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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3030
Location: Vermont
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 Posted: Fri Apr 16, 2021 5:24 pm Post subject: Installing Rubber Seals for Fresh Air Grills |
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I have read quite a few posts about people having issues with installing Fresh Air Grills with new seals. I spent more time on this than I expected and I can see why so many are having trouble with what should be a simple job. Maybe there are better seals available than what I ended up with but for those that are having trouble, I hope this will help.
As with many reproduction parts I've used, the new seals I have are not easy to use. I have no idea who makes these because they came in a box of parts with the car. Here is what I started with.
Aothough the seals are new, I could tell that the previous owner had tried to use them. They were a bit dirty and there is holes in the ends from them being stapled together.
First problem is that the seals are very hard. The portion of the seal that is visible when on the car is the round half. It has a hollow center and it will compress some but this section is not the problem. The oval section goes around the back edge of the grill. This section of my seals is quite hard and does not compress enough to fit behind the grill properly which then prevents the grill from fitting into the opening. The hardness of the seals also caused issues at the corners as the seals could not make the sharp bends while staying flat.
I was able to modify the seals and make them usable by trimming them with a razor blade. I trimmed approximately 1mm from the bottom of the oval section.
I also trimmed a thin layer to make the oval section thinner.
I have some ratty originals and the dimensions seem to be the same as the new seals, but even though they are old and ratty, they are not nearly as hard so they have the ability to compress and fit into place. The originals are joined at the ends with a staple but I took someone's advice on this site and used superglue. It worked great and no staples to get rusty.
For the corners, I cut small triangles out of the back oval section and this allowed the seal to turn the corners while staying in place against the edge of the grill.
Once glued together, I put the seal around the back of the grill and used clips to hold it in place for installation.
I rubbed some dish soap around the portion of the seal the rests against the metal opening and that helped get the final seating of the assembly. I remove the clips one at a time as the grill goes in place.
If I was to do it again, I think I would leave a little more on the thickness. I think that shortening the oval is what helped the most. Thinning at the ends was part of the fix but thinning along the top and bottom is probably not necessary.
_________________
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 |
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obus 
Samba Member
Joined: March 08, 2001
Posts: 11063
Location: just off Garden State Parkway Exit 81
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Braukuche
Samba Member
Joined: September 03, 2004
Posts: 10997
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| Posted: Fri Apr 16, 2021 7:18 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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I just stapled the ends together, fit them in the grill and installed. I believe that’s what the factory did.
_________________
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 |
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hitest
Samba Member
Joined: September 30, 2008
Posts: 10296
Location: Prime Meridian, ID
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| Posted: Fri Apr 16, 2021 9:05 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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| Braukuche wrote: |
| I just stapled the ends together, fit them in the grill and installed. I believe that’s what the factory did. |
I found a staple in one of mine and one in a junkyard Ghia a couple weeks ago. Thought it was coincidentally lazy. 
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| EverettB wrote: |
I wonder what the nut looks like.
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'62 L390 151, '62 L469 117, '63 L380 113, '64 L87 311, '65 L512 265, '65 L31 SO-42, '66 L360 251, '68 L30k 141, '71 L12 113, '74 ORG 181
FU#5 |
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3030
Location: Vermont
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| Posted: Sat Apr 17, 2021 2:35 am Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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| Braukuche wrote: |
| I just stapled the ends together, fit them in the grill and installed. I believe that’s what the factory did. |
The 2 originals I have both have staples as well so I agree that is how the factory did it. Where did you buy your seals? I suspect yours are better quality than what I have.
_________________
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 |
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olspeed
Samba Member
Joined: May 01, 2008
Posts: 489
Location: In the shadow of Denali, I still don't give a damn how they do it outside
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| Posted: Sat Apr 17, 2021 5:26 am Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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| Braukuche wrote: |
| I just stapled the ends together, fit them in the grill and installed. I believe that’s what the factory did. |
This is what I did when I put my grills back in after I repainted my car... that was 32 years age now and the seals still look fine. At the time I purchased them from a local dealer (no longer in business) so I don't know who the supplier was.
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66- Ghia
76-Beetle |
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Braukuche
Samba Member
Joined: September 03, 2004
Posts: 10997
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| Posted: Sat Apr 17, 2021 7:00 am Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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| Marcdeb wrote: |
| Braukuche wrote: |
| I just stapled the ends together, fit them in the grill and installed. I believe that’s what the factory did. |
The 2 originals I have both have staples as well so I agree that is how the factory did it. Where did you buy your seals? I suspect yours are better quality than what I have. |
I think I got them from KGPR. Did you get yours from West Coast Metric?
