US style towel rail bumper installation *pic heavy!

[sputnick60]

[Figment]

Outstanding documentation.

I can't tell you how many hours this would have saved me six months ago!
_________________
'71 Ghia coupe

[mcdonaldneal]

I'm pretty upset, but I feel I should share my experience to anyone using this thread to build up their bumpers...

The take home message is double check your bolt lengths during assembly!

I loosely assembled the front bumper before mounting on the car and then tightened all of the bolts. The bolts at the overrider where the towel rails join were a bit stiff, and stuck with a tiny bit of the bolt still sitting proud. I tightened a bit further and there was a crack...
I had mixed up the 55mm and 60mm bolts (which attach the tip of the bumper blade to the car). The bolt was forcing against the inner surface of the overrider and eventually cracked the small threaded bracket inside. Unfortunately, it also bent it a little, so the whole thing wouldn't then line up with the correct bolt.

So. I bent the bracket back to shape with a padded clamp and stuck the joint with JB weld. I'm hoping I've put enough on, but if anyone thinks I should add more before I loosen the clamp, please let me know!

Sadly, both overriders now have a visible bulge from the bolt pressure point and I feel like a careless fool! Still, worse things happen. I can always look out for replacements, although I doubt anyone other that me (and all of you!) would notice!

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[KGCoupe]

[sputnick60]

[mcdonaldneal]

[brianc73]

Super helpful, lots of great tips. I never would have noticed that the uprights are labeled (in German) according to which corner of the car they belong. This was a surprisingly tedious job, with several uncooperative bolts but this post made it faster and easier than it would have been otherwise. Thanks!

[William Miller]

Thanks for the writeup especially the pictures.
Im working on a '66 vert.

Luckily I have a lift and I was able to hang it almost piece by piece.
You saved me hours of sorting all the pieces.

It all went together but took a long time trying not to scratch the new paint.
My only issue was the rubber trim on those bracket covers were different than what you have. I don't know if mine were correct but they were difficult.
Thanks again!

[mcdonaldneal]

Cheers both, I’m glad the thread was helpful!
William, I didn’t actually use the original style rubber on the brackets, I ordered some rubber ‘U’ channel and cut it to size and glued in place. The originals had a flared ‘skirt’ with punched cutouts but it was hard to get them to fit, and I couldn’t see a functional advantage.
_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[pennacook]

question to mcdonaldneal:
Brackets for the reverse lights - were they intact on your rear bumper? Or how do they attach? I've been trying to locate just the brackets for my '69.

PS: I read through your other longer restoration thread - appreciate sharing your experience, makes a new guy like me feel a bit better about trying to do things.
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1969 VW Karmann Ghia

[mcdonaldneal]

Thanks pennacook. I’m afraid I can’t answer your question as my revering lights are part of the indicator assembly, so no bracket.
Good luck with your Ghia!
_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[sputnick60]

I think this photo from my car can answer your question.

I understand 1967 was the first year for standard reversing lights like this. Previously they were an option that needed holes added to the centre section. My 66 had a rear collision in its history that was repaired with a later bumper that has the holes and recesses pressed in it but no lights were ever fitted. Since reversing lights are rather handy I added them and wired up the power via the ignition coil and gear box switch per the VW norm.

Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[Larmo63]

Your 1969 rear bumper looks like a '70-71 bumper with the non-wraparound towel bars.

Is the car an early '70 model?

Great write-up, by the way.
_________________
Lawrence
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
‘61 Mango Green Single Cab
'62 Pearl White Ragtop sedan
'66 Ruby Red Cabriolet
'86 Porsche 911 Carrera

[mcdonaldneal]

[c21darrel]

pennacook most likely does not have the original 1969 rear bumper. Pics tell all.
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GhiaBuild
http://www.thesamba.com/vw/forum/viewtopic.php?t=481184
1967 DC build
https://www.thesamba.com/vw/forum/viewtopic.php?t=693583&highlight=67+dc
Stop dead photo links! Post your photos to The Samba Gallery!

[pennacook]

Aha! Thanks sputnick60 that helps immensely. I have bolt "plugs" in those holes - so no bracket needed
_________________
1969 VW Karmann Ghia

[NoDents]

Don't mean to revive this thread but I found it VERY useful.

I would like to add that as I assembled mine using these instructions, I use strips of old intertube rubber sandwiched between the main bumper sections (where the chrome roundhead bolts are used) in an attempt to prevent the chrome from getting scratched.
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No Dents

1963 Bug - Sold in 1980
1966 Karmann Ghia Convertible - Stolen in 1988
1971 Karmann Ghia Convertible, resto/mod COMPLETED 10/2020

[Ellison]

Super useful. Thank you everyone .
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Praise the lowered.

[chaas67]

Hopefully people still watch this thread as I didn’t want to create a new thread on this related question.

I have a question about the rubber stand offs at the ends of the front and rear bumper, are they bolted through the body panel?

On my Ghia, I don’t see any holes in the area where the standoffs would be positioned so I have to assume that they’ve been filled or I’m missing how they are fastened.

Thanks all

[crocteau]