DJ's Oct '58 Coupe - Motor '57

[CiderGuy]

[djway3474]

[CiderGuy]

Great ! Would you happen to have a better picture of the copper coil ? I just bought a two stage 80 gallon compressor , it got old running out of air.
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Cars Currently Owned:

1970 Karmann Ghia Coupe
1973 Karmann Ghia Coupe - Project car for sale
1970 Karmann Ghia Convertible (Body off restoration)

Timing is everything

[Bills85Westy]

I just read your thread from start to finish and compliment you on your great work. You are in the home stretch now! You've come up with some creative solutions to some difficult problems. I can't wait to see your Ghia finished!
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89 Tristar Syncro Doka - White
85 Westfalia Syncro (conversion)
SAH 1.8T Conversion - 2005 AWP
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L

[djway3474]

Cider Guy -I looked and I have no more picts of the copper coil. If I clear some space in front of it I will take another shot.
Bills85Westy - thank you for the kind words. I learned most of my skills in Scale auto modeling. Break down your project into multiple smaller projects. Since you can not just go buy parts for scale models for a project you learn how to make it yourself. I just had to do things on a larger scale. One project after the next, rack em up and knock them down

[djway3474]

I installed the front and rear hood seals. Got the window winder mechanism installed and the door latch mechanicals installed also.
It appears that I am going to need to add spacers under the rear shock tower mounts to get the top of the door gap down to at least 4mm. I ordered some .125in aluminum to make the spacers.
I worked on polishing the aluminum door weather strip channels that go over the doors. Mine were really beat up bad so I will do what my skills and tools allow.

Odd finding is that the body color was found inside the channels. Were these entirely painted from the factory?

Hood latches go in next and final front hood alignment.

[CiderGuy]

[djway3474]

[djway3474]

This was the trial fit......and I mean it was a trial.

I finally gave up on attaching the chrome strip with the aftermarket clips. I found the originals and reconditioned those, then the license plate light chrome when right on without problem.
The tail lights have also been a difficult task. There was no body damage in this area but these lenses and rubber seals were not close to fitting out of the box. I have done a lot of trimming to the inner lip of the seals and I have done some reshaping of the bulb holders. I am also going to run long screws through the lens to the inside of the body and add an internal nut. I can't get a good fit without that addition. Who would have thought these few items would take a few days

[djway3474]

Got the horns in

The fuel tank is being tested for any leaks at the fuel tap

I used a shift boot to reduce any air intrusion through the steering shaft.

One by one the projects are done

[lonotch]

That shift boot is genius!
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It's not about the window, it's about the people.

German Folks

[John Moxon]

[djway3474]

[djway3474]

Question above about adjusting the door gap with spacers over the shock tower body mount.
First is an example of a thin spacer I have

Here is a picture of the spacers installed. It took many trial and errors with different sized rubber and metal spacers. Finally got both doors to the 4mm per the Body Manual.

Here are two pictures of the clips I made that retain the rubber weather strip to the door.

I got the door windows out of storage and cleaned them off for the first time. Passenger glass has deep scratches. I sanded and polished all day and I could not get them out. I had to go to such a heavy grit trying to get to the bottom of the scratches that the window just cant be saved.

SO, the hunt is now on for a passenger window. I have a window from a later Ghia that I placed over the original, drivers side. It appears that if I can find someone to cut the bottom edge that the remainder of the shape is the same. Anyone else ever tried that?

[PeteSC]

[djway3474]

[djway3474]

Fabricating a holder for the wiper fluid bottle which will use a pump. The holder will have rubber tubing over it and it will hook into the body openings where the body to beam bolts are.

[bobnorman]

[djway3474]

Well the wiper reservoir is in, the pump is in and wired up, the hose to the ANCO nozzles is in. This car had one ANCO nozzle/jets when I got it and luckily I found a pair of NOS nozzles.
The jack and spare are in place to make sure all fits good.

the nozzles and the wiper shafts installed

[djway3474]

After days and days and.............days and days of polishing this once heavily and deeply scratched passenger window glass is a good as its going to get.

I think the drivers window may even be worse. I have ordered a heavier grit stone polishing pad to see if I can cut to the bottom of the scratches quicker.