Front suspension rebuild 1966

[Era Vulgaris]

Well I'm deep into it!

The front beam has been cleaned and repainted, as has the entire napoleon hat area.
Alot of those parts won't be going back on the car. I'll be installing drop spindles, new ball joints, wide 5 discs, a new big bore dual circuit M/C, and a rack and pinion steering kit from Samba member -Alex77-
_________________
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

[Era Vulgaris]

Alex just sent me this pic of my newly fabricated R&P steering kit before he boxed it up to ship.

Here's some more info on this setup if anyone's interested:
https://www.thesamba.com/vw/forum/viewtopic.php?t=580737
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

_________________
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

[Era Vulgaris]

New ball joints that were installed by the PO. Anyone see a problem?
Not a single one out of the 4 that's lined up correctly!
I've got 4 new ones on the way

_________________
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

[Disc]

Last year I ordered the "bracket" from Alex that holds the R&P, unwelded and also got the other parts from Ebay. Well unfortunately the bracket does not fit on the beam, some grinding is needed. The radius of the cut does not fit the OD of the beam. Some other modifications needed too, but I'm still not to that point, probably late this year.
_________________
The glory never gets old, just need new paint.
-------------------------------------------------
Nick

[Era Vulgaris]

Yeah I figured it would need some adjustments. Most non-stock things do. I'm used to taking things apart and modifying them before install
When I decided to get another Ghia, it was under the condition that I was going to ditch the crappy OE steering box at all costs. Whatever it takes man!
_________________
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

[Era Vulgaris]

I installed new ball joints yesterday, and cleaned and painted my trailing arms.

The last time I replaced ball joints was on my first Ghia about 6 years ago. I'd like to go on record as saying that I'll happily go another 6 years, or hopefully more, before I do that again!

I've got new trailing arm seals and it'll all go back into the beam once the paint has had a couple days to completely dry.

_________________
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

[Era Vulgaris]

I'm still waiting for the R&P steering kit to show up. But in the meantime I've been able to reassemble the front beam, install the new drop spindles, and the wide 5 disc rotors. I used the AC Industries disc conversion kit with drop spindles from Socal Auto parts. But I ditched the KML bearings that comes with it, in favor of FAG bearings all around.

Test fit with the wheels looks pretty good! I couldn't get a direct-on side shot because our other car was in the way, but the car now has the slightest forward rake - like just a degree or two. If you just glanced at it, you'd think it was level. The stance is exactly what I was after. I'm glad I went with the drop spindles, and not an adjustable beam like I had originally considered doing.

Also, that's my new custom geared trans in the big box by the rear wheel! Rear end rebuild will be happening after I finish the front end.

_________________
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

[Era Vulgaris]

It also looks like I hopefully won't have an rub issues. The PO installed new 175/65/15 tires in 2017. We'll see how it behaves under load once I get the car running. But at full L and R there's clearance galore.
Everything I'd read said that a stock width beam with drop spindles and a wide 5 disc conversion would definitely rub, so I was just kind of crossing my fingers and hoping I'd be ok. I guess maybe with stock 80 aspect ratio tires it might be an issue, but the with the 65's it seems like there's tons of room.

_________________
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

[Era Vulgaris]

Well, I haven't updated this in a long time. As it does, life gets in the way. I got married at the end of April and then the honeymoon and traveling! We had a blast! And then after we got back home, the brutal summer NC heat and humidity in July and August really de-motivated me from getting much of anything done on the car until this month.

Also another thing that kept me from making progress was Alex's bracket. As Disc mentioned, it just did not fit, and the positioning of the mounts made it impossible for it to ever fit correctly. I sent the whole thing back to Alex and got a refund, less his "restocking fee"

Anyway, I picked up another R&P kit from Kerscher Tuning in Germany, and this install has been flawless. Everything fit right, everything went together great. There are a few small bits that aren't included in the kit, and if you're interested on details PM me.
I've pushed the car in and out of my garage and around my driveway, and even at what is probably 1mph it's a totally different world. No slop, no play, just direct precise steering feel. I can't wait until I have the car running and I'm out on the road!

