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overboost Samba Member
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Joined: June 11, 2021 Posts: 178 Location: Huntersville, NC
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Posted: Sat Aug 14, 2021 4:35 am Post subject: Re: 69 road race Ghia rebuild |
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Nothing beats the sound of the 48 IDA for sure. That groan leading into WOT is nothing short of a sirens song.
_________________ The older I get... The faster I was... |
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Rome Samba Member
Joined: June 02, 2004 Posts: 9914 Location: Pearl River, NY
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Posted: Sat Aug 14, 2021 9:18 am Post subject: Re: 69 road race Ghia rebuild |
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Very impressive fabrication and assembly work!
Will you add small, short "J" hooks to the rear shocks' bottom mounting studs to hold those handbrake cables steady so that they don't droop or whip when driving over bumps?
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Sat Aug 14, 2021 2:51 pm Post subject: Re: 69 road race Ghia rebuild |
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Rome, yep, I haven't finished them yet, but I was waiting until I get the axles in so I can see how high I can lift them up. I'm thinking of making brackets that with a hole so I can use the lower shock bolt as an anchor. |
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Sun Aug 15, 2021 2:35 am Post subject: Re: 69 road race Ghia rebuild |
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So, on to the gear box. It's a Berg 5 in a Zig Zag '76 case, with a Quaife torque sensing diff. This kind of diff is very good on acceleration but doesn't work like a ZF clutch style diff while braking. I have a ZF which I would prefer to use but I worry about its strength. Quaifes are guaranteed not to break and have Bus output splines and use Bus 100mm CV's. We'll see how it all works when I drop the clutch. I don't build gearbox's, Dave Butler in Brisbane built mine and took quite a few Kilos out with drilling. Inside is a work of art But I did take care of lightening the nose cone and the clutch cable guide, as well as drilling the clutch shaft.
Anyway, the alloy mounts I made
mid mount
the gear box
And the finished mid mount with RevShift BMW urethane mounts with alloy spacer.
Last edited by Ian Godfrey on Sun Aug 15, 2021 2:45 am; edited 1 time in total |
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Sun Aug 15, 2021 2:40 am Post subject: Re: 69 road race Ghia rebuild |
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I like original gear shift couplers much better than the aftermarket ones with red urethane. I have had them just crumble with old age
And now some gearshift porn, a CAE 5 speed shifter. To fit it you need to weld a plate to the top of the tunnel and 'hack' the opening in the tunnel so you can get 5th and reverse, and make some custom parts but...... it's all worth it
lastly I finished up the clutch cable. I was putting it together and noticed I had no holes drilled in the adjuster so being the 'sick puppy' I am I stopped to drill a couple of holes!
finished up with a seal on the end of the bowden tube
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overboost Samba Member
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Joined: June 11, 2021 Posts: 178 Location: Huntersville, NC
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Posted: Sun Aug 15, 2021 4:55 am Post subject: Re: 69 road race Ghia rebuild |
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This thread is straight up car porn. Love it! _________________ The older I get... The faster I was... |
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TRS63 Samba Member
Joined: December 17, 2017 Posts: 1050 Location: Stuttgart - Germany
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Mon Aug 16, 2021 12:54 am Post subject: Re: 69 road race Ghia rebuild |
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Thank you for the comments
Next job was axles/drive shafts, I'm not sure what they get called in the US.
I've used Vanagon axles as they are the right length and way stronger than type 1. I had them drilled out for lightness.
I've also used type 2, 100mm lightened, race prepped CV's with Stage 8 lock bolts. These are a fiddle, you torque them up, fit the plate, then put on the circlip, and loose a couple of circlips when they fly into space.
but the bolts do not come loose and thats what matters, dragging an axle when one end comes off is no fun
the inner
the outer
top view
and finished both sides
now I'll finish of the hand brake cables.... well soon anyway ![Wink](images/smiles/icon_wink.gif) |
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slayer61 Samba Member
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Joined: June 01, 2021 Posts: 1129 Location: CA
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Posted: Mon Aug 16, 2021 6:56 am Post subject: Re: 69 road race Ghia rebuild |
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What an inspiration. Thanks Ian! |
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halbug Samba Member
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Joined: March 09, 2006 Posts: 487 Location: Germany
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Tue Aug 17, 2021 1:09 am Post subject: Re: 69 road race Ghia rebuild |
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Halbug, I HOPE it will be lighter. A stock '69 coupe is 870Kg i believe,
I'm working towards 800 Kg, so far all my lighter parts offset the heavier parts (5 speed/roll cage), my spread sheet has about a 20 kg saving so far.
