Restoration thread: my 60 strato blue coupe

[KGCoupe]

Antoine, I have a couple questions for you ...

First Question - Have you considered changing the name of this thread to something more appropriate?

... say, perhaps "How To Build a 1960 Karmann Ghia From Scratch", or even "Metal Shaping Magic Made To Look Easy"?



As usual, outstanding work and a joy to follow along.
Thanks again for continually taking the time to share.

Second Question - Are you currently taking applications for an Apprenticeship, and if so how do I apply?

[TRS63]

You are way too nice with me
I am really happy to share my passion with you all and of course if your way crosses Stuttgart, keep me in touch

So, new update is due
You remember this area:

Well I checked it and there was more rust than first thought:

So I cut the top of the rear fender to eradicate the rust:

Inside was some surface rust:

So I brushed it, cleaned it and treated it:

Prepared the first patch :

And the first welding points:

And then welding it completely :

And dressed :

Second patch, same process:

One welding point every 2 cm like original:

In place:

And welding:

Dressed :

And with some chrome, good for the motivation :

Stay tuned for the second side!

Cheers

Antoine
_________________
Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685

[ELFRIED]

Great work Antoine.
Great welds too.I don't seem to get them as nice as yours.
I'm wondering is it due to the welding machine or me
In the beginning I decided to buy a cheap second hand migwelder as I didn't know if it was going to be something for me.
I use 8 mm wire ,have set the gas on 8 l/ minute, and the wire speed seems ok.
Perhaps my technique isn't good and I really can't put the eye protection on,it drives me crazy...
Anyway the final result is that it works but I d like to get it better and smoother.
Winter is coming now and i do it all under a carport so end of the season for me.
I'm gonna start looking at the motor,do some tests ,get the timing wright,checking the valves,etc...etc....
And in the meantime following your great posts.

[KGCoupe]

[Braukuche]

You are dong it the smart way, cutting little pieces out, patching as you go, that way you make sure you keep the original contours. There was some guy on here who literally dissected his entire car throwing most of it away with plans to weld in all new metal. While interesting to see how a Ghia was made, I think what you are doing will net better results.
_________________
Go Reds! Smash state!

Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now

[Marcdeb]

Bonjour Antoine. Je suis très impressionné par votre talent.

Thank you for the support on my 71 Ghia Cabrio. I have been reading your thread for your restoration of the 60 coupe and all I can say is WOW. You are ambitious and very talented. I will be watching your Ghia's progression and will enjoy seeing your work.
_________________
Marc
68 Karmann Ghia Cabrio Autostick
71 Karmann Ghia Cabrio

Previously Owned:
2011 VW EOS Hard Top Conv
2008 Saab 9-3 2.0T Conv
2003 Saab 9-3 SE Conv
2001 Saab 9-3 Conv
1998 BMW 3 Series Conv
1997 Saab 900 Conv
1997 Mazda Miata

68 Ghia Vert Survivor with 22,350 miles: https://www.thesamba.com/vw/forum/viewtopic.php?t=768107&highlight=
71 Ghia Vert Restoration: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc

[TRS63]

Hi Guys,

thanks for the support as always!

@Elfried: I am using similar settings I think. But couldn’t weld without the automatic welding mask, need to see what I am doing. Perhaps that would help you too? For your information, my MIG is a Migatronic Rallymig. And I am starting TIG-Welding since one month approximately but it’s a hard learning process so not used it much on the ghia until now.

@KGcoupe: sure is the most used expression in the ghia world

@Braukuche: thanks a lot for the kind words. I had a teacher who told me, never cut anything before having the appropriate patch for it.. I am trying to focus on areas, and then move to the next one in order to not be overwhelmed.. Let’s see how it goes!

@Marc: merci beaucoup!

Well, long time with no updates but work has been going on. Let’s show it to you.

After finishing the first side, it was time to start on the second one:
Initial condition was also quite..bad:

So as usual: cut, treat, replace:

I decided this time to do it a bit differently and point-weld the 2 parts of the patch before welding it back:

And then weld it completely, a bit of it using my newly acquired TIG to train myself:

Finished:

After that, I decided to turn my attention to the right side of the engine hood sealing bead. Here it was, quite damaged:

So I made a patch:

Then cut, planished the OG metal that was deformed and adjust in place:

And start to weld:

Between each weld I planished it:

And then it was fully welded:

And grinded:

Checking with the hood:

Stay tuned, a few more updates will come shortly to be back to the current status again.

Cheers

Antoine
_________________
Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685

[dubulup]

Excellent work staying motivated! I was glad to see hearing protection in one of the photos...I just looked through this entire thread and kept thinking how loud it must be in your shop, haha!

