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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1205
Location: Melbourne Australia
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 Posted: Thu Nov 03, 2022 12:55 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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I also put some channel locks on the swage end just where it meets the cable, to stop the cable turning as you try to adjust it.
good luck |
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rbsurfguy
Samba Member
Joined: August 10, 2008
Posts: 1780
Location: Fairfax, Northern Virginia Formerly Huntington Beach, SoCal
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| Posted: Thu Nov 03, 2022 3:58 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Thank you Sir, will definitely lock the cable in place as I make the adjustment!
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= |
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rbsurfguy
Samba Member
Joined: August 10, 2008
Posts: 1780
Location: Fairfax, Northern Virginia Formerly Huntington Beach, SoCal
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| Posted: Fri Nov 04, 2022 6:05 am Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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I need some guidance. As mentioned previously, suddenly my left turn signal is now not working. When I pull just the emergency flasher, all works. When I power everything up, including headlights, and pull emergency flasher, nothing activates. Right turn signal works fine. Headlights low and high beam work.
So I powered everything up, put a test light to the back side of fuse panel, under hood, and got positive light on right side, nothing on the left side, fuses 3&4. I checked the fuses, all good. Opened up front and rear lenses, checked bulbs, all good.
With things still powered up, I touched test light to relay, the one that sets on lower panel next to fuse panel, positive reading on all points but the one going to left side. Could the relay be bad? It's a new relay I installed only a few months ago. Is it possible only one link on a relay can go bad?
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= |
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rbsurfguy
Samba Member
Joined: August 10, 2008
Posts: 1780
Location: Fairfax, Northern Virginia Formerly Huntington Beach, SoCal
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| Posted: Sat Jun 24, 2023 2:51 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Been a while since I have posted, but have done a lot between work travel. I was a bit concerned about not having a Drain Tray over my engine, and having a Porsche style fan/cooler, obviously the stock tray wouldn't work. I did a search through the Gallery and was inspired by a modification by member alansvwTwinCab. From Gallery
His looks really nice with the carbon fiber design.
Now I just had to figure out how he did that. Since my drain tray was cracked I thought it was worth trying. So I mounted it, made some rough measurements, took out the cutting tool and went to work.
Once I made the cut, I had to figure out what to use for a mold to make some kind of shape. Found one of my wife's plastic plant covers...luckily she hasn't noticed, cut it in half, and attached to the tray.
Busted out the fiberglass, something I haven't done for a while, and attempted to mold a shape. Had to do several layers and trimming.
Once it dried after a few days, I did some cutting, sanding, and shaping.
Mounted it to decklid, and it was still hitting the fan shroud.
So more cuts and measurements, mounted, took off, cut, trimmed repeat several times, until I finally was able to get a shape close enough to fit and close the lid without too much damage to tray.
After a bit more trimming, I finally got it to a shape that fit. Sanded the entire tray, bondo fiberglass filler, spot putty, sanded, primer, spot putty, sanded....seeing a pattern here?
After getting it reasonably clean, I sprayed on several layers of primer and finally paint to match the rest of the engine trim.
Mounted it once again, and it came out pretty good. It's tight up against the lid and just touches the shroud, so I think it will actually drain water through the tubes once connected.
Now on to trying to install the convertible top and headliner. Prepping the step by step manual from the 'How To' section!
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= |
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1205
Location: Melbourne Australia
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| Posted: Sat Jun 24, 2023 3:37 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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A great job there, looks fantastic  and I really like the way you have a good seal around the engine 'tin'. What seal did you use? |
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crocteau
Samba Member
Joined: March 31, 2005
Posts: 1229
Location: Philaburbia
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| Posted: Sat Jun 24, 2023 5:09 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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| rbsurfguy wrote: |
| ... It's tight up against the lid and just touches the shroud, so I think it will actually drain water through the tubes once connected. ... |
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rbsurfguy
Samba Member
Joined: August 10, 2008
Posts: 1780
Location: Fairfax, Northern Virginia Formerly Huntington Beach, SoCal
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| Posted: Sat Jun 24, 2023 5:22 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Thanks guys.
