Need Help with Fresh Air Nose Grill Screens and Boxes

[Marcdeb]

I'm at a huge disadvantage. I'm putting together a car that someone else took apart and he did a half ass job putting it back together. When I got the car, many of the parts were put in with just a few loose screws.

I'm installing the plastic Fresh Air Screens and Boxes that are behind the Nose Grills. I have what I think are my cars original parts. I also acquired a full 2nd set from another 1971 Ghia. I'm using the spare set only for comparison. The holes in the plastic screens are identical. They all match perfectly. However the holes in the boxes are not. Out of 4 boxes, not one matches to another. It looks like the holes in the boxes and the car are drilled through at the same time. No problem here as the holes for the boxes do line up as long as I put the correct box on the side that the corresponding holes line up.

The problem is that it appears the design of the screen is that the pair of screws for the boxes should also go through the screen first. The molded in holes are approximately in the same are but do not line up at all. There is plenty of holes in the screen so I can just put the screw through a square hole rather than the designated molded holes.

The last hole which is supposed to hold the inside end of the screens also does not match up with the holes in the car. These are also not even close to being in the same spot from one side to the other? I see no signs that any holes were filled in and new ones made. The front of my car is completely original and has never been hit or had any metal replaced. It's all original.

Question: As seen above, the boxes have an angled top or bottom. The box actually fits in the hole either way so what is the intended design? I suspect the angle is on the bottom?

In the two pictures above, the screws that hold the boxes, are not at the same distance when measuring from the outer edge of the openings.

In the above pictures even the holes for the screen are not at the same distance when comparing one side to the other?

I
_________________
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

[Braukuche]

Hi Marc,
I suspect that they popped the screens in, then placed the grills over using the three mounting points as a rough template and drilled away. The different locations are likely due to shifting around when holding the grill up there.
I will do the same when I mount mine. I’ll just pop the screens in, place the grills over and drill.
Dan
_________________
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

[Vladiiiii]

I have read about this in a different thread, it seems they had no real template in the factory (yes, imagine that ), they just drilled them into place.

So the "hand made" thing, it seems it also has some down sides mind you

I know it's not that satisfying down the line, but 50 years ago, for the kind of price, "that will do" was used quite often. Maybe not so often as with British cars of the time, but let's not get into that

Vlad
_________________
Vlad's 72 Ghia (Once in a Lifetime Restoration topic)
https://www.thesamba.com/vw/forum/viewtopic.php?p=9237746#9237746

[Marcdeb]

Glad to know I'm not doing something wrong. Thanks for the reply's
_________________
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

[kent70ghia]

If I have time in the next week I will pull my grills and look. I don't remember when I put them back after painting, but they are original install for a 70 coupe. But I think baskets in, the screen screwed in to hold them.

[rbsurfguy]

I had the same problem Marc, my outer screens did not match up at all with the holes drilled, so I just locked them in place through the square lined up with the hole. I thought I was doing something wrong and kept flipping sides thinking I was using the opposite part, but I soon realized they fit one way and I just tapped them in place.
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=

[Marcdeb]

[rbsurfguy]

[Braukuche]

[Marcdeb]

[rbsurfguy]

I'm using original bulb holders and lenses. Not sure what order they go on, I just put the bulb holders on first then the lenses. I may try tightening the lenses first, then slowly tighten up the holders, maybe they will stay closer together, and the holders will conform better around the curve of the fender. I have a feeling there was so much bodywork that original items just don't line up. No expert here, but as you said, since these were basically handmade, had I been doing any body work, I would have placed any connecting pieces to their location and worked the body to conform the the shape of the component, but that's just me....
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=

[Braukuche]

I never thought about installing as a complete assembly. I assumed they are designed to be put on sequentially cause you have to remove the lens to replace a bulb, but then that was 50 years ago and some things have changed. I’ll try the whole assembly idea.
_________________
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]

I think it makes sense to put the bulb holder on first but it seemed difficult to do the lenses after. Doing the bulb holder first is safer for the lens. In any case, be careful if you do the whole assembly. If the lens is tight and you over tighten the bulb holder to close a gap, the lens may crack or break altogether. Ask me how I know!
_________________
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

[Braukuche]