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Late 1969 Ghia vert preservation/ restoration
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mcdonaldneal
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PostPosted: Sat May 02, 2015 1:38 am    Post subject: Reply with quote

As promised, a couple of photos from the window of the cottage where we stayed the night with friends of ours. Just sitting by the log fire waiting to get ready to move on!...
28mpg (imperial) at our last fill up, but that does include carb tuning and draining the carb. 60-65mph mostly. Happy with that!

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1969 signal orange Karmann Ghia convertible

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mcdonaldneal
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PostPosted: Sat May 02, 2015 1:45 pm    Post subject: Reply with quote

Well....
Eventful day today! I'll get to all the events eventually, but I'll take things in order!
We left our friends (and their two huge German Shepherd dogs), knowing we basically had all day to travel about 150 miles or so. That figure soon went up a little, as we had to turn back to get something we had forgotten! It then went up further as we had to follow a couple of diversions to make it on to the road South... Rolling Eyes Confused
They live in a beautiful part of the country, so we stopped for a photo! Cool

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mcdonaldneal
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PostPosted: Sat May 02, 2015 2:06 pm    Post subject: Reply with quote

We had travelled about an hour South and I realised that the steering was judderingly alarmingly (worse than the day before Confused ) especially when we got to about 45mph. Tyres are new and balanced with good pressures, so when we stopped for a coffee I fished out the idiot book to see if it agreed with me that it might be the wheel bearings.
I followed the procedure to check the bearings, jack up the front corner and give the wheels a waggle, and both sides had significant play at 12/6 o'clock and worse at 3/9.
Oh dear!
I wasn't sure if I could adjust them myself, so we visited about four garages, and rang about eight but, being Saturday at midday, no one was able to help. Crying or Very sad
Nothing for it, but to get out the tool bag and try and sort it myself! Hubcaps off and then spent ages thing to knock off the grease cap from the hub with a tyre iron, which was the heaviest thing I had. Eventually asked at the garage that had last refused us and the chap obliged with a heavy screwdriver.
Then, faced with a 6mm allen lock nut, I cursed the fact that I hadn't included any Allen keys in the toolkit! Embarassed it's always the thing you don't have that you need!
Until..
By some miracle, I DID have one Allen key, 6mm! It was in my bag for adjusting the alternator belt in the Kombi, yippee!

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Got the bearing nuts adjusted, but there was still a bit of play at 9 and 3. We packed up and carried on...
Better, but still a fair bit of juddering, especially at 40-50mph?? Shocked
We stopped for lunch, and I consulted the idiot book again...
Reassuringly, after a couple of diagnostic twiddles of the steering wheel, it seems likely that the steering damper is buggered! Didn't sound too serious to me, so we set off South again with a smile! Long drive through the rain, a few navigational mishaps, adding to the distance again and again until FINALLY we arrived at our hotel, about 11miles from the show. hallelujah!
We had averaged about 65-70mph (while we were moving! Wink ) and are getting 25mpg imperial at the moment.
Parked up next to a gorgeous beetle, and went to find dinner! Very Happy

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1969 signal orange Karmann Ghia convertible

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mcdonaldneal
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PostPosted: Sun May 03, 2015 10:58 am    Post subject: Reply with quote

Had a great day today at the Stanford Hall VW show. Didn't start very promisingly, as it was hosing down with rain, and just opening the car door would dump pints of water on the seats, not the best! The drive there also seemed to involve lots of travelling up muddy country lanes, so the wheel wells and the underneath got a pretty good coating of cowshit etc!
It's a beautiful setting though, and the historic VW's display in front of the house looked magnificent!

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The Karmann Ghia owners club had turned out in force, and managed to reach exactly 60 Ghias to celebrate the 60th anniversary of the marque!

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There were loads of beautiful cars on display, mostly at the stock end of the spectrum, and not all VW's! Rather than list them, I'll show a few choice photos...
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Finally, as the day brightened up considerably, it gave us a chance to get some pretty pictures of our own car, and enjoy the attentions of everyone who stopped by and asked us about her and soak up some compliments! Very Happy

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1969 signal orange Karmann Ghia convertible

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Bleyseng
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PostPosted: Sun May 03, 2015 12:56 pm    Post subject: Reply with quote

Nice, even a VoPo!
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70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!
76 Porsche 914 2.1L L20c, 120hp Djet
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mcdonaldneal
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PostPosted: Sun May 03, 2015 1:35 pm    Post subject: Reply with quote

Bleyseng wrote:
Nice, even a VoPo!


