri Jun 06, 2014 7:52 am    Post subject: Reply with quote

It's been a while since the engine was built, I'd have to look up what the cam is.

Took the car for its MOT today, and passed Very Happy Very Happy (this is a big thing in the UK Wink just need the paperwork through from the Insurance and I can tax then drive it
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