Ian I just used whatever engine seal I bought from one of the usual vendors, JBugs or West Coast, can't remember. It has two layers. Unfortunately the upper part showing got overheated on the header so it split when I pulled it up over the lower cover. I may try to make some kind of patch if I can figure out how or just tuck it back under. Not that pressing at the moment.
Onward!
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= |
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3250
Location: Vermont
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| Posted: Wed Jun 28, 2023 4:43 am Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Great to hear some news on your car. Your rain tray came out great. Good luck with the top And headliner. Having the top on the car will be a huge step forward.
_________________
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 Wed Jul 19, 2023 3:39 pm; edited 1 time in total |
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rbsurfguy
Samba Member
Joined: August 10, 2008
Posts: 1780
Location: Fairfax, Northern Virginia Formerly Huntington Beach, SoCal
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| Posted: Wed Jul 19, 2023 3:10 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Spent most of last week installing the headliner on my Ghia. Thanks to the step by step instructions in the 'How To' section posted by @Ghiaddict, it made things fairly easy. Except for the heat and humidity I think things went well.
I forgot to take a pic of the elastic bands between the intermediate and tubular bow, I didn't forget to do that!
I started on the top cover a couple days ago and will post pics soon. The top cover has gone fairly well until it came to installing the rear cable, where it definitely takes two people to work it under the lip to pull the material under and lock it in place. My friend John came over to assist...He's the one with the mostly stock 70 Vert I've posted and he has on his thread. Thanks again John!
The question I have for @Ghiaddict I think his name is Vince, or anyone else who has installed a late model convertible top, after tightening the cable down, when I tried to fold the top forward to close, it won't go all the way down, about a foot away, it appears to be too tight at the back.
Question is, do I need to now loosen the rear cable a bit until I can close the top and latch it, then adjust as needed?
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= |
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3250
Location: Vermont
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| Posted: Wed Jul 19, 2023 4:33 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Hey Jeff,
The headliner work looks fantastic.
I have not done a complete top, but I have installed a top from another car, frame and all, onto my car. It's true that every car is a little different and even though both cars were 71's, the back half of the top did not fit which required undoing all of the back half and starting over. Like you, I used the same instructions from Ghiaaddict. The top as I got it was so tight that there was no way it could latch up front and the rear window was so far off, it was unable to latch to the rear bow. I had to peel the outer layer away and redo the straps on either side of the back window. Vince says to go 26 inches. This top had 28 inches. Way too long, but 26 inches on my car was way to tight. I ended up going with 27 inches and it was perfect. I think that measurement might be dependant on each car. I would adjust as necessary so that the top is tight but can be latched. I had to also reposition the rear bow so the rear window latch would line up properly.
If it helps, you can look at page 22 of my OGhia thread to see how I got mine properly installed.
https://www.thesamba.com/vw/forum/viewtopic.php?t=...;start=420
Good luck.
_________________
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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Braukuche
Samba Member
Joined: September 03, 2004
Posts: 11204
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| Posted: Wed Jul 19, 2023 4:53 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Loosen the rear window cable until you can latch it. The top will stretch in time and you can always tighten it later.
_________________
Go Reds! Smash state!
Retirement is here!
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
1989 Westfalia |
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obus 
Samba Member
Joined: March 08, 2001
Posts: 11633
Location: just off Garden State Parkway Exit 81
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 4116
Location: In Molinya Orbit
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rbsurfguy
Samba Member
Joined: August 10, 2008
Posts: 1780
Location: Fairfax, Northern Virginia Formerly Huntington Beach, SoCal
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| Posted: Thu Jul 20, 2023 4:01 am Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Gents, Thanks for the input and ideas.
Marc, I checked all along the way as I was installing the headliner and had no problem latching the top, checking strap length, frame, and window latch, all worked fine. It wasn't until I skinned it and locked down the rear cable that I couldn't close all the way. I'll run through everything again and see if I can figure it out.
Brau, I haven't connected the rear window cables yet, just the cable that holds the outside rear of the top into the slot. We really tightened the cable tight to lock in the material underneath, so I am thinking I need to back it out a bit. Maybe that's the cable you meant?
Nicholas, sad to hear when any of our people go missing, but yes, his step by step was perfect and I had little problem finding anything too problematic.
Obus, It has been hot and steamy here in Virginia, so today I will let it sit in the sun for a bit to give the top a bit of stretch before I go at it again.
