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Ghia coming home
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halbug
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PostPosted: Mon Feb 17, 2025 1:39 pm    Post subject: Re: Ghia coming home Reply with quote
DaveB9 wrote:
Nice! Are they all original hardware parts you had cad plated?

Great game of Name that Part there!


Yep! I even build in a "find the mistake" LOL

All the hardware that came off my Ghia when taking off the body are included in these parts, yes. Plus a few extra washer plates from a 70 bug as spares and some brackets and parts I made for the build.

The extra chrome brakets are my new seat adjusters, not chromed in below pic:
Image may have been reduced in size. Click image to view fullscreen.

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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
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DaveB9
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PostPosted: Wed Feb 19, 2025 10:36 am    Post subject: Re: Ghia coming home Reply with quote
Amazing! The quality of your work is outstanding and I love the innovation.
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TRS63
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PostPosted: Wed Feb 19, 2025 10:52 pm    Post subject: Re: Ghia coming home Reply with quote
Nice bunch of clean parts, well done! This project really is second to none, enjoying every update ! Keep the good work Lars!

Grüße
Antoine
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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
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halbug
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PostPosted: Sat Feb 22, 2025 9:27 am    Post subject: Re: Ghia coming home Reply with quote
Thanks Antoine!

I made an aluminum adapter tube and a support ring from steel to close out my steering column to the body. This became necessary as the first joint sits half way inside and the steering column tube is to narrow to house it.

This solution closes out the wet and should give the column additional support.

Image may have been reduced in size. Click image to view fullscreen.

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Finally some warmer weather today, so I could primer all black sheet metal spots on the body.
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Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
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halbug
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PostPosted: Fri Mar 07, 2025 7:32 am    Post subject: Re: Ghia coming home Reply with quote
The old escutcheon arround the ignition switch has always been an eyesore. I was not able to find a replacement, so switched my lathe on and made one today.

The part looked good, but installing was a b... - not nice!!! Next time, after the body has been painted, I will have to find a softer material.

I installed the emergency flasher switch as well. The cigarette lighter came with the car.

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Image may have been reduced in size. Click image to view fullscreen.

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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
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sputnick60
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PostPosted: Fri Mar 07, 2025 10:00 pm    Post subject: Re: Ghia coming home Reply with quote
halbug wrote:
The old escutcheon arround the ignition switch has always been an eyesore. I was not able to find a replacement, so switched my lathe on and made one today.

I did the same for mine with similar issues with it. More than a couple were made till I got one that worked well enough. The plastic ends up being quite thin and tends to ripple.
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


I'm not sure that a softer material will make it easier to turn. I'm thinking instead of metal tools to face the front surface, a sharp knife and higher speeds might help it not end up tearing at the edges.

A few weeks after making mine I found this at KGPR.

Nicholas
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Disc
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PostPosted: Fri Mar 07, 2025 11:53 pm    Post subject: Re: Ghia coming home Reply with quote
It is available in Europe too.

https://www.paruzzi.com/uk/karmann-ghia/electricity/ignition-system-ignition-switch/10631/

I got one but never tried to install it.
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halbug
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PostPosted: Sat Mar 08, 2025 12:18 am    Post subject: Re: Ghia coming home Reply with quote
Bummer! Great to know and thanks allot!
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halbug
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PostPosted: Tue Mar 11, 2025 7:48 am    Post subject: Re: Ghia coming home Reply with quote
With my plans for a large engine I prefer to have more free airflow into the engine compartment. First I thought about using a later engine lid. I even bought one but found out, that the these later lids had some changes done to the A-surface, so I decided to modify the original lid.

Before:
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After:
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I just ordered this custom profile to weld it in between the deck lid hinge-attachment-points:
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The other edges will also be reinforced with sheet metal ribs. I used the laser again to get plane surfaces on the the compound angled cuts:
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Can't wait to get the profile to continue the fabbing.
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My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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DaveB9
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PostPosted: Tue Mar 11, 2025 11:26 am    Post subject: Re: Ghia coming home Reply with quote
Looking forward to seeing what you come up with here!