There were two or three! They make me feel quite nostalgic, as I spent three teenage years in Berlin, where they were super popular!
The lime green one won its class (which I think was the Porsche class, but I'm not certain! Embarassed )

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mcdonaldneal
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PostPosted: Sun May 03, 2015 10:57 pm    Post subject: Reply with quote

Bleyseng wrote:
Nice, even a VoPo!


Your post confused me at first, because when I lived in Berlin, the 'VoPo's' were the East German 'Volkspolizei' or police force! Shocked
I had to use a popular search engine to find out which VW you were talking about! Embarassed
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Duck58
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PostPosted: Mon May 04, 2015 2:08 am    Post subject: Reply with quote

Met you briefly at the show yesterday (with my head under your deck lid enquiring about the valve I have missing on my fire wall....)
Beautiful car and certainly something to aim for with my 71.

Mark
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Bleyseng
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PostPosted: Mon May 04, 2015 6:14 am    Post subject: Reply with quote

That's Ravenna Green not lime green, Haha they are fun to drive and good to see some at the show.
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70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!
76 Porsche 914 2.1L L20c, 120hp Djet
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PostPosted: Mon May 04, 2015 6:16 am    Post subject: Reply with quote

That dark blue VoPo belongs to a friend of mine...I wasn't there this year Sad
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mcdonaldneal
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PostPosted: Mon May 04, 2015 11:57 am    Post subject: Reply with quote

Duck58 wrote:
Met you briefly at the show yesterday (with my head under your deck lid enquiring about the valve I have missing on my fire wall....)
Beautiful car and certainly something to aim for with my 71.

Mark


Good to meet you Mark, and it was great to meet a few folk who knew me (ie the car!) from the Samba!
You can be sure that even if they stay below the radar, there are plenty of fellow Sambanistas in the UK! Very Happy

We're home now after a 320 mile drive, in glorious sunshine this time!
I think the keys to a comfy long drive are:
Stop frequently
Lumbar support pad
Ear plugs!
Keep it relaxed at 65-70mph!

Hosed the mud off the underside, and put the car to bed...
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mcdonaldneal
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PostPosted: Mon May 04, 2015 11:59 pm    Post subject: Reply with quote

I've just had a look at the petrol receipts for the weekend away. Popcorn

750 miles altogether, mostly motorway driving at 65-70 mph on the speedo, although lots of very long stretches of roadworks, which were 50mph! Rolling Eyes Well packed car, with two passengers.
Overall fuel consumption, using supermarket, low octane unleaded was just over 35 mpg imperial (29.5 US), with one fill up working out at 37.7 mpg (31.4 US). Shocked
I was interested to see what it would be after I had rejetted the carbs for a lean mix at light cruise, and I'm pretty pleased with that. Very Happy With an AFR of 15.5 at 50mph the engine didn't run hot at all, warm to touch, and the 'save my bug' dipstick was nowhere near the hot temp contact point, all good! Cool
While we were away, the new jets arrived to try and get the mixture just right, which might improve things even more? The only downside I noticed was that it did tend to stall at idle when the engine was cold, until it reached normal temp. Might just need the idle mix checked?
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mcdonaldneal
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PostPosted: Tue May 05, 2015 1:21 pm    Post subject: Reply with quote

I had a bit of trouble getting the decklid release adjusted last week, but over the weekend it became a two man job to get it open. So, the catch releases, but it doesn't 'pop up' and so if you let go of the release it locks again!
I can't make the top peg on the lid shorter, or it won't lock at all. My thought is maybe to lengthen the spring a little, so it does the 'pop'. Thoughts welcome!
In the meantime I'm very glad of the emergency release hole I drilled (from above) last year, which allows a tiny screwdriver through to operate the catch (where the control wire attaches).
I took a pic in case anyone needs to drill a hole blindly from below to rescue a stuck lid! You can see where it is in relation to the catch bolts. Bottom of the pic is the rear of the car. Hole is just left of centre between the top two bolts.

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I also ordered a new, German, steering damper today, as well as a new oil pressure switch, which you can see is leaking a little. No sign of a crack to the case, which can happen if they are overtightened. They degrade with time, so I figure it is best to replace, although maybe I should try tightening? (Actually with my record on stripped bolts and pulled studs, I don't think I'll bother! Embarassed )
I don't know if it's original, but you can see it is a Bosch switch that is there

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PostPosted: Wed May 06, 2015 9:07 am    Post subject: Reply with quote

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Mine's second from the right ! it was great turnout on the day.