I am leaving the body and pan all steel, no holes, but there will be good savings with no sound deadening, radio etc, light weight seats and fiberglass bumpers with aluminium brackets. I will try to make polycarbonate rear quarter windows as well. A fiberglass engine lid would be nice but nobody seems to make one at the moment.
I've also taken weight out of the engine with Nickie cylinders.JP pistons, Carrillo rods, super light pulley, no heat exchangers and aluminium tail pipe/muffler from the collector back. Dry sump tank will be behind the seat bringing that weight nearer the centre of the car
I've focused getting weight out of the back as much as possible.
I think 800Kg is possible, plus me...... I see a diet in my future
just for interest a '73 911 RS is 975 Kg, and I want to catch them ![Question](images/smiles/icon_question.gif) |
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Thu Aug 19, 2021 2:50 am Post subject: Re: 69 road race Ghia rebuild |
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on to some last small jobs:
the hand brake need to be shortened because of the large shifter base, so I 'cut and shut' it, taking 2 inches out and drilled a few holes in it and the pivot. I;m waiting on some parts to finish the cables.
I tidied up the front sway bar with better high misalignment rod ends from QA1.
the ones that came with the front end went into a bind situation as the suspension compressed. the new one give 55 degrees of movement
fitted
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Thu Aug 19, 2021 3:02 am Post subject: Re: 69 road race Ghia rebuild |
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The rear hard lines needed clips because of their length. I found these aluminium ones for the 3/16" (4.75mm) line
I drilled and tapped some M5 holes in the arms:
these little details make me very happy
I designed and had machined and anodised some centre caps, the car won't go any faster, the beauty is that this is a hobby
and last is a nice view of the pan with unfinished hand brake brackets...... nearly done.
7 years of thinking and a year of work
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halbug Samba Member
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Joined: March 09, 2006 Posts: 487 Location: Germany
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slayer61 Samba Member
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Joined: June 01, 2021 Posts: 1129 Location: CA
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Posted: Thu Aug 19, 2021 6:43 am Post subject: Re: 69 road race Ghia rebuild |
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Excuse me while I wipe the drool off of my keyboard....
Very nice. |
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Sat Sep 04, 2021 8:48 pm Post subject: Re: 69 road race Ghia rebuild |
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Time for a big of an update.....
I've been trying to sort out my steering, some stops in the rack so the tyres won't hit the inner body, ordered a new starter, and worked on the fuel tank.
my old set up was a Holley red and matching 'dead head' regulator. Noisy and lots of plumbing so I've gone for a more modern 'in tank' solution.
https://aeromotiveinc.com/product/phantom-200-stealth-fuel-system/
It was not to difficult to fit, it has a compressible gasket that accommodates the uneven top of the tank, as well as the pump, filter and baffle all in the tank.
fortunately the fuel gauge float goes sideways
and got to use a spanner I hardly ever use
I took the this plug out so I could shine a light inside and see what I was doing.
Of interest I coated the inside of this tank over 10 years ago with a POR 15 tank kit and it still looks perfect, no rust.
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halbug Samba Member
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Joined: March 09, 2006 Posts: 487 Location: Germany
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Braukuche Samba Member
Joined: September 03, 2004 Posts: 11092
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Posted: Mon Sep 06, 2021 6:56 am Post subject: Re: 69 road race Ghia rebuild |
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Thread never ceases to amaze. _________________ 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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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Sun Sep 19, 2021 9:02 pm Post subject: Re: 69 road race Ghia rebuild |
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I've been waiting on a few parts to arrive, first was modern rear bump stops.
I only have 90mm of rear travel metal to metal and 60mm before the bump stop so I got 2 different heights of foam bump stops and threaded the arm so I could just screw them in. These are the short ones, 32mm
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1165 Location: Melbourne Australia
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Posted: Sun Sep 19, 2021 9:14 pm Post subject: Re: 69 road race Ghia rebuild |
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The other job was a bit more complicated. The Mendeola front suspension is very good in its adjustability along with a good camber curve, and it fits in with very little trimming of KG steel. But.... it has quite a lot of bump steer, over 3mm across the wheel travel. Halbug solved this by lowering the rack into the tunnel, inverting the tie rod ends and reworking the rack mount. His solution is very elegant and I was tempted
But in the end I went a different way, raising the outer end of the tie rods with spacers.
Unfortunately I couldn't find any 14mm high misalignment rod ends so I opted for 1/2". I drilled out the 1/2" thread and retapped it M14, luckily both tie rods (Golf 1) are RH thread, and then I used 1/2" bolts and spacers to get the 19mm rise.
I now have to measure the bump steer to confirm if I need to change the size of the spacer.
Meanwhile I've been woking on my engine upgrades, match porting manifolds to new heads. I'll post some pix in a few days |
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