_________________
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 |
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 996
Location: Stuttgart - Germany
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c21darrel
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Joined: January 22, 2009
Posts: 8211
Location: San Dimas
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3030
Location: Vermont
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| Posted: Sat Apr 17, 2021 7:36 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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| c21darrel wrote: |
I use a super glue type product made for gluing rubber. A drop on the end and hold together for 30 seconds. Still holding after 7-8 years. Seam on bottom middle.
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That was weird! I thought I was looking at my picture until I saw the bumper guard.  Our cars are very similar in color.
_________________
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 |
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c21darrel
Samba Member
Joined: January 22, 2009
Posts: 8211
Location: San Dimas
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3030
Location: Vermont
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| Posted: Sun Apr 18, 2021 2:46 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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| c21darrel wrote: |
| Marcdeb wrote: |
| c21darrel wrote: |
I use a super glue type product made for gluing rubber. A drop on the end and hold together for 30 seconds. Still holding after 7-8 years. Seam on bottom middle.
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That was weird! I thought I was looking at my picture until I saw the bumper guard. Our cars are very similar in color. |
Every time you post a pic of your car i think the same thing. Side by side i dont think they are anywhere near the same color. Mine i call Sage Green, yours a white? |
It supposed to be Light Ivory. But it's kind of a chameleon. The guy that did the paint job calls it yellow! It really depends on the lighting. There are times when I see yellow, but in person, it's no where near white. I looked at your car in your gallery and I thought it looked ivory at first, but then I did start to see the green tint. Beautiful car! I like the sunroof.
_________________
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 |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4854
Location: Connecticut
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| Posted: Sun Apr 18, 2021 2:55 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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Nice that there is a seal that I do not have to worry about.
_________________
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! |
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3030
Location: Vermont
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| Posted: Sun Apr 18, 2021 3:59 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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| Trylon wrote: |
| Nice that there is a seal that I do not have to worry about. |
Yup, having a low light does have its benefits! You are very lucky that you do not have to deal with the later wrap around directional lights. They can be very problematic as well.
_________________
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
Last edited by Marcdeb on Sun Apr 18, 2021 5:31 pm; edited 1 time in total |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4854
Location: Connecticut
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| Posted: Sun Apr 18, 2021 4:07 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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Will be watching for the tutorial on that!
_________________
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! |
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61karmann
Samba Member
Joined: January 01, 2004
Posts: 119
Location: south San Francisco
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| Posted: Sun Apr 18, 2021 6:35 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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Nice! super clean. thought I just had crappy rubber!, ill have to redo
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www.tonydegrazia.com
www.analogtattoo.com |
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3030
Location: Vermont
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| Posted: Sun Apr 18, 2021 6:41 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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| 61karmann wrote: |
| Nice! super clean. thought I just had crappy rubber!, ill have to redo |
I suspect there are better (softer) seals available other than the ones I had to modify. Maybe someone will post where to get the best seals.
_________________
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 |
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Mon Apr 19, 2021 1:38 am Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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I've had good success with West coast Metric seals here, pretty soft, but they still needed little pie shapes cut out to go around the pointy end of the grill.
Also worth noting is the lip on some of the aftermarket grills is not as deep as the factory originals, so the seal doesn't 'tuck in'.
I also had good success with the super glue joining technique.
It would be interesting to know how many different seals are out there. |
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c21darrel
Samba Member
Joined: January 22, 2009
Posts: 8211
Location: San Dimas
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Peter D.
Samba Member
Joined: February 25, 2004
Posts: 718
Location: Stamford, CT
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| Posted: Sun May 09, 2021 6:35 pm Post subject: Re: Installing Rubber Seals for Fresh Air Grills |
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I pulled this original seal off the passenger side of a '67 Ghia. It was held together with a staple. Right before I took the last picture the staple fell apart so I took a cross section photo too. The slight differences between original and reproduction parts are enough to make a five minute job last hours. Ahhh, the joys of restoring a Ghia!
Front of Rubber
Staple, Front Side
Rear Side of Rubber
Staple as Seen from the Rear
Detail of front facing side
Cross Section
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2019 Golf Alltrack, '65 Ghia Coupe Restoration in Progress |
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