Didn't realise you were at the show on Sunday, how's my old wiring loom getting on is there much left Wink
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mcdonaldneal
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PostPosted: Wed May 06, 2015 9:54 am    Post subject: Reply with quote

That's funny you posted Carl! I remembered today that I meant to look out for you and say Hi! I saw your Ghia though, looking good!
The wiring loom has seen great service replacing wrongly coloured bits of wiring in my engine bay, looks much better!
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PostPosted: Thu May 07, 2015 5:31 am    Post subject: Reply with quote

I was impressed by the shininess of your convertible, didn't know it was yours on the day. Just read through your wheel bearing incident, if it wobbles more in the 3+9 o'clock directions then you may have some play in the track rod ends.

Agree that the steering damper can make a big difference to vibrations coming through the wheel.
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PostPosted: Thu May 07, 2015 9:39 am    Post subject: Reply with quote

carl4x4 wrote:
I was impressed by the shininess of your convertible, didn't know it was yours on the day. Just read through your wheel bearing incident, if it wobbles more in the 3+9 o'clock directions then you may have some play in the track rod ends.

Agree that the steering damper can make a big difference to vibrations coming through the wheel.


It would also be a good idea to get your front tires balanced. Vibrations while driving straight ahead at 35-50, especially a shimmy is from the tires being out of balance..
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mcdonaldneal
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PostPosted: Thu May 07, 2015 11:12 am    Post subject: Reply with quote

One shiny new 'Boge' steering damper has arrived, so I thought I'd see how easy it was to fit with the fuel tank still in place!
Jacked up the front end and put axle stands in place.
Tried to take off the wheels but they wouldn't budge! (Yes the nuts are off! Confused )
Whacked with a mallet, sprayed penetrating oil around the lug nut holes and kept on bashing! Eventually needed to hammer an old screwdriver between the wheel and the flat part of the hub and they came free. Rolling Eyes
Access to the damper nuts is fairly easy, although I wouldn't recommend doing it in a garage that's only 3' wider than the car! Embarassed

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The driver's side of the damper passes through a rubber bush. I couldn't work out how to get it out, so although I had a replacement, I took photos and decided it was good enough to leave! Very Happy

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Plenty of squirming later and the new damper was in!
The old one felt ok to extend, but there was a leak of oil from around the seal, so the whole thing was a good call!
Wheel balancing next, while they're off.
I tugged away at the tie rods. There is a little play and they rotate very easily, but I think they can wait just now and I'll see about ordering new ones along with a ball joint separator. There's still a fair bit of lateral play at the front wheels, so it may be that the steering box will need replacement, but one thing at a time!

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PostPosted: Thu May 07, 2015 5:31 pm    Post subject: Reply with quote

Try adjusting the steering box first before replacing it. It probably could use it to take out some of the slop in the steering.
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70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!
76 Porsche 914 2.1L L20c, 120hp Djet
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mcdonaldneal
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PostPosted: Sun May 10, 2015 10:55 am    Post subject: Reply with quote

Thought I'd try a job that would give Shona and I some quality time together today! Wink
Trunk liner repair.
I had got hold of low viscosity (wicking) cyanoacrylate adhesive, and 'kicker' to speed up the set.
Started off by using two pieces of wood, covered in Sellotape (so the glue doesn't stick to them, thanks 'LastTriumph' Very Happy ) By clamping the delaminated sections, wicking the glue in, and setting it with the kicker you get a nice neat repair.

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Some sections you can't get into to clamp, so either your glamorous assistant holds them together, or you can use a Sellotape covered roll to smooth things out as the glue sets, then use the kicker. Here's a horribly delaminated corner.

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I started off lining up and glueing the rips and tears on the visible side, then turning over and wicking glue into the backside of the tears.
I discovered that this kind of glue gets very hot as it cures, and also that it gives off noxious vapour (probably cyanide, now I think on it! Embarassed )
Once all the cracks were glued, I used flexible, waterproof tape for wetsuit repair to strengthen the underside of the rips.

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A lot of effort, but hopefully I have a strong, more intact, original liner to go back in the car! I plan to use little powerful rare earth magnets to hold it in place, rather than the metal tabs, which do a good job of tearing the cardboard!
Before and after...


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