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Ghia coming home
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Era Vulgaris
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Joined: August 22, 2012
Posts: 1887
Location: Raleigh, NC
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PostPosted: Thu May 08, 2025 2:57 pm    Post subject: Re: Ghia coming home Reply with quote

Absolutely gorgeous! When your car is done it should be featured in every automotive enthusiast magazine. Really top level work! I can't wait to hear how this handles and drives when you finish it.
_________________
Currently own:
66 Karmann Ghia, L390 Gulf Blue, under construction, here: www.thesamba.com/vw/forum/viewtopic.php?t=760505&highlight=
99 Mazda MX-5 10AE, Sapphire Blue Mica, 6 speed, LSD

Previously owned:
98 Porsche Boxster, silver, 2.5L -- 67 Karmann Ghia, Black, 1500sp -- 98 BMW Z3, Atlanta Blue Metallic, 2.8L I6 -- 75 Porsche 914, Laguna Blue, 2270cc -- 72 Porsche 914, Signal Orange, 1.7 FI -- 74 Karmann Ghia, Black, 1600dp -- 74 Triumph TR6 with O.D., sapphire blue
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TRS63
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Joined: December 17, 2017
Posts: 1124
Location: Stuttgart - Germany
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PostPosted: Thu May 08, 2025 10:43 pm    Post subject: Re: Ghia coming home Reply with quote

Wow !!!!!!
_________________
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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Joined: March 09, 2006
Posts: 567
Location: Germany
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PostPosted: Wed May 21, 2025 12:45 pm    Post subject: Re: Ghia coming home Reply with quote

Time for try on... I need to check out a couple of things with the body in the chassis.


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BTW these extra attachment point make excellent locator pins for lowering the body to the chassis Wink
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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
The motor: https://www.thesamba.com/vw/forum/viewtopic.php?p=10343324#10343324
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DaveB9
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Joined: October 20, 2021
Posts: 355
Location: UK
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PostPosted: Thu May 22, 2025 1:54 pm    Post subject: Re: Ghia coming home Reply with quote

TRS63 wrote:
Wow !!!!!!


What he said! I have never seen a gearbox with external filtering and cooling like that. The whole chassis looks amazing. I can't wait to hear how it handles compared to an original, it really is state of the art.
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halbug
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Joined: March 09, 2006
Posts: 567
Location: Germany
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PostPosted: Fri May 23, 2025 10:59 pm    Post subject: Re: Ghia coming home Reply with quote

Thank you guys!!! Your motivation feels good. Sometimes I feel like it's all too much Wink
_________________
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
The motor: https://www.thesamba.com/vw/forum/viewtopic.php?p=10343324#10343324
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halbug
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Joined: March 09, 2006
Posts: 567
Location: Germany
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PostPosted: Fri May 23, 2025 11:24 pm    Post subject: Re: Ghia coming home Reply with quote

Looking for an exhaust that is somewhat quiet and yet does not compromise the power of my 2.6 or 2.8 OXY. I opted for a Porsche 911 sport muffler in street version from Cargraphic.de

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First try on:
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Another custom bracket Laughing
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... assembled to the motor:
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Fits great! imo Very Happy
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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
The motor: https://www.thesamba.com/vw/forum/viewtopic.php?p=10343324#10343324
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sputnick60
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Joined: July 22, 2007
Posts: 4097
Location: In Molinya Orbit
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PostPosted: Sat May 24, 2025 2:31 am    Post subject: Re: Ghia coming home Reply with quote

Impressive fabri-cobbling right there! This is something special.
Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
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Ian Godfrey
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Joined: September 25, 2006
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Location: Melbourne Australia
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PostPosted: Sat May 24, 2025 3:38 pm    Post subject: Re: Ghia coming home Reply with quote

that porsche muffler is a perfect shape for the back of a Ghia!
the bracket is a bit like a T3 Transporter. well done
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TRS63
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Joined: December 17, 2017
Posts: 1124
Location: Stuttgart - Germany
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PostPosted: Mon May 26, 2025 7:09 am    Post subject: Re: Ghia coming home Reply with quote

Wow, that is a perfect fit!
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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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Joined: March 09, 2006
Posts: 567
Location: Germany
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PostPosted: Tue May 27, 2025 7:20 am    Post subject: Re: Ghia coming home Reply with quote

Thank you guys!!!

Tomorrow is header prime time
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Image may have been reduced in size. Click image to view fullscreen.