I did use a later engine lid and then had to modify the rain tray to clear the fanhousing because of the "bubble top" aluminium engine case that moves the fanhousing up. I still haven't been able to test that it now clears ...
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halbug
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PostPosted: Tue Mar 11, 2025 1:27 pm    Post subject: Re: Ghia coming home Reply with quote
DaveB9 wrote:
Looking forward to seeing what you come up with here!

I did use a later engine lid and then had to modify the rain tray to clear the fanhousing because of the "bubble top" aluminium engine case that moves the fanhousing up. I still haven't been able to test that it now clears ...


I should have the same if not more space after my conversion.

However, for my aluminum case in my bug, I modified the fan shroud at its bottom to restore its correct height in relationship to the generator and the rest of the motor. Could this be an option in your case?

Cheers
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DaveB9
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PostPosted: Tue Mar 11, 2025 2:38 pm    Post subject: Re: Ghia coming home Reply with quote
I trimmed the fanshroud in the centre a little, but even when located correctly for the alternator stand it still fouled the plastic rain tray. I was always going to modify the rain tray as the recess for the single carb would look odd running twin carbs, it just became a bigger job!

Something tells me when you are done modifying the old lid in steel I will wish I had done it that way ...
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halbug
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PostPosted: Sat Mar 22, 2025 1:47 pm    Post subject: Re: Ghia coming home Reply with quote
The deck lid got pretty flimsy when I removed the rain tray. I used a custom bent sheet metal profile in 1.5mm to create a new "backbone" for the lid. The ends needed to be raised a litle:
Image may have been reduced in size. Click image to view fullscreen.


Next I made some more parts to fit along. Thanks Wrenn for your inspiration using sheet metal screws:
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I welded the bits together on the outside to clean the welds and paint the backside. The complete piece barly fit into the lid:
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First a couple spot welds:
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Comleted:
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Cleaning up the welds is next

BTW, for especially for Ian... this is 300g lighter than stock Laughing
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Ian Godfrey
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PostPosted: Sat Mar 22, 2025 2:13 pm    Post subject: Re: Ghia coming home Reply with quote
Lars, you crack me up Very Happy
yes I'd be very happy to loose 300g off my Ghia, and it will be a bit more when you clean up those welds Laughing
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halbug
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PostPosted: Mon Mar 31, 2025 10:36 am    Post subject: Re: Ghia coming home Reply with quote
Happy 60th Birthday !!!

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Maybe I will get her back onto the street this year...
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My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0
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TRS63
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PostPosted: Mon Mar 31, 2025 11:46 am    Post subject: Re: Ghia coming home Reply with quote
This ghia aged well, happy birthday to it !

And for sure we want to see it on the street this year Very Happy

Bests

Antoine
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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
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halbug
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PostPosted: Mon Mar 31, 2025 11:48 am    Post subject: Re: Ghia coming home Reply with quote
Thanks Antoine!
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DaveB9
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PostPosted: Wed Apr 02, 2025 9:30 am    Post subject: Re: Ghia coming home Reply with quote
Beautiful work as always. Will there be a rain tray beneath the vents?
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halbug
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PostPosted: Wed Apr 02, 2025 11:58 am    Post subject: Re: Ghia coming home Reply with quote
DaveB9 wrote:
Beautiful work as always. Will there be a rain tray beneath the vents?


Thanks!

Not planned at the moment. Volkswagen got away from using them in the bugs and I don't think it will hurt.
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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
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halbug
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PostPosted: Thu Apr 03, 2025 10:17 pm    Post subject: Re: Ghia coming home Reply with quote
Finally summer is here. Warm enough to crack a 2K rattle can and spray some paint over the modified areas.

Image may have been reduced in size. Click image to view fullscreen.

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I will assemble the car without restoring the body first, for tryout of all my technical modifications. Once everything works out, I will redo the body, top and interior in a second step.
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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
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