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Restoration thread: my 60 strato blue coupe
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TRS63
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PostPosted: Mon May 15, 2023 10:31 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Sorry, I did work on the ghia but did not took the time to update since then..so let's do it !
Next patch, here template building :
Image may have been reduced in size. Click image to view fullscreen.


And putting the metal in form :
Image may have been reduced in size. Click image to view fullscreen.


Ready to cut:
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Cut:
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Adjusting:
Image may have been reduced in size. Click image to view fullscreen.


Tack-welding:
Image may have been reduced in size. Click image to view fullscreen.


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


Stay tuned, next update comes really soon and not in 2 months, I promise!

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
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halbug
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PostPosted: Sun May 21, 2023 10:01 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Hi Antoine, all right you are back on it! Good to see you working on the Ghia again Cool
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TRS63
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PostPosted: Mon May 22, 2023 2:09 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks ! Yes, I am still working on it, sadly it won't build itself Laughing Embarassed

So next step was this closing part, so first the template:
Image may have been reduced in size. Click image to view fullscreen.


And the part :
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Image may have been reduced in size. Click image to view fullscreen.


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


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


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


Ready for welding:
Image may have been reduced in size. Click image to view fullscreen.


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


Before/after:
Image may have been reduced in size. Click image to view fullscreen.


Stay tuned!

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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halbug
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PostPosted: Mon May 22, 2023 2:42 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Amazing work, as always!
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DariuszPlich
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PostPosted: Tue May 23, 2023 1:30 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Very good job. It's nice to see such an approach to sheet metal repair. Applause
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TRS63
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PostPosted: Sat May 27, 2023 6:55 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks a lot guys! Really appreciated !

So, the next logical step: closing it..so positionned the part :
Image may have been reduced in size. Click image to view fullscreen.


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


And then welding:
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Welded:
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Some planishing left but getting close:
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Image may have been reduced in size. Click image to view fullscreen.


Bests

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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TRS63
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PostPosted: Wed May 31, 2023 6:02 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

After that, it was time for me to (re-) do the fresh air inlet using the original dimensions. The original one for the template :
Image may have been reduced in size. Click image to view fullscreen.


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


And building the parts one by one:
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Ready:
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Image may have been reduced in size. Click image to view fullscreen.


Stay tuned!
Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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TRS63
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PostPosted: Wed May 31, 2023 12:17 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

And adjusting them on the car and welding the parts together :
Image may have been reduced in size. Click image to view fullscreen.


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


One new fresh air box!:
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Ready to weld:
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Parts painted/welding primer where it will be welded:
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And here we go :
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Image may have been reduced in size. Click image to view fullscreen.


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


Bests

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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TRS63
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PostPosted: Wed Jun 07, 2023 11:11 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Well, you remember, I did build the part in front of the tank:
Image may have been reduced in size. Click image to view fullscreen.


It was time for the last checkings:
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Image may have been reduced in size. Click image to view fullscreen.


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


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


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


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


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


Bests

Antoine
_________________
Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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TRS63
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PostPosted: Tue Jun 13, 2023 8:02 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Little side work, I rebuilt (by replacing some parts of it) the front bumper mounts:
Image may have been reduced in size. Click image to view fullscreen.


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


And removed the broken bolt on the rear left bumper mounts:
Image may have been reduced in size. Click image to view fullscreen.


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


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


Stay tuned,
Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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kiwighia68
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PostPosted: Tue Jun 13, 2023 11:54 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Every post a lesson in craftsmanship and perseverance.

I can't wait for the next one.
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Marcdeb
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PostPosted: Tue Jun 13, 2023 5:00 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

The front of the car has come a long way! I am amazed at your skills.
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68 Karmann Ghia Cabrio Autostick
71 Karmann Ghia Cabrio

Previously Owned:
2011 VW EOS Hard Top Conv
2008 Saab 9-3 2.0T Conv
2003 Saab 9-3 SE Conv
2001 Saab 9-3 Conv
1998 BMW 3 Series Conv
1997 Saab 900 Conv
1997 Mazda Miata

68 Ghia Vert Survivor with 22,350 miles: https://www.thesamba.com/vw/forum/viewtopic.php?t=768107&highlight=
71 Ghia Vert Restoration: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc
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art_lessing
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PostPosted: Wed Jun 14, 2023 11:29 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Hey man, since we are so deep in this thread, can you answer these questions:

what welder?
what settings?
what metal?
do you mock everything up with carboard first?

You make it all look so easy. Is it as easy as it looks , or do you go through much headache before the final result?

Thanks for your hard work!
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TRS63
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PostPosted: Fri Jun 16, 2023 12:39 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks a lot guys for the support, really appreciated !!

art_lessing: happy to help, here the answers, please feel free to ask more if needed !

-what welder?
I have both a MIG-Welder (Migatronic Rallymig) and a TIG-Welder(Stahlwerk AC/DC 200) and use both almost as much depending on the access (to weld and to planish), the condition of the metal,...

