Restoration thread: my 60 strato blue coupe

[TRS63]

Looking at the driver's side, fun times are coming:

Starting (as the other side) with the back. I do have parts I did order at the start of the project so will save some fabrication time for this part of the car. So, let's start:

Really nice here ahah:

So let's remove the corner by cutting every weld point:

In order to weld this part:

Here:

I hope to have time next week for it.. let's see !

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

[JeffL]

Nice work. That’s a very early 60.
_________________
http://karmannghias.org/
https://karmannghias.org/GAlken/index.html

[TRS63]

Thanks a lot Jeff!

Yes, it is a very early one, love all the small details!

So, I did continue a bit, first by removing the end panel I needed to replace:

You can also see that the bottom corner of the panel next to it was also to replace, that's why I marked it.
Then I removed the whole heater channel :

You can see why they all rust from inside-out, you find bare metal inside the heater channel..

I then started on the little corner :

Making the patch:

Adjusting:

And fully welded:

Then adjusting the end panel:

And welding:

Some epoxy primer:

And some before/after, always good for the motivation :

Bests

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

[TRS63]

So, I did make some progress here
Turned my attention to the A-pillar :

Removed the connection to the fender on the bottom:

And draw the minimum amount of metal to replace:

Made some space:

And repaired the part in the wheel well:

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

[halbug]

Antoine, I envy your dedication

It is almost like building a dreamcar body fram scratch. Keep going!
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0

[kingkarmann]

[calexican]

Bravo!! Seems there is no repair too tricky for you. It’s been great following this thread and seeing every nook and cranny getting some love.

[TRS63]

Thanks so much guys, you are too kind!
Quick check how the back part of the pillar will look:

So,in order to adjust well my A-pillar and confirm all my measurements, I started by positioning my heater channel:

And then adjusted with the pan, screwed to it :

And a couple of spotwelds, it's in position:

To be continued!

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

[TRS63]

So, after the heater channel was positioned, I could adjust the A-post:

And after all checks, put some welding primer, made some holes for the welding..and go:

And here we are, the A-post is already looking quite better:

And finally, after 5 years, no more braces at the door opening!! The body stays square alone !!

Next will be to finish the A-post with the part enclosing the hinges..

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

[Marcdeb]

Takes a lot of skill to achieve proper alignment of all these body parts properly. There's so much to consider with so many parts not being removed at the same time. Incredible 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

[Braukuche]

Lot of thin, thin metal on that lower A. That’s going to be a major hurdle jumped when it’s done.
_________________
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

[TRS63]

Thanks guys!

Went further on the A-post, first check with the replacement part:

Marked where to cut:

And made some space and started the cleaning:

And removed the locking plate to take care of the broken screw and the Rust:

And cleaned, blasted, ..:

Mounted again, A-post all cleaned and primed:

And adjusted the replacement part..and welded it :

Here we are,no more rusted-through A-Post:

This part will come when adjusting the front fender:

Bests

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

[TRS63]

So, continuing with the underdash part, I did repair it before, putting in position :

Looking good but something is missing here :

Yes the connection part to the heater channel so I am building it:

Test fit:

Looks good so building the second one:

Test :

And welded on:

All welded back on the body:

And checking the fit with the pan:

Loving this view:

Bests

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

[TRS63]

While I was there, I took care of a couple of holes that were made in the wheel housing:
Before:

During:

And after:

And some epoxy primer on it :

I also removed the broken screw in the upper door fixation plate:

By making it longer via Tig-welding some extra metal to make it longer and finally welding a nut on it :

And it's out:

I could almost re-use it as a screw:

Bests

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

[TRS63]

So, before putting all the bottom of the ghia in primer, there was one thing left: the heating tubes between the heater channel and the dashboard. On the left it was still there but cut at the bottom:

So I fixed that:

And the other side had been removed (due to its rusty fixation at the dashboard) and the rusted bottom cut so there was a need of work too:

I of course always checked that the parts on top to guide the air are fitting well:

I also received a restored door latch to replace the one that had some play in it:

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

[halbug]

It' s amazing how much dedication you put into your Ghia... most of us would probably have give up long time ago

Thanks for sharing all the detailed pictures.
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0

[Inchpincher61]

Antoine, WOW!

That A-pillar was a nightmare ! But perfectly fixed!

I think the same like halbug. What an dedication! I am not sure if I would have the patience for that. But that's the way how Ghias are rescued. Keep Going!

Can you give a feedback regarding the Atelier K parts? They seam to fit quite well and have a good quality?

[TRS63]

Thanks a lot guys, really appreciated!!

@Inchpincher61: parts are amazing, the best repro parts I ever had! For sure not the cheapest and delivery time can be a bit long as Fred is working alone but well worth it !

So, the upper part of the dash is still yet to be rebuilt but I started by a part of it that was really annoying me..the radio opening or what was left of it:

So let's build the patch :

And checking:

Markings where to cut:

No coming back:

Adjusting:

TIG-welded:

And the repair done and in primer:

It was then time to primer all the bottom parts:

It feels so good seeing it so solid again!!

And for the motivation :

Next step: top and under the dashboard..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

[TRS63]

So, a small update today!
Under the dashboard was still some work, some small holes and a bad repair I did make at the beginning (good to see it good now, redoing things isn't really progressing but I couldn't feel the idea of somewhere not reaching my wanted quality level!):

So I prepare the patch :

Cutting:

Adjusting:

And welding the patch and all the small holes:

And some primer :

Bests

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

[TRS63]

So, long time no updates but doesn't mean I did nothing.. I mostly work on the interior of my 62 ragtop to make it ready for the summer but some small steps were done on the ghia. If you remember well, I already did start the part for the bottom of the back of the right rear fender:

So I finished adjusting it:

And marked for the cutting:

And started to make some cutting:

Under it, more panels are needed so as usual, first build the repair panel and then cut:

Ready:

But before welding it, I want to make the repair panel under the bumper fixation. And before that, I needed to solve an issue with one of the screw for the rear bumper. Someone in the past tried to remove the broken screw by welding it..but did really bad :

So no chances other than removing the fixation :

So I removed it:

And found the great previous work..

So, time to redo the fixation, the new one next to the rest of the old one:

Oh, maybe better seen here :

The built one in details:

Test fit:

As I didn't have a square nut, I built one with a normal nut and a cut disc:

And repaired:

Next: built the bottom patch panel, and then weld all these panels to finish this area!

Bests

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