Had some time for my '58 low light today

Porschedave · Posted: Fri Jan 24, 2014 10:13 am Post subject:

Good morning Dwayne

Thanks for the reply. I would like to have a picture from below of the transition of the rocker to the front curved portion to the straight run to the back. Looking at the pictures I posted, at the front end, the track that sits on the pan is 2" wide. Does it stay 2" all the way to the back corner? Also, on the front curve piece, there is a lip and I assume that carries all the way to the back as well. Can you confirm that and perhaps take a picture for me?

And secondly, what happens at the back corner? Does it just run straight to the back and stop where it intersects the cross member?

Thanks for helping.

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

djway3474 · Posted: Sat Jan 25, 2014 12:42 am Post subject:

I just posted 9 photos to the Ghia coupe section of the gallery. Hope they help you figure out what you need to know

Porschedave · Posted: Sun Jan 26, 2014 9:12 pm Post subject:

Dwayne

The pictures were perfect. Thank you for taking and posting them. I am now ready to work on the rocker repair. 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

djway3474 · Posted: Sun Jan 26, 2014 9:58 pm Post subject:

You are welcome Dave, Its all about the love of the Vdub Cool

Porschedave · Posted: Tue Feb 25, 2014 4:41 pm Post subject:

Hi Folks
I've been a bit distracted and work on the Ghia has been slow. But here are a couple of updates - work in progress. First, I am working on repairing the passenger side rocker. I've looked at the sites here and everyone has a different solution, depending on the amount of damage. For me, the outer skin needs replacing as well as the internal strengthening section and the mounting plate. So, I am building my own. Here's the cleaned up area.

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

And then a section to be welded in.

And now trying to fit the new skin and the inner fender piece.

The fit is not great - yet. I'll have to do some more trimming before I start welding. Oh, and while I was working on this I knocked out a piece of filler along the back fender. Take a look at this wrinkle and repair.

I'm off to Germany this weekend and will get a factory and museum tour while in Osnabruk. I hope to see some old Ghias.

To be continued ...

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 · Posted: Fri May 02, 2014 9:26 am Post subject: rocker repair

Hi Folks

Finally managed to get some time ont he Ghia this week, mostly removing metal. I thought I'd show these photos for those who haven't seen a rocker in pieces. The first shows the pieces as I separated them after drilling out the welds and the second shows it all clean.

I didn't want to replace the whole thing since the inner portion is still in good shape and it would be less likely that the body would twist.

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

Bobnotch · Posted: Fri May 02, 2014 9:46 am Post subject: Re: rocker repair

oldbusboy · Posted: Fri May 02, 2014 11:26 am Post subject:

Looks great Dave!

Trevor
_________________
1968 porsche

ScottDoonan · Posted: Fri May 02, 2014 2:22 pm Post subject:

Very nice work, stay at it. Rockers are not fun, but as you know they are a very essential part of structural integrity. With good rockers set right, a lot of other repairs can be made easier, fitment is more symmetrical and measuring points a bit more accurate.
_________________
If you take time to do it, do it right and don't be so damn cheap.....🤙🏻

1959 Karmann Ghia Cabriolet (current restoration)
1965 Porsche 356 SC coupe
1967 Volkswagen Convertible Beetle
1969 Porsche 911E Targa 3.2 twin plug
2006 Porsche 987 Rüf 3400K Prototype #2 of 2

Porschedave · Posted: Wed May 07, 2014 8:28 pm Post subject:

Hi Folks

Look at this - it fits!

I have a question tho. Behind the front fender where the wiring tube comes out, does anyone have a picture of this area. I've looked around a bit. I am assuming that the exact shape under there is not that important. I am curious about the area where the wiring tube comes out.

I'm pleased with this fit.

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 · Posted: Wed May 07, 2014 8:47 pm Post subject:

"LIKE"
_________________
1968 porsche

djway3474 · Posted: Wed May 07, 2014 9:14 pm Post subject:

after rebuild

before rebuild

hope this helps

Loren · Samba Member Joined: January 10, 2004 Posts: 1700

Here is what I started with on my Ghia

Here is the same section after the body guy fixed it.

Porschedave · Posted: Thu May 08, 2014 8:57 am Post subject:

Hi Dwayne and Loren

Thank you for posting those photos - they were exactly what I needed. I'm off to the garage to see if I can make those pieces. Photos to follow.

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 · Posted: Thu May 08, 2014 10:50 am Post subject:

Hi Loren and Dwayne and others

On this piece inside the front fender, sitting behind the wiring harness pipe runs, is there a special purpose for the shape behind the pipe? It seems to me that this could be a flat piece rather than this fancy curved bit. It does not appear to help air flow up the tubes and certainly wouldn't be there to flow air up behind the door jam. Making it flat would make my repair easier. Your thoughts/experience would be helpful

Thanks.

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

djway3474 · Posted: Thu May 08, 2014 10:54 am Post subject:

Dave, the bend is because the wire harness is coming from above and the tube is bent up to meet it. There is a grommet that goes over the end and seals the tube.
Danny at Gab Fab makes the tube with the bend and the flared tip.

Porschedave · Posted: Thu May 08, 2014 11:19 am Post subject:

Dwayne
Thanks - that helps. Another question, if you are looking to the front from inside the rocker (ya, I know that's difficult) how large or what shape is the opening for hot air into that section at the junction with the door jam? I think that where the wiring harness passes through it is closed - I think I can see that from one of your photos. But I am not sure about the opening for air since and I have to make a new section, I don't want to make the opening too small nor too large. Maybe you have a photo of that section.

Thanks.

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

djway3474 · Posted: Thu May 08, 2014 11:28 am Post subject:

The wire tube runs in the rocker section outside of the heater channel so I am not exactly sure what you are asking.

Porschedave · Posted: Thu May 08, 2014 11:43 am Post subject:

Ok, I'll take a picture and post it. Just have to find and charge the camera ...
_________________
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 · Posted: Thu May 08, 2014 12:18 pm Post subject:

Hey Dwayne

here's a picture of a temporary piece I made that would box off the end of the rocker channel.

I am curious about whether this door jam section has a cut out for the heating, to the left of where the wire harness hole is. I looked at Scott's page and got some idea but not complete.
Thanks for hanging in with me.

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


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