1961- My First Bug

Eric&Barb · Posted: Wed Jun 10, 2015 7:11 am Post subject:

Hey, no problem! Just found out somewhere about 1961 VW added in drain holes in bottom of "A" pillars. No one knows everything about these old VWs and just trying to pass on what little we have found out.
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jzjames · Posted: Wed Jun 10, 2015 6:19 pm Post subject:

Yeah.
I wonder why all the other car manufacturers didn't put paint drain holes in their window channels.

Seems like there's a missing back-story here somewhere though. Maybe they were really meant to be dual purpose when those German engineers designed in those drain holes Laughing

Eric&Barb · Posted: Thu Jun 11, 2015 7:58 am Post subject:

Think the main difference is that VW dipped the entire body in primer. Have not heard of any other auto manufacture that did that.

As for dual purpose, VW well after putting in the "A" pillar holes, still put out notices that the primer drain holes were to be sealed off.

Having dealt with rust in the "A" pillar, heater channels and pan floors it just seems better to keep out water...
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dc · Posted: Wed Jul 08, 2015 6:38 pm Post subject:

Back at it Smile

I've had the bug for a year now and its time to fix a few more things. The rusty door is first up this summer; remember this:

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

Compare that with a year ago:

So let's grind off all the Bondo (pretty thick Shocked

) and here's the old accident repair....Yuck Exclamation

I've got very good repair metal in the correct spot. Gonna cut out the old damage and carefully weld in the new. Then I will paint with special custom made spray can single stage from Napa Westbay at Navy Yard City.

Updates soon--- then I will replace the deck lid with the correct one Smile

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1963 Karmann Ghia

Eric&Barb · Posted: Wed Jul 08, 2015 7:01 pm Post subject:

Get a shrinking disc, you will be a lot happier with the results and not have to cut, weld up, and still have to shrink it back down.

Link

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dc · Posted: Wed Jul 08, 2015 7:38 pm Post subject:

I don't know-- its pretty bad. Lots of holes/missing metal in addition to the paper-bag texture of the door panel Confused

The video is good- sounds like the shrinking disc would be good for the welded seems if not the whole panel.

I'll post some gory details...
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1963 Karmann Ghia

Eric&Barb · Posted: Wed Jul 08, 2015 7:48 pm Post subject:

Weld up the holes, grind them down, and shrink it up. BTDT on the passengers side of this one:

http://www.thesamba.com/vw/forum/viewtopic.php?t=462164&highlight=wounded+westie

Plus doing same on our 1960 walk thru camper conversion panel. Several DEEP body damage scrapes that were just covered with bondo. Flatting out real nice with the shrinking disc. Will post about that soon.
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dc · Posted: Wed Jul 08, 2015 7:54 pm Post subject:

It would be nice to avoid lots of cutting and welding-- I've done it before but it's slow work that has to be done just right--- here's a detail of the worst- hard to weld rust...

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1963 Karmann Ghia

dc · Posted: Fri Jul 10, 2015 8:34 pm Post subject:

Made some progress on the repair Smile

Carefully measured and cut out the bad stuff and did some test-fitting. Cleaned up the back-side and applied some weld-thru primer on the door edge (re-using the holes for factory spot welds).

Got tacked in and it looks nice and straight so far Cool

Tomorrow I will continue to SLOWLY spot in the seams and go from there.

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1963 Karmann Ghia

63vbug82 · Posted: Sat Jul 11, 2015 1:46 pm Post subject:

Looks good Wihat color is this .mine is the same color and trying to find the paint code so i can paint my hood and deck lid

dc · Posted: Sat Jul 11, 2015 9:17 pm Post subject:

Not an original color for this car...my was originally Beryl Green. However, I think there was a 1961 Light Blue color offered (one year only?) not sure where I saw that.

When I paint the door and the decklid I'm using the same blue (well, as close as I could get).

Spectramaster Color is the brand I'm using and it is called
Color Atlas Blue - CAS6862

I have the exact formulation if you need it.
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1963 Karmann Ghia

dc · Posted: Sun Jul 12, 2015 10:39 am Post subject:

According to the "Technical" Section on this site. There was a similar (but not the same?) blue for 1961: L391 Pastel Blue
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1963 Karmann Ghia

dc · Posted: Sun Jul 12, 2015 1:49 pm Post subject:

Door work continues--- got it finish welded in. Fit was good but not perfect-- welding heat caused some warpage. Careful heat and hammer work got it acceptable. Got ground down and put a layer of Bondo on to fill the low spots.
My camera got full so I missed out on the seam welding and grinding, but you get the idea. Next is some Primer/Filler, more sanding, etc. until top coat.
Fun times Rolling Eyes

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1963 Karmann Ghia

dc · Posted: Mon Jul 13, 2015 10:02 am Post subject:

Many coats of primer and sanding led to a coat of color. Looks like my blue is a bit too dark: I was afraid that might be the issue. Tough because there are about three different shades of blue all over and inside the car. I will give it a few days to dry and harden and then I will buff it to gloss and see how it looks. At worst, I have some paint left over and I could paint the rear quarter area under the chrome trim.

