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Thu Dec 15, 2022 6:31 am

It's amazing what the buffing will do for it!

d

Thu Dec 15, 2022 7:19 am

Redlabel6 wrote:

It's amazing what the buffing will do for it!

d

Yes that really looks good. I'm looking forward to getting into the buffing and starting to put the car back together.

Tue Dec 20, 2022 3:22 pm

Like Redlabel6 said, it amazing what the buffing will do for it.

Here is a side by side comparison of 3000 grit wet sanded on one side and step one of buffing (3M rubbing compound using a wool pad on a rotary buffer machine).

Can’t wait to get the whole car done with the 3M three step process (rubbing compound, machine polish, hand glaze)

Mon Dec 26, 2022 7:59 am

It'll be a lot of work, but worth it!

Sun Jan 01, 2023 4:00 pm

Finished the buffing process of the car. I used the 3M three step process.

First step was applying rubbing compound using a wool pad in a buffing machine. Next I applied machine polish using a foam pad in a DA polishing machine. Final step was to hand apply the 3M hand glaze. I’m sure there are other ways to buff and polish a new paint job, but this process worked good for me.

Below are sume pictures after the buffing process was completed. Overall I’m pretty satisfied with how the paint job came out. The important thing is my wife gave it a “thumbs up” and since this is her car I guess it passed her test --- Happy Wife, Happy Life.

Started putting exterior parts back on. Will spend the next few winter months getting the car done so my wife and I can do some summer cruising in her restored car.

Sat Jan 07, 2023 3:51 pm

Spent some time putting bits and pieces on the nose of the car. Installed the headlights, turn signals, fresh air vents, and horns.

I have to say it would have been much more difficult installing these items if it wasn’t for all the great tips and tricks I found in various posts on TheSamba.

Headlight ring gaskets went on fairly easy thanks to Era Vulgaris’ suggestion to use blue painter’s tape to hold the gasket in place until the headlight chrome ring is installed. Worked great. Only thing I did different was after installing the chrome ring I sprayed the blue tape with window cleaner to make it easier to remove the tape from the gasket and fender.

Struggled for a couple of hours trying to get the horns into the rubber boot until I did some research on TheSamba.

• I tried the suggestion made by VWLIMO to install the bolt on the back of the horn, then put the horn inside the boot thru the oval opening, clamp the horn bolt into a vice and grab the boot with both hands and pull the boot evenly over the back of the horn. Took me less that 15 minutes to get both horns installed in the boot.

• I then followed russelltatedotcom suggestions to tape the horns to the boot so they don’t move, put wire inside the lip of the oval boot opening and install the boot in the front opening by pulling the wire to bring the lip of the boot to the exterior of the oval opening. The wire trick is basically the same as when installing the windshield or rear glass.

Overall, it took me about an hour from the time I clamped the horns in the vice to the time the boot was mounted in the oval opening.

Tue Jan 24, 2023 3:29 pm

Continued installing the various exterior pieces.

Installed the door window exterior scrapers. Also installed the side trim. Had to use a reamer to clean the paint in the trim clips mounting holes, otherwise the trim clips wouldn’t fit into the holes.

Disassembled the original jack, cleaned all the various parts, painted the parts that had originally been painted, and mounted the jack in the trunk.

Spent some time trying to organize the wiring birds nest behind the dashboard. Was a real mess but got it somewhat better organized. The hazard relay wasn’t working. Was going to install a universal hazard relay but decided to break open the case of the original VW hazard relay. Discovered a trace on the circuit board had a break in it. Soldered in a wire to bridge the gap and complete the circuit. Works fine now plus keeping the car as original as possible is a good thing from my perspective.

While playing with the wiring decided to install a lights-on warning buzzer to prevent the lights from being inadvertently left on. Now if the lights are left on after the engine is shut off the buzzer will sound to remind the driver to turn off the lights.

After finishing with all the wiring related work installed the trunk liner and carpeting. The carboard liner that came with the car had a lot of tears, etc. Used Gorilla tape to repair it than contact cement to attach the trunk rug. Also used some rare earth magnetics to hold the sides of the liner against the trunk sides since the liner sides were pretty floppy and would not stay upright.

Sun Apr 09, 2023 2:46 pm

Well, although a car is “never done” I’m calling the restoration completed for now. Pictures of the "finished car" are below.

Sun Apr 09, 2023 5:33 pm

Beautiful. Nice job. Must feel awesome to drive it.
=D>

Mon Apr 10, 2023 1:36 am

Thanks for providing a great inspirational restoration for the "Stickies" Legacy. It's these detailed restorations that make The Samba the very best place anywhere to pick up advice, techniques and inspiration for a Karmann Ghia rebuild.

Enjoy the drive and the plaudits wherever you go, it's a rare beauty. :D

Mon Apr 10, 2023 4:32 pm

Well done!

Tue Apr 11, 2023 4:00 am

Thanks to all for the very kind comments. Really appreciate the feedback.

Tue Apr 11, 2023 7:39 am

Beautiful result!
I hope your prepared for your new found stardom 8)

Thu Apr 13, 2023 5:00 pm

As someone who has gone through a similar from-the-ground-up restoration as you, all I can say is that you have done a fantastic job. A tribute to your love for your wife.

I doff my hat to you, Sir. Well done.

Chris M

Fri Apr 14, 2023 4:29 am

Again I just want to say thanks to everyone for the very kind comments.

When I started this restoration, I had very little experience making and welding patch panels, so it was a learning experience that gave me lots of satisfaction.

My advice to anyone who is considering undertaking a restoration project is don’t be afraid to try. If you make a mistake, as I did many times, just try again until you are satisfied with the outcome. And read all the great threads on TheSamba,com and watch lots of You Tube videos.

Thu May 25, 2023 4:46 am

Just a quick update. Took the KG to a local car show this past weekend. Fair size show with about 300 cars. Wife's KG was selected as best import. Guess judges thought the restoration came out ok.

Thu May 25, 2023 5:30 am

Congratulations! :D Very well deserved...you see it's not just the Samba regulars who appreciate your restoration.

Thu May 25, 2023 8:50 am

John Moxon wrote: Congratulations! :D Very well deserved...you see it's not just the Samba regulars who appreciate your restoration.

Thanks for the kind words.

Yea, lots of older folks looked at it in detail and we heard stories of when there was one in their family. Younger folks not so much, not sure they even knew Karmann Ghia's existed in the past.

We live in Southern Maryland and I don't think there is more that a very few KGs in the whole area.

Mon Aug 05, 2024 8:18 am

Legacy wrote:

Great work. Have downloaded many of your pics for reference.

Do you have the measurements of:
1. From headlight down to turn signal top screw hole?
2. from centerline to bumper bracket opening?
3. from front of trunk opening to top of the oval hole for the horn?

I need these three for my car as my car came missing all three.

Thanks
Byas

Mon Aug 05, 2024 9:02 am

bnam wrote: Legacy wrote:

Great work. Have downloaded many of your pics for reference.

Do you have the measurements of:
1. From headlight down to turn signal top screw hole?
2. from centerline to bumper bracket opening?
3. from front of trunk opening to top of the oval hole for the horn?

I need these three for my car as my car came missing all three.

Thanks
Byas

Byas
Thanks for the nice comment about the work on the car. One reason I tried to upload pictures and comments was because when I first started the restoration I have no idea what to do. If it wasn't for all the help I received from members of this forum I would never have been able to complete the job.

I have some hand written notes with dimensions but I'm not sure they would be very helpful to you. But don't worry, I will take all the measuresments off the car and post them as answers to your questions. I may not be able to get to that today but will surely get to it in the next few days.