_________________
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
The motor: https://www.thesamba.com/vw/forum/viewtopic.php?p=10343324#10343324
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Era Vulgaris
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Joined: August 22, 2012
Posts: 1887
Location: Raleigh, NC
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PostPosted: Tue May 27, 2025 2:25 pm    Post subject: Re: Ghia coming home Reply with quote

Did you know beforehand that the curvature of the 911 muffler matched the curvature of the Ghia's rear valance so well? That really looks like it could've been made for a Ghia, the fit is so perfect.
_________________
Currently own:
66 Karmann Ghia, L390 Gulf Blue, under construction, here: www.thesamba.com/vw/forum/viewtopic.php?t=760505&highlight=
99 Mazda MX-5 10AE, Sapphire Blue Mica, 6 speed, LSD

Previously owned:
98 Porsche Boxster, silver, 2.5L -- 67 Karmann Ghia, Black, 1500sp -- 98 BMW Z3, Atlanta Blue Metallic, 2.8L I6 -- 75 Porsche 914, Laguna Blue, 2270cc -- 72 Porsche 914, Signal Orange, 1.7 FI -- 74 Karmann Ghia, Black, 1600dp -- 74 Triumph TR6 with O.D., sapphire blue
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halbug
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Joined: March 09, 2006
Posts: 567
Location: Germany
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PostPosted: Thu May 29, 2025 9:14 am    Post subject: Re: Ghia coming home Reply with quote

Era Vulgaris wrote:
Did you know beforehand that the curvature of the 911 muffler matched the curvature of the Ghia's rear valance so well? That really looks like it could've been made for a Ghia, the fit is so perfect.


It's amazing how well it matches the body curvature, isn't it...

I have been playing with the thought of using a 911 muffler for some time and tried to fit an original 911 unit, I borrowed from a friend. It was extremely tight and was about to look for something else. I gave it one last try and called Cargraphics, manufacturer for high quality sport mufflers. The where very! helpful on the phone and offered to send me one of theirs for try out. It's the one I have bought and installed now. The curvature is exactly the same as the 911 stocky, but overall a little smaller, making it the perfect fit.
_________________
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
The motor: https://www.thesamba.com/vw/forum/viewtopic.php?p=10343324#10343324
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halbug
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Joined: March 09, 2006
Posts: 567
Location: Germany
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PostPosted: Thu May 29, 2025 10:39 am    Post subject: Re: Ghia coming home Reply with quote

Tobi from TMR https://tmr-performance.de/schweissen/ came over to do all the welding for the header. For you guys living in Germany and near, call him if you want something welded. His work is extraordinary!!! just check out below pictures.

Connection from the 2 into one onto the aeroquip muffler fitting took us a lot of effort, grinding and forming:
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Connected for forming and welding:
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Only problem using the 911 muffler:
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...and solved:
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Everything was welded using forming gas (is this the correct term? )
[mg]https://www.thesamba.com/vw/gallery/pix/2593532.jpg[/img]

After 18!!! hours of intense work:
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Technical details:
Step header, 2x 45mm into 48mm into 51mm into 64mm collector into muffler. Internal tubing 64mm and 2x baffeled exhaust tips 64mm.

We added 4 EGT and 2 lambda bungs.
_________________
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
The motor: https://www.thesamba.com/vw/forum/viewtopic.php?p=10343324#10343324
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Ian Godfrey
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Joined: September 25, 2006
Posts: 1203
Location: Melbourne Australia
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PostPosted: Thu May 29, 2025 7:29 pm    Post subject: Re: Ghia coming home Reply with quote

what a beautiful design, I also like the steps, very well thought out . Very Happy
What are those clamps, like V bands but different?
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halbug
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Joined: March 09, 2006
Posts: 567
Location: Germany
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PostPosted: Fri May 30, 2025 2:06 am    Post subject: Re: Ghia coming home Reply with quote

Ian Godfrey wrote:
what a beautiful design, I also like the steps, very well thought out . Very Happy
What are those clamps, like V bands but different?


Thank you Ian!

I' ve been told it's a scaled down version of a Porsche Design. The tube ends have a round flare, on the inside is a custom made hemispherical olive and the rounded clamp comes from aeroquip. You can see all this on the right side of the picture with all the separate parts I bought for the header.

Cheers
_________________
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
The motor: https://www.thesamba.com/vw/forum/viewtopic.php?p=10343324#10343324
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