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Restoration thread: my 60 strato blue coupe
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halbug
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PostPosted: Thu Jul 09, 2020 3:56 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Hi Antoine,

again... my utmost respect Cool

Both, for not giving up and the the quality and persistence of your great work. One thing that is great about your posts is, that I am learning so many details of how our beloved Ghias are build Laughing

Cheers
Lars
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TRS63
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PostPosted: Tue Jul 21, 2020 1:49 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks a lot for the support guys! Still having issue with my beetle's engine, can't wait for it to be finished and start again 100% on the ghia!

But in the meanwhile I still did manage to do more on it Very Happy
There was still one last step to finish the right wheel well:
Image may have been reduced in size. Click image to view fullscreen.


Yes, this bottom part was pretty rusted out so time for it to go..preparing the replacement:
Image may have been reduced in size. Click image to view fullscreen.


under it wasn't better either: Laughing
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all cut:
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I changed the wheel well metal and the new heater channel will then be welded on it. So let's take the TIG out Twisted Evil :
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and fully replaced:
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and in primer:
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Feels so good seeing the progress here:
Image may have been reduced in size. Click image to view fullscreen.


stay tuned for a next update soon!

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
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TRS63
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PostPosted: Mon Jul 27, 2020 4:29 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

So, still doing some progress on that project Very Happy

After finishing the right side, I started on the left.

First checking/adjusting the parts I made for the left airbox:
Image may have been reduced in size. Click image to view fullscreen.


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And then removed the old rusted airbox:
Image may have been reduced in size. Click image to view fullscreen.


Under it.. well some holes Laughing
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So I started checking the replacement panel:
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As for the other side, the top curve doesn’t fit:
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So I corrected it:

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And also made the hole for the wiring:
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Then marked how big this panel is:

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And where I should cut to remove all the rust but keep the original indent:
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Then.. cut!

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And putting the panel to cut it precisely, cut and adjusted for welding:
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Sadly I then discovered that my argon bottle is empty.. so welding next time!

I also prepared the next steps by grinding down the old welding points:
Image may have been reduced in size. Click image to view fullscreen.


Cheers

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
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Braukuche
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PostPosted: Mon Jul 27, 2020 6:25 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Looking good!
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1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1963 356 B coupe
1967 21 window rust bucket
1967 912
1969 Ghia convertible
1970 Ghia convertible
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Mellow Yellow 74
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PostPosted: Wed Jul 29, 2020 1:32 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Hi can you please provide some more details on how you did the fish mouth holes for the wiring?
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Marcdeb
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PostPosted: Wed Jul 29, 2020 3:32 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Your work along with these great pictures are very educational and provide much information so useful to understanding the construction of the Karmann Ghia. I am learning a lot from seeing your work. The hard part for me would be getting new inner metal lined up perfectly so that exterior metal will line up properly and have correct gaps! You have a lot of skill.

Votre projet est très intéressant.
Nice work Antoine.
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1971 Karmann Ghia Cabriolet

Restoration thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc
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TRS63
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PostPosted: Fri Jul 31, 2020 12:11 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks a lot guys for the nice words! Very Happy

@Mellow Yellow 74: sure, here is how I do it:
1)First cutting the opening (if I remember well 2cms long but not sure..) with the angle grinder
2) Push a bit each side of the hole using something softer than steel to not mark it ( I love my corking tool from Cornfield custom but you can use whatever you want!):
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


3)push through a tube with a growing diameter (I used my tool to point before boring holes, I don’t know the name in english):
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


So basically, I use an angle grinder and these tools:
Image may have been reduced in size. Click image to view fullscreen.


So, I finished welding my panel after picking up a new bottle of Argon:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


And after planishing:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


I also continued the front axle assembly:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Putting grease wherever needed:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


And started cleaning the 60 only gearbox:
-before:
Image may have been reduced in size. Click image to view fullscreen.


-Current Status:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Cheers

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
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rbsurfguy
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PostPosted: Fri Jul 31, 2020 2:08 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Great work as always Antoine. As for the name of the tool with the point, it is called a Punch...Peut-être un coup de poing?

Not sure if that translates correctly in French. Love watching your build!
Jeff
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TRS63
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PostPosted: Tue Aug 11, 2020 1:48 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks for the tool name.. and the kind words Very Happy

So, sometimes you have to take a few steps back to get it as wished.. I had welded my pan halves almost 1,5 years ago and even if robust, the welding aspect wasn’t that good.. i had left it, but I decided that I can’t let a part of the build not making me proud so.. I redid it Embarassed

Primer removed, welding cleaned, rewelded where necessary, ground down and back in primer Very Happy
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And as it’s good for regular checking, I mounted the front panel back with some grips and this time didn’t forget to take some pictures:
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And my favorite, my motivation-boosting picture: Twisted Evil Cool

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Cheers

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
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dc
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PostPosted: Tue Aug 11, 2020 9:03 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Well Done!
Starting to look like a car Wink

Clamping on the fenders and the nose has to motivate you - keep going Exclamation
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slalombuggy
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PostPosted: Fri Aug 14, 2020 11:21 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

WOW. Thanks for taking the time to archive your build and show all the detailed work that you have done. It will help a lot of people with their cars and be a great source of information for years to come. Well done Sir. You have inspired me to begin my long stalled project.

brad
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Ant B
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PostPosted: Sat Aug 15, 2020 1:32 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Looking real good now sir.
wonderful work.