Also, ther is some wrinkling ripples in the metal under the front edge of the door handle from working the panel with a hammer--- couldn't really see this until a top coat was applied--- Rolling Eyes

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1963 Karmann Ghia

dc · Posted: Tue Jul 14, 2015 8:56 pm Post subject:

More updates to report:
Got the correct steering wheel installed. Turns out the wheel in my truck was better suited to the Beetle and I was able to dig through the stash in my garage and find the correct type three wheel for the truck as well Cool

Zero dollars spent.

Here's the before -one year ago- shot:

Here's the after -today- shot:

Not everything is correct/exact but it's MUCH better than when I brought it home - IMHO

Next is the rear end...
The wrong decklid and tail-lights (this car was made in Sept 1960) have annoyed me long enough.

Got the correct lid (closer anyway) blasted by Blast Worx in Poulsbo (they did a great job at a reasonable rate). The license light was taken apart and cleaned up as well:

The decklid has some problems: pin holes along the bottom edge and several small shallow dents/dings. There was a lot of Bondo on it that was hiding the imperfections. Not sure how many hours I want to spend "massaging" it --- sort of want to do the minimum and get it on the car. The overall condition of the paint is mediocre and it's really just a driver at this point....hmmmm
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1963 Karmann Ghia

Jon's62 · Posted: Wed Jul 15, 2015 6:41 am Post subject:

Things are looking really good so far, Keep it up!

Rome · Posted: Wed Jul 15, 2015 6:46 pm Post subject:

Your complex door rust repair turned out impressive.

As to your later taillights- strongly consider keeping them. Their additional light output and separate blinker are much better suited for today's careless drivers behind you. If you polish/brighten up the metal reflectors and possibly use high-tech LED bright bulbs and good amber-top lenses, you'd have good rear lighting. At least straighten out the left taillamp (top tilts outward slightly) and bring it down slightly to be level with the right one.

dc · Posted: Wed Jul 15, 2015 10:23 pm Post subject:

I have definitely considered keeping the slightly larger lights...they do seem safer.

Another option would be LEDs in the smaller snowflake style (if I find a pair-- they are pretty spendy) and/or a thrid brake light.

The door repair is OK- their is some minor warpage that is bothering me but I'm not quite done with it yet Wink

-- I may dig back into it and do some more body work. Tomorrow I will need to get more paint mixed for the decklid anyway--- gonna ask for a lighter shade of blue.
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1963 Karmann Ghia

Eric&Barb · Posted: Thu Jul 16, 2015 11:19 am Post subject:

You can use the earlier taillights and still have all of the safety by installing yellow accessory lights on the license plate frame. Just wire them in to work as both brake/turn signal. Fellow drivers notice yellow signal lights a lot more than red lights, found that out ages ago when went from all red TL on our 1963 K. Ghia with 12 volts to yellow topped euro version. Huge difference...

Here is the same setup on our 1960 bus:

Have done same with our 1963 SC recently, and added LED bullet style lights thru the lower license plate screw holes.

Found these for less out at all car swap meets, and they even work on 6 volt though made for 12 volt.

http://www.amazon.com/Lighted-Bullet-Style-License...olts+Amber

Having two bulbs is a lot safer, because now if one bulb is out you have the other is most likely still working.
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dc · Posted: Thu Jul 16, 2015 3:19 pm Post subject:

What about a license plate frame with a built in brake light?

Like this:
http://i.ebayimg.com/00/s/MTE0OVgxNjAw/z/IpUAAOSw~uhUqv19/$_57.JPG

In the meantime...I'm reworking the door again--- dark paint and flaws are too glaring. Got a nice new mix of paint and have started using high-build primer to make the flaws smoother.

Prime - Sand - Prime - Sand - Prime - Sand - etc.

Decklid is coming along as well...
Hammer work and some pin holes were filled now getting painted.

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1963 Karmann Ghia


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