Also, I did a test spray in the area under the gas tank with L444 Malachite Green, just to see how the color looks in real life. That's going to be the color when I'm done with this build!

_________________
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

[rbsurfguy]

Is this the version you bought?

Conversion kit on rack and pinion steering gear
Conversion kit on rack-and-pinion steering gear for VW models Type 11/15 (1200/1300/1500) and Type 14
(Karmann) with crankshaft axle
from year 08/65

Would this fit later years like a 71? Their website isn't too clear, even using translator.

Thanks, Jeff
_________________
1971 Ghia convertible (Body off rebuild)
2019 VW Atlas 4Motion
2012 Passat-Sold


See my build on The Samba at:
Jeff's 71 Vert Restoration/Reassembly http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=

[Era Vulgaris]

Their website has an English version. There's a German flag and British flag off to the left. Click the British flag for English.
You can also email them. I did with several questions. Their English is pretty good.

Here's the kit:
https://www.kerscher-tuning.de/kaefer/index.php?gruppe1=Lenkung&gruppe2=Lenkung

There's a ball joint beam version (8/65 and later), and a link pin beam version (7/65 and earlier). Those are build dates, as August 65 was the beginning of model year 66.
You'd want the ball joint version for your 71, same as on my 66.

You have to cut your steering column down, and weld in the column adapter that fits into the steering u-joint. That was the scariest part - the measuring and the cutting. I don't know if your 71 has the earlier solid steering column, or the later crash-safety steering column. I had free reign to cut wherever I wanted. I don't know if the late accordion steering columns could pose a problem or not.

Other than that, everything else is bolt on. But you do have to source your own tie rod ends (two stock ghia right hand thread ends), tie rod end nuts, and tapered tie rod jam nuts (you can get these from ISP West. Otherwise hard to find).
_________________
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

[TDCTDI]

[Era Vulgaris]

[kiwighia68]

[TDCTDI]

Unfortunately, his product fits more than just Ghias & the next unsuspecting buyer may not think to search here. I still suggest, at the very least, posting your experience of his product in his feedback thread.

Think of it as doing the community a favor.
_________________
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.

[rbsurfguy]

Thanks for the follow up info Era. I have the late model crash safety accordion steering column, so if I went this direction, would have decide if that would work or use an earlier version. Not anywhere near doing this now, but something to think about at a later date should I get tired of the drifty feeling I always felt my Ghia had previously.

And I always get concerned when it comes to making precise cuts, I'm better trained and more skilled at breaking things or damaging beyond repair, damn Army!!!
Jeff
_________________
1971 Ghia convertible (Body off rebuild)
2019 VW Atlas 4Motion
2012 Passat-Sold


See my build on The Samba at:
Jeff's 71 Vert Restoration/Reassembly http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=

[3de]

Well, after rebuilding 2 German steering boxes, tearing down a brand-new Brazilian made box and finding out it was complete garbage, then rebuilding a new TRW box and still getting unsatisfactory steering, I'll go the R&P route now.

Thanks to this post I've just placed the order for the Kerscher unit. Any chance there are any more pics of the weld required for the steering column to input-shaft?

[Era Vulgaris]

I don't have a pic of it freshly welded, which would probably be more helpful. But here it is cleaned up and painted.
What I first had to do was decide how much of the steering column I wanted to cut off. You'll want to mount the rack to the beam with the u-joint on the rack, then based on where that lands, with the adapter in the u-joint, you'll find a point where you'll cut the column. Since you're creating the length of the column, you can change the steering wheel position if you want to. I have long arms so I moved the steering wheel about an inch closer to the dash for a more comfortable driving position.
Once you cut the column, you'll probably need to spend some time with a wire brush cleaning rust expansion out of the inside of the column, because the adapter is a very tight fit.
I drilled holes through the end of the column in both the X and Y axis, and plug welded the adapter through those 4 holes (you can just barely see the outline of one of the plug welds after I ground it down in the first pic below). Then I also welded the end of the column directly to the adapter all the way around.

Here it is installed. Still finishing assembly on the car after a bare metal body-off resto.

_________________
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

[jeffrey8164]

No steering dampener?
_________________
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[Era Vulgaris]