-what settings?
My MIG-Welder has pre-configurarion depending on the thickness of the metal and they are really good, it is really rare that I need to change something. For the TIG-Welder: 30A/millimeter thickness of the metal.

-what metal?
I bought my sheet metal from a body shop so don't know the market name. I have 0,8/1/1,5mm thickness and I try to always use the same thickness as original when redoing something.

-do you mock everything up with carboard first?
Not everything but really often!

-You make it all look so easy. Is it as easy as it looks , or do you go through much headache before the final result?
Second option definitely ! I am only a hobby-restaurator, did not study it, and it's far from my daily job so it is a lot of trial and error. More than often I try to build something, then realise another methode is necessary, and start back from new. That can be frustrating but it is also the interesting part to me as I am learning a lot on the way! I also spend a lot of time for the planning and what to do when, as to not need to undo/redo something afterwards because of forgetting a step.

So, let's make another update as I do have more to share!

The front and rear parts of the fenders will be adjusted on the car but they had a lot of holes from either bad fixes or accessories that needed to be taken care of and it's easier with them disassembled so:
Driver's side:
Image may have been reduced in size. Click image to view fullscreen.


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


And fixed:
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Passenger side:
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And fixed:
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And the antenna hole (my car won't have a radio, I love the look with the plate and only hear the flat 4-sound in my VWs):
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Bests

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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TRS63
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PostPosted: Wed Jul 12, 2023 10:44 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

So, long time no update but a lot of work in the background!

Since I will be finishing the bottom/front of the fenders when everything will be mounted/aligned, I thought I should start on the front mask. I know, it is available as a repro but where is the fun, right?

So, first removing the rest of the air-boxes to have a good access:

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


They will require a lot of work (or I will build new ones!):

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


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But focus is the mask first. Lots of small repairs:

Before:
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During:
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After:
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Before:
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During:
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After:
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Before:
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After:
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Before:
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During:
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After:
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Before:
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During:
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After:
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Before:
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During:
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After:
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Before:
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After:
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What is left is the bottom part:
Image may have been reduced in size. Click image to view fullscreen.


But first I focused on getting it back in shape as it was completely out of form:
Image may have been reduced in size. Click image to view fullscreen.


Lots of checking:
Image may have been reduced in size. Click image to view fullscreen.


And trial mountings:
Image may have been reduced in size. Click image to view fullscreen.


It is starting to look good, at least good enough to position it and use it to mount the fender. But before that, some steps are still necessary, stay tuned!

Antoine
_________________
Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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Braukuche
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PostPosted: Thu Jul 13, 2023 6:45 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Looking good.
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Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
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TRS63
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PostPosted: Fri Jul 14, 2023 2:27 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks Dan, I am enjoying the process!

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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TRS63
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PostPosted: Mon Jul 17, 2023 11:34 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

There will be much more to do on the doors but I was tired of seeing the cut there so I fixed it:
Before:
Image may have been reduced in size. Click image to view fullscreen.


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


After:
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And the second door:
Before:
Image may have been reduced in size. Click image to view fullscreen.


After:
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Bests
Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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Marcdeb
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PostPosted: Tue Jul 18, 2023 4:40 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Always super interesting to see your posts and amazing photographs. I like that you are showing all The details of how the Karmann Ghia body was engineered.
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Marc
68 Karmann Ghia Cabrio Autostick
71 Karmann Ghia Cabrio

Previously Owned:
2011 VW EOS Hard Top Conv
2008 Saab 9-3 2.0T Conv
2003 Saab 9-3 SE Conv
2001 Saab 9-3 Conv
1998 BMW 3 Series Conv
1997 Saab 900 Conv
1997 Mazda Miata

68 Ghia Vert Survivor with 22,350 miles: https://www.thesamba.com/vw/forum/viewtopic.php?t=768107&highlight=
71 Ghia Vert Restoration: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc
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TRS63
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PostPosted: Wed Jul 26, 2023 6:36 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks a lot!

So, I took the doors out of the storage to use them to adjust the parts under and around them but before adjusting on the car, I had to put the tube for the wiring harness like here on the orginal part:
Image may have been reduced in size. Click image to view fullscreen.


So let's start:
Image may have been reduced in size. Click image to view fullscreen.


But it has to go through the A post so I made a template:
Image may have been reduced in size. Click image to view fullscreen.


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


To get the position :
Image may have been reduced in size. Click image to view fullscreen.


And I made the fixations:
Image may have been reduced in size. Click image to view fullscreen.


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


And welded it :
Image may have been reduced in size. Click image to view fullscreen.


And some paint to protect it durably:
Image may have been reduced in size. Click image to view fullscreen.


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


Then it was time to adjust it:
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And welding:
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Door fits well:
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And A-Post was next:
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One day this will fit like that:
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But some more work left before..stay tuned, I am already further but late with updating!

Antoine
_________________
Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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