Amazing metal work, true artist.
_________________
http://vimeo.com/108749110

[Braukuche]

Rust is weird stuff. All that rot in unusual spots yet your battery tray looks solid!
_________________
Go Reds! Smash state!

Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now

[kiwighia68]

I've been wondering, Antoine. If you can do work of that quality with those old gloves with holes in them, imagine how good you'll be with new ones.

Just teasing you a bit. Your work is outstanding and an inspiration for the rest of us.
_________________
Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015

[kingkarmann]

Either accidental or intentional, you are a great photographic eye besides being an incredible sheet metal artist.
It helps that the structure you work in is very cool
I have saved a few of your photos to make prints and hang in my office.

A couple of my favorites;

_________________
"Depression is a malfunction of the instrument we use to determine reality.”

Mike Gerson

What is your "Bespoke Reality"?

[TRS63]

Thanks a lot guys for all the kind words!!

@dubulup: Yep you saw it right. Usually that‘s one of the first thing I do when starting in the shop: putting my ear protection hammer smashes are quite loud

@Braukuche: agree totally. My battery tray has small holes but compared to a lot of other ghias (and the condition of the rest of the body of mine), it is quite good!

@kiwighia68: I know, I should invest in gloves

@kingkarmann: wow never believed my project will get so much attentions and even inspire other members. Really happy that you like the pictures, I love sharing all the details

So, I am already here so Let’s make an update

You probably know (or can imagine) that the bottom of my A-Post are toast here the confirmation:

I got some repair panel I bought when starting the project:

But they were delivered without the outside part connecting to the fender and of course mine will need fresh metal. I made several attempts doing it in one piece but did not manage the quality level I am after so did it in 3 pieces welded together. Here the whole process:

And one side is done:

Now for the second side:

And both sides ready:

Cheers

Antoine
_________________
Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685

[djkeev]

Looking good!

I really appreciate the photos, i know how much work it is to make a tutorial with photos, I for one express a hearty THANK YOU!!!!

Dave
_________________
Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[Peter D.]

Wow, awesome work. I love that your restoring the body and not chopping it up for money like so many do. And I love the workshop your in. Somehow it's the perfect setting and atmoshphere for car restoration. When I was grinding and welding in my garage at home I got a lot of complaints about the noise, dust, and smell.
_________________
2019 Golf Alltrack, '65 Ghia Coupe Restoration in Progress

[Evil_Fiz]

I have renewed respect and admiration for the work you are doing. I've had to make very basic patches to repair rust damage and the time and effort involved is significant. I can only imagine how long it would take me to make the complicated panels you have created.

-----
Emil
_________________
“…It's not just about what's interesting. It's also about what's helpful, and it's helpful even if it helps just one other guy working on a Ghia.”
kiwighia68

See my build on TheSamba at:
The K_R_A_K_E_N_N : a 70 Ghia Convertible reinterpreted

[mdege]

That's incredible bodywork your doing on that Ghia. Makes mine look like a piece of cake.
_________________
- Michael

1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
1988 Multivan Magnum 112i
1984 Standard: My son wanted a bug for his first car

[TRS63]

Hi guys,

@djkeev: thanks a lot, it’s a pleasure to me to share this adventure with you!

@Peter D. : thanks, also really loving the atmosphere in my shop. Concerning noise, dust, smell, I have to say that I avoid working late at nights or on sundays. But the wall are also really thick, so it helps

@Emil: yes, when one think of the time invested in such a project, it’s crazy but hey, passions are not reasonable!

@Michael: thanks a lot! Your progresses and careful builds are really inspiring! Hope to meet you once our VWs are ready!

Well, I think it is due time for another update!!

So, I decided that before sending the body for soda blasting, I had to take care of the front firewall.

As already seen, it quite rusted on the bottom, on both sides:

So as usual, let’s open the rust box and fix it!

No surprises that it rusted, when you see that there was absolutely no rust protection, paint,..:

Both parts will require new metals, as you can see here:

So I started on the part still on the body.
First side:

And second side:

That view is already way more enjoyable:

Stay tuned for the next update!

Antoine
_________________
Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685

[Trylon]

It’s like magic!
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire

More tomfoolery on
The Karmann Ghia Fever YouTube Channel!

[TRS63]

Thanks Trylon!

Next:
I also made some repair on the part of the firewall I removed:
Here a before:

Some origami:

Cutting:

Welded:

I even did put the indent back like original:

And on the other side:

One more repair on the bottom left and it will be ready to be put back on, but I will do it after having welded the new heater channel, as I have a better access like that.

Stay tuned!

Antoine
_________________
Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685

[Rome]