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Ghia coming home
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TRS63
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Joined: December 17, 2017
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Location: Stuttgart - Germany
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PostPosted: Sat Apr 05, 2025 11:47 am    Post subject: Re: Ghia coming home Reply with quote
Cool Cool top plan, and with such a solid body, totally understandable!

Antoine
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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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Joined: March 09, 2006
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PostPosted: Sun Apr 13, 2025 11:29 am    Post subject: Re: Ghia coming home Reply with quote
halbug wrote:
First I thought it's cool to vent tank through the flange of the Aeromotive fuel pump as it is forseen. However, I find it altmost impossible to run a straight or better yet slightly constant raising line for venting the tank without creating a siphon in the line...
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... and here is how I will pass through with the fuel lines from the trunk to the outside. I stole this idea from VW as they do exactly the same pass through for the tank vent line on the other side.

Sheetmetal forming becomes so easy with a die Laughing

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BTW, this solution alows me to place a spare tire in the original location.
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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Ian Godfrey
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PostPosted: Sun Apr 13, 2025 4:38 pm    Post subject: Re: Ghia coming home Reply with quote
that is a very tidy solution for the fuel lines. I think on later KG's the vent line went across tucked near the wipers to solve the syphon problem.
are you going to use the bung welded in on the opposite side to the filler?
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halbug
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PostPosted: Sun Apr 13, 2025 9:59 pm    Post subject: Re: Ghia coming home Reply with quote
Hi Ian, yes VW developed the vent line further and further up to the catch cans.

I am using an anti roll valve to start splash and will run the line across the windshield wipers, as you describe and have it end at the original pass through.
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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halbug
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PostPosted: Mon Apr 28, 2025 1:56 pm    Post subject: Re: Ghia coming home Reply with quote
I have started to assemble the chassis today Cool Cool Cool

Puzzle
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Sealed and torqued
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Seals to protect the ball joints
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Brake line routing
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Try out of excenter adjuster tool, works great
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First day
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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Ian Godfrey
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PostPosted: Mon Apr 28, 2025 4:12 pm    Post subject: Re: Ghia coming home Reply with quote
Eye Candy Very Happy
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TRS63
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PostPosted: Tue Apr 29, 2025 11:18 am    Post subject: Re: Ghia coming home Reply with quote
Now you're showing off Razz Just kidding, looking fantastic as always !
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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: Thu May 01, 2025 3:12 am    Post subject: Re: Ghia coming home Reply with quote
Thank you guys!

TRS63 wrote:
Now you're showing off Razz Just kidding, looking fantastic as always !


Antoine, maybe you are right, but after 10 years (on and off, of course) of hard work, I am so happy that everything is coming together, that I like to share my joy... Wink
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
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halbug
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PostPosted: Fri May 02, 2025 12:02 pm    Post subject: Re: Ghia coming home Reply with quote
I don't know how you guys do it faster, but it took me two days to run all the brake lines Laughing

To try out the best way routing the lines and for templating I used solid copper wire on the more complicated corners:
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Brakelines done! Cool
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
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halbug
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PostPosted: Fri May 02, 2025 12:18 pm    Post subject: Re: Ghia coming home Reply with quote
And today was fuel line time.

Straightening the rolled lines was a lot of work
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Detail shot of the bulk head
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Finished lines
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Side view
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Detail shot of rear bulkheads, left room for starter cable through hole
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Do you guys protect the aluminum fuel lines against corrosion? I am not sure what to do.

Cheers!
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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Ian Godfrey
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PostPosted: Fri May 02, 2025 4:03 pm    Post subject: Re: Ghia coming home Reply with quote
beautiful work again. Smile
For the aluminium lines I spray them with clear lacquer after bending.
where your RH front brake hard line passes through the hole in the Mendeola front end I'd suggest a grommet for that length of line to stop the possibility of rubbing. Sometimes I use planking grommets and punch a hole in them as the are soft and easy to push the 'nut' through.

A couple of builds ago I bought one of these tubing straightners Cool
https://raceworks.com.au/tools/tube-straightener/
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halbug
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PostPosted: Sat May 03, 2025 12:16 am    Post subject: Re: Ghia coming home Reply with quote
Ian Godfrey wrote:
beautiful work again. Smile
For the aluminium lines I spray them with clear lacquer after bending.
where your RH front brake hard line passes through the hole in the Mendeola front end I'd suggest a grommet for that length of line to stop the possibility of rubbing. Sometimes I use planking grommets and punch a hole in them as the are soft and easy to push the 'nut' through.

A couple of builds ago I bought one of these tubing straightners Cool
https://raceworks.com.au/tools/tube-straightener/


Ian, I am amazed by what you always catch, I need to be more careful of what I post. Laughing Seriously, thank you very much for your hint. It helps me, should I overlook something Cool

The hole you mentioned was done to pass the brakeline through to retain it with an original brakeline grommet. I am just out of those and need to order more.

Cheers
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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halbug
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PostPosted: Sat May 03, 2025 1:49 pm    Post subject: Re: Ghia coming home Reply with quote
I was lucky to find a NOS shifting rod some years back. Time to install it!
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I tried to install the rod with this new bushing from https://kaefertuer.com/produkt/schaltstangenfuehru...u-zone-1/Käfer
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It took me hours!!! to find out why it would not want to fit into my chassis After doing some machining on my lathe I got them installed and working! Frustrating part of today Rolling Eyes
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
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halbug
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PostPosted: Sat May 03, 2025 2:15 pm    Post subject: Re: Ghia coming home Reply with quote
halbug wrote:
Hi Ian, I will pull them into the tunnel with the oil hoses, no cutting planned Smile Button head screws, screwed from the bottom, will hold them in place.

I will machine some sleeves that will keep the holders together until the main screw is in place.

Cheers
Lars


After the shiftrod was in, oil lines were next.

Clamps pre-install with the sleeves I made, lined up to the previosly drilled holes on the tunnel underside
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I pulled the complete assembly in from the front
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Hoses attached to the tunnel floor
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Rear exit, will need some silicone sealer
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Button head screws to hold things in place
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Front exit
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_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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TRS63
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PostPosted: Sun May 04, 2025 11:45 am    Post subject: Re: Ghia coming home Reply with quote
Looking sooo fantastic, wow!! Lars, I am really really happy for you to see it coming together !!

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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DaveB9
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PostPosted: Mon May 05, 2025 2:26 pm    Post subject: Re: Ghia coming home Reply with quote
Those lines look brilliant secured to the floor! Some careful measuring gone on there. This is looking so good, keep the pictures coming.
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karl h
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PostPosted: Mon May 05, 2025 11:02 pm    Post subject: Re: Ghia coming home Reply with quote
read to the whole thread, very nice work! makes me want to pull my vert out under the pile of junk it is under
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halbug
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PostPosted: Wed May 07, 2025 12:16 pm    Post subject: Re: Ghia coming home Reply with quote
Guys! Thank you so much...
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halbug
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PostPosted: Wed May 07, 2025 12:28 pm    Post subject: Re: Ghia coming home Reply with quote
I completed the rear end today. No new technical solutions here, simply stuff finally put together on a freshly painted pan. I hope you enjoy anyhow.

Hand brake cables are out to get their threaded ends pressen on.

And I was able to shift through all gears with the shifter for the first time Cool

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_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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halbug
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PostPosted: Thu May 08, 2025 1:45 pm    Post subject: Re: Ghia coming home Reply with quote
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_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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