Ant B.
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TRS63
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PostPosted: Mon Sep 07, 2020 11:51 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Thanks so much guys, really feels good being a part of the ghia Community! Very Happy

Due to family holidays, I had only a couple hours for the ghia but step by step it‘s getting solid Very Happy

I took care of those holes:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Cutting after lots of measurement:
Image may have been reduced in size. Click image to view fullscreen.


And a „Pizza-Box“ Template for the tube:
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Patch panel ready:
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Welded from behind like original:
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In position:
Image may have been reduced in size. Click image to view fullscreen.


Welded:
Image may have been reduced in size. Click image to view fullscreen.


And in primer:
Image may have been reduced in size. Click image to view fullscreen.


Cheers

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
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Marcdeb
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PostPosted: Tue Sep 08, 2020 3:14 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Always excited to see your posts Antoine. Your project is especially helpful as you are showing the deepest parts of
the Karmann Ghia that are not normally visible. It is a great way to document how these cars are built. Your work is motivating. Applause
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Restoration thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc
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Inchpincher61
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PostPosted: Tue Sep 08, 2020 12:34 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

Antoine,

very nice to see continious progress.

You even made the best of the less hours you had for the 60. Looks pretty good and I am always inspired of the creative way you´re making new parts. I really like the Pizza-technique!! AWESOME Wink

Keep going!
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djway3474
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PostPosted: Fri Sep 11, 2020 1:15 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

TRS63 wrote:
Thanks a lot guys for the nice words! Very Happy

@Mellow Yellow 74: sure, here is how I do it:
1)First cutting the opening (if I remember well 2cms long but not sure..) with the angle grinder
2) Push a bit each side of the hole using something softer than steel to not mark it ( I love my corking tool from Cornfield custom but you can use whatever you want!):
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


3)push through a tube with a growing diameter (I used my tool to point before boring holes, I don’t know the name in english):
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


So basically, I use an angle grinder and these tools:
Image may have been reduced in size. Click image to view fullscreen.


So, I finished welding my panel after picking up a new bottle of Argon:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


And after planishing:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


I also continued the front axle assembly:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Putting grease wherever needed:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


And started cleaning the 60 only gearbox:
-before:
Image may have been reduced in size. Click image to view fullscreen.


-Current Status:
Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Cheers

Antoine

When I first pulled the split case trans in my 59 the thing looked like the Mother Alien had gooped the thing. I replace the front seal and re-torqued everything. After driving it a bit I had a leak in the nose cone area and assumed it was from the shift rod tube. Pulled it out and stuck it in a corner. After a good coat of dust settled I realized the shift rod was totally dry. There was mild indication of some weeping at the case halfs but not much. All the oil was coming out of the breather then trailing back from there. I have recently installed a small small brass L hose connector that I will connect a hose vent to. Hopefully this will stop the leaks. Lots of other people have had issues with early vent holes.
Your metal work looks great and makes me want to work some more metal.
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VeloMikey
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PostPosted: Sat Sep 12, 2020 9:33 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

What makes a 60 split case one year only? I know he front mount is one year only. Your work is amazing! Keep it up!
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61karmann
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PostPosted: Tue Oct 13, 2020 5:00 pm    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

TRS63 wrote:
Saying I was excited to come back home on friday is under the reality as I knew of a box waiting for me Embarassed Cool
Here it is:
Image may have been reduced in size. Click image to view fullscreen.


Yes you guessed:
Image may have been reduced in size. Click image to view fullscreen.


Oh man how great are these mats: Twisted Evil Cool
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Thanks a lot Luis for making it available Very Happy

Cheers

Antoine


Awesome!! What color mats? I just ordered some in olive with extra paint for the shifter & ebrake boot.
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TRS63
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PostPosted: Thu Oct 29, 2020 5:59 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

VeloMikey wrote:
What makes a 60 split case one year only? I know he front mount is one year only. Your work is amazing! Keep it up!


I am no expert there but I think the front part that connect to the chassis mount is the différence..maybe someone knows it better? Embarassed

@61karmann: the mats are grey like they would have been originally Very Happy

So, long time no updates, and this is a really small one Crying or Very sad but I had some issues the last months on the daily drivers and they are the time priority.. I want to work on the ghia without stress to enjoy the journey Wink

So I had only a couple hours this week but put back the tab holding the spare wheel on the driver‘s side Wink
Here on the original part I cut, doing a Template for the position:
Image may have been reduced in size. Click image to view fullscreen.


Position marked:
Image may have been reduced in size. Click image to view fullscreen.


Holes ready to weld it from the back:
Image may have been reduced in size. Click image to view fullscreen.


And then welding-primer and it's welded:
Image may have been reduced in size. Click image to view fullscreen.


Back side cleaned:
Image may have been reduced in size. Click image to view fullscreen.


And a small coat of primer to protect that part until I can continue:
Image may have been reduced in size. Click image to view fullscreen.


Cheers to all,

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
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Vladiiiii
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PostPosted: Fri Nov 20, 2020 10:53 am    Post subject: Re: Restoration thread: my 60 strato blue coupe Reply with quote

I congratulate you on the quality of your work! So many small details Wink I especially like the coated, protected floorboards Applause I really like when someone tries to improve the original design in order for it to last longer Cool

Vlad
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