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= |
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Braukuche
Samba Member
Joined: September 03, 2004
Posts: 11204
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| Posted: Thu Jul 20, 2023 6:14 am Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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| rbsurfguy wrote: |
Gents, Thanks for the input and ideas.
Marc, I checked all along the way as I was installing the headliner and had no problem latching the top, checking strap length, frame, and window latch, all worked fine. It wasn't until I skinned it and locked down the rear cable that I couldn't close all the way. I'll run through everything again and see if I can figure it out.
Brau, I haven't connected the rear window cables yet, just the cable that holds the outside rear of the top into the slot. We really tightened the cable tight to lock in the material underneath, so I am thinking I need to back it out a bit. Maybe that's the cable you meant?
Nicholas, sad to hear when any of our people go missing, but yes, his step by step was perfect and I had little problem finding anything too problematic.
Obus, It has been hot and steamy here in Virginia, so today I will let it sit in the sun for a bit to give the top a bit of stretch before I go at it again.
Jeff |
I misunderstood.
Yes you could loosen it a bit, see if you can get it too latch but from my experience they all are super tight. What I do is run the hooks out as far as possible and push the top down until I can get them to grab the receiver. Then I wait a while and run the hooks in a bit and grab the receiver. I do a bit at a time until I can actually get it to latch. Do it on a hot day in the sun is even better. Once it’s latched leave it a while closed.
_________________
Go Reds! Smash state!
Retirement is here!
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
1989 Westfalia |
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rbsurfguy
Samba Member
Joined: August 10, 2008
Posts: 1780
Location: Fairfax, Northern Virginia Formerly Huntington Beach, SoCal
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| Posted: Thu Jul 20, 2023 6:34 am Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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That's a great idea, thanks, will try that. Thank you Sir!
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= |
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John Moxon
Samba Moderator
Joined: March 07, 2004
Posts: 14202
Location: Southampton U.K.
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| Posted: Fri Jul 21, 2023 1:58 am Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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| rbsurfguy wrote: |
Nicholas, sad to hear when any of our people go missing, but yes, his step by step was perfect and I had little problem finding anything too problematic.
Jeff |
Yes Vince was the font of all knowledge concerning practical Ghia restoration and endlessly patient with enquiries. He had to give up his KG business in Florida due to health problems and moved up to Georgia boondocks where he had a poor internet connection. Pleased to know his input is still appreciated around here.
We miss him a lot, if anyone has any update on Vince a lot of people here would like to know. 
_________________
John.
Judson Supercharger Information on The Samba
My 1958 Shorrock Supercharged Karmann Ghia
Stop dead photo links! Post your photos to The Samba Gallery! |
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rbsurfguy
Samba Member
Joined: August 10, 2008
Posts: 1780
Location: Fairfax, Northern Virginia Formerly Huntington Beach, SoCal
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| Posted: Tue Jul 25, 2023 2:46 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Finally got the convertible top fitted after numerous adjustments.
I still have a few little things things to tidy up and am sure I will adjust more as the top loosens up a bit, but otherwise it fits pretty well. Some last minute headliner adjustments need to be made after I install the carpet, so that looks to be next on the agenda. Sorry for the dirty look, haven't given her a bath yet, was waiting until the top was on.
Also got my Vintage 1971 Virginia license plates registered, so hopefully on the road soon. Unlike Marc in Vermont, my Vintage tags don't require a safety inspection!
Another step closer!!
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= |
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Braukuche
Samba Member
Joined: September 03, 2004
Posts: 11204
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| Posted: Tue Jul 25, 2023 2:57 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Looking good!
_________________
Go Reds! Smash state!
Retirement is here!
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
1989 Westfalia |
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 3250
Location: Vermont
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| Posted: Tue Jul 25, 2023 3:45 pm Post subject: Re: Jeff's 71 Vert Restoration/Reassembly |
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Nice! Installing the top is a big step that helps the car look more complete. I was excited to see what my car looked like with a top.
You are lucky that your state has common sense. Vermont is a nice state but it's the 7th most expensive state to live in, and they keep making it more and more expensive. A lot of young people leave and now a lot of retirees are leaving too. By the time we get close to paying off our mortgages, we can't afford to keep our property! 
_________________
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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