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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3916 Location: In Molinya Orbit
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Figment Samba Member
Joined: October 27, 2016 Posts: 218 Location: Connecticut, USA
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Posted: Tue Mar 13, 2018 8:16 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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Outstanding documentation.
I can't tell you how many hours this would have saved me six months ago! _________________ '71 Ghia coupe |
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mcdonaldneal Samba Member
Joined: June 13, 2013 Posts: 2649 Location: Gullane, Scotland
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Posted: Thu May 10, 2018 1:44 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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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! |
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KGCoupe Samba Member
Joined: July 01, 2005 Posts: 3580 Location: Putting the "ill" and "annoy" in Illinois
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Posted: Fri May 11, 2018 6:00 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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mcdonaldneal wrote: |
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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!
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Have you considered that perhaps your overriders may just be happy to see you?
Seriously, I hate when things go wrong like that!
If there is a bright side, it may be that you no longer need to worry about your shiney flawless brand-spanking new bumpers getting that first little bit of damage each and every time you take your Ghia out for a drive.
Now that you've predamaged them, there's no longer any need to worry and you can now relax and fully enjoy each drive. |
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3916 Location: In Molinya Orbit
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mcdonaldneal Samba Member
Joined: June 13, 2013 Posts: 2649 Location: Gullane, Scotland
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Posted: Fri May 11, 2018 10:53 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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KGCoupe wrote: |
mcdonaldneal wrote: |
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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!
... |
Have you considered that perhaps your overriders may just be happy to see you?
Seriously, I hate when things go wrong like that!
If there is a bright side, it may be that you no longer need to worry about your shiney flawless brand-spanking new bumpers getting that first little bit of damage each and every time you take your Ghia out for a drive.
Now that you've predamaged them, there's no longer any need to worry and you can now relax and fully enjoy each drive. |
Lol. You're right of course!
There are three 'long' bolts.
55mm: towel rail joint
60mm: blade tip to bodywork and
70mm: through bracket to centre of overrider
I can't be sure, but I don't thing the shorter bolts will reach the centre of the overrider, so I think I got the 55mm and 60mm mixed up.
Anyway, the warning stands! _________________ 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! |
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brianc73 Samba Member
Joined: June 03, 2014 Posts: 20 Location: Santa Maria, CA
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Posted: Tue Aug 14, 2018 8:31 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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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! |
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William Miller Samba Member
Joined: March 29, 2010 Posts: 22 Location: MD
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Posted: Tue Aug 14, 2018 3:09 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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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! |
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mcdonaldneal Samba Member
Joined: June 13, 2013 Posts: 2649 Location: Gullane, Scotland
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pennacook Samba Member
Joined: June 06, 2018 Posts: 20 Location: New Hampshire
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Posted: Thu Aug 16, 2018 3:21 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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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. _________________ 1969 VW Karmann Ghia |
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mcdonaldneal Samba Member
Joined: June 13, 2013 Posts: 2649 Location: Gullane, Scotland
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3916 Location: In Molinya Orbit
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Posted: Thu Aug 16, 2018 5:24 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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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 _________________ '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! |
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Larmo63 Samba Member
Joined: May 26, 2015 Posts: 338 Location: SoCal
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Posted: Thu Aug 16, 2018 7:47 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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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 |
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mcdonaldneal Samba Member
Joined: June 13, 2013 Posts: 2649 Location: Gullane, Scotland
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8211 Location: San Dimas
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pennacook Samba Member
Joined: June 06, 2018 Posts: 20 Location: New Hampshire
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Posted: Thu Aug 16, 2018 4:23 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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Aha! Thanks sputnick60 that helps immensely. I have bolt "plugs" in those holes - so no bracket needed _________________ 1969 VW Karmann Ghia |
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NoDents Samba Member
Joined: May 31, 2017 Posts: 438 Location: So Cal
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Posted: Wed Jul 24, 2019 9:12 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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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. _________________ No Dents
1963 Bug - Sold in 1980
1966 Karmann Ghia Convertible - Stolen in 1988
1971 Karmann Ghia Convertible, resto/mod COMPLETED 10/2020 |
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Ellison Samba Member
Joined: October 16, 2006 Posts: 212 Location: Spokane, WA.
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Posted: Fri Sep 20, 2019 9:35 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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Super useful. Thank you everyone . _________________ Praise the lowered. |
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chaas67 Samba Member
Joined: August 11, 2012 Posts: 52
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Posted: Sat Apr 25, 2020 3:01 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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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 |
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crocteau Samba Member
Joined: March 31, 2005 Posts: 1204 Location: Philaburbia
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Posted: Sat Apr 25, 2020 4:35 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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chaas67 wrote: |
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? |
Yes, they are bolted through the body panel at each "corner" Sorry I don't have measurements to help you locate the holes properly. |
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