pans of a 63 ghia

[c21darrel]

I didn't think it looked quite ready either, thats why I said "a little grinding". I thought the edge of the original pans were still attached, its that bright metal "edge" that looked out of place. Carry on. Sheesh, taking vacation while this important work awaits, break out the whips.
Enjoy your time off!
_________________
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!

[ELFRIED]

picture of the pans and everything cut out which is still neede
second picture , the curve seems to be ok....

[TDCTDI]

[ELFRIED]

Today came the tricky part ,fitting the pans .

I began cutting of the tunnel side of the pan according to the measurements I made
I knew I shouldn t cut anything off the front and back side.
It took me a lot of cutting - afraid to cut off too much- but finally the drivers side pan was in.
Odd enough the other pans fitted immediatly after my first cut????
Anyway they seem to fit the 2 outside angels and I think this is good. Though the pans seems to be a little bit short.see pictures.
Tunnel side they fit nicely ,also the back bend.

Now I m wondering if I should drill the

Now I m wondering if I should drill holes or weld the pans directly to the tunnel.
I m certainly not a crack in welding.
Anyway this will be for september ,time enough to think about it....

[TDCTDI]

I suggest drilling & filling the holes. The replacement pans are much thinner than the tunnel flange. To get proper penetration, you have to turn up the heat on the welder & weld start welding directly to the flange & then swirl the weld pool/puddle to the pan so that it flows into the sheet metal. If you don't, the welds will not be hot enough to penetrate the tunnel flange & you will hear them let go as they cool & you weld others. The heat necessary to penetrate the flange will blow right through the pans.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.

[Sketchy_1]

You can pick up a metal hole punch / flange tool for cheap. Makes perfect holes for rosette welds quickly. I prime the metal chassis flange with a weld through primer before welding or leave it raw and hit with a thin wicking primer that will creep into all the tight bare metal spots after welding. I also use clecos to hold the pans in place and remove them as I weld. By doing spot welds it recreates the factory look. Seam seal, paint and you're done.
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69' Karmann Ghia Convertible AWD Project (FB Build) (STF Build)

[ELFRIED]

Thanxs First i m gonna search my. English. Dutch. Dictionnairy....

[c21darrel]

As I recall, rosette welds along the tunnel and solid welds front and rear. Right?
_________________
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!

[TDCTDI]

[ELFRIED]

This is one of the floor seat belt attachements I cut out of my old pans last year.
How can I take them apart? There seems to be thread on the round thing underneath but I really can't get any movement in it.

Also don't know the correct way to mount it to the new pan. I expect drilling a hole but then....

[TDCTDI]

How anal are you about originality? The easiest thing to do is to source a piece of steel about the same thickness, cut it to shape, drill a hole in it, slide a bolt through it, thread a nut onto the bolt & tighten it, & then tack weld the nut to the plate.

This is the pedal stop reinforcement on my car.

There wasn’t a lot to work with on the original on my car.

If you’re hung up on originality, grind the pan side of the plate off, drill out the broken bolt, & clean up the threads


Once that’s done, drill a hole in the pan for the bolt to go through, then drill a hole on either side of that initial hole, bolt the plate to the pan, & plug weld the plate to the pan with the other two holes.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.

[ELFRIED]

Thanks a lot gonna do that

For now I am making my first steps mig welding the pans
I tried to do it as told but it seems the current isn t strong enough to penetrate the thicker lip. I rosetteweld the holes but if i give a good tap on the pan it comes loose again. Grrrr
My welder is put on maximum current , wire speed is ok and gas about. 10 l .

In fact it s a cheap welder ,perhaps it's simply not good enough
If i keep to long in the middle of the hole it stops giving flame....

[TDCTDI]

Grab a piece of scrap steel & start practicing laying a bead on it. You will need to turn the amperage up all the way on a small unit. There is usually a guideline on the inside of the welder that gives you an idea of what the settings need to be at for a given gauge of metal. You will need to be proficient at making a weld that penetrates the thicker metal before you can join the thinner metal to the thicker.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.

[TDCTDI]

Also know that the seat belts use a different thread. The shouldered bolts that are used in modern VWs still use the same thread pitch/diameter.

This reminds me that I never got around to making reinforcement plates for my seatbelts.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.

[ELFRIED]

Oh dear, it seems you're never done with a ghia

[ELFRIED]

Well hoeree. I made my first succesfull rosettewelds
Don,t know how I exactly did it 'must be wright wirespeed,write current and good torch handeling.
Perhaps specialists will say they're not that good but I'm happy with them now.
But then I came at the curve and it went all wrong again. Pan is too far from lip ,I must find a trick to hold them close,tried tapping with a punch but the damned thing keeps coming upward.
Anyway enough for now it's summer here. Time for a Westmalle tripel.

[TDCTDI]

Use a punch or drift to beat the pans down near & after each weld to tighten the fitment.

[ELFRIED]

well this is very nicely done.
I kept having problems with the wire speed being to fast.With my cheap mig welder I couldn't properly set the good speed.
I was rather dissapointed with that so I decided to buy a new welder .Then
I read on a welder forum here that I should change the potmeterprint by a PWM controller.I bought the controller for a lousy 8 euro, started figuring out how the welder electrically was setup and spent a few hours looking how to implement the controller.There's 230 Volt circuit ,there's 24V circuit there's minus en plus ....not so easy.I had no schema.
Anyway it worked. The controller regulates very fine the motor wiring speed even in lower speeds.
I welded the 2 pans in , not so nice as TDCTDI has done , I still burnt a bit too much pan material .But anyway they're in and they won't come loose.
Next to do is filling the seams with polyurethaan kit and then putting truck bed liner on the bottomside. After that I'm gonna change the torsion bar bushings ....Then the chassis will be as good as ready.

[ELFRIED]

DONE. !!!

[ELFRIED]

Next project