The push against entropy

[mac3]

Doh should have read the thread completely before posting -Rotisserie
-sweet ..

[sputnick60]

Continuing on, we have the finalization the RHD change.
It has been tricky wading through the photos here on The Samba, and the technical manuals. Though well covered for earlier systems, the cluster design changed in 1966 and those details are more difficult to find. RHD is just not that common.
Luckily Boris from Vintage Vee Dub at Campsie allowed me to scrounge through his loft and gather a full set of pedal components. These all had to be sand blasted and painted with primer before setting up.
The parts welded to the pan floor were the trickiest to find.... well obviously they weren't going to be in the boxes of bits. There is the 50mm x 5mm support plate, the accelerator hinge and the captive nut for the end stop plate.
The test fit job had to occur before the pan got its final paint.
This support plate stops the pan fatigue and cracking under long term load. It is drilled to suit both the old style pedals and the later version. Nutserts were used to provide a good anchor in the tunnel wall. Checking on several beetle chassis I found VW had welded captive nuts in this position without a support plate like there is on the other side. The nutsert it is a good solution since I can't easily get access to the inner tunnel with a welder.

Here the pedals are in position but held in just loosely to allow adjustment. I've got wire twisted up where the circlips should be.... don't do that for a permanent fix

Same again but viewed from above.

And finally the view from the other side of the tunnel showing the accelerator lever. (sorry you'll have to turn your heads to one side.) There is a cover held on with the two 17mm bolts omitted at this time because it does not affect fit. As an aside, look in the background of this shot to see the donor guard remains.

The main things to check are
1. The tubes and sleeves all insert far enough to stay together.
2. The stop plate has sufficient adjustment to hold pedals in the right position.
3. The large support plate is in the right spot
4. The clutch pull lever is in line with the clutch bowden tube (if not, a lot of broken clutch cables will curse this chassis in the future)
5. The brake line is clear of moving parts so it does not rub and eventually wear a hole in itself.

Next is painting.

Oh by the way... I got a real job... Start Monday, in Canberra

Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[ddwbeagles]

[John Moxon]

[sputnick60]

[slafa]

Nice work Nicholas and congrats on the job! (I think)
_________________
'63 KG Roadster proj.
1973 Mercury Montego MX Brougham
1977 Dodge Tradesman 200 "shorty" Van
1983 Ford 350 Econoline Ambulance
1997 Mercedes S500 W140
1976 BMW 75/6 bike
various Honda, GMC daily drivers

[sputnick60]

More updates on progress..
here the body is back from the spray booth after being covered in etch primer. I'm still waiting for the engine bay sheet metal to arrive from the US. My buddy Vic (the Aussie) is loading his container right now, so its not far away.

Here the Chassis is seen having a little bask in the sun. The bottom side is covered with stone guard. Over that, the rest of the chassis has been sprayed with the usual black.

I've got the Chassis at home now and I've started adding the bits that attach to it. Here the pedal cluster is finalised. There is a new clutch cable and throttle cable installed and of course the ATE master Cylinder and new hardline to the rear are in place.

The shift control rod has been cleaned up, re-greased and reinstalled.Here's a photo of the new bush and retaining spring.

Next job is to order the drop spindles and disk brakes from CSP.... The Aussie dollar has been increasing in value in the last few weeks and every day expensive items become more affordable.

Cheers
Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[sputnick60]

In the last week Chris has finished the prep on the front of the car. He has now covered it with a thin layer of spray putty and sanded that smooth in preparation for the first layers of paint

Further up this thread you can see how mucked up this guard was.....not any more!

this is the nose.... somewhat better than before you'd agree

We await the imminent arrival of Vic's container with the engine bay floor sheet metal before we can complete the car. So it will go on the back burner at Chris's shop for a few weeks whilst he does some Xmas rush jobs and I finish the pan.

Nicholas

Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[sputnick60]

I remember John Moxon's lament when I got this job in Canberra. I think he was right! Progress has slowed alot. However, some progress is better than no progress and here we have a few pictures of developments in the past several weeks

Firstly we have the front beam bolted to the chassis. The torsion plates and arms have been inserted. Boy was that a job to get lined up right! Phew! I now await the drops spindles, disk brakes, steering arms and steering box all to go on.

Then we have the Rancho transmission installed, the side covers and axle tubes are on as are the spring plates.

I used boots from the IRS suspension so I don't have to muck about leaks thought the seam held with those nuts and screws on the other boot type. To get them on You invert then, heat them up in boiling water and then pull them over wide opening over the bell. It helps to wear gloves to improve your hand grip and protect from the heat. Once they're on you invert them so they are around the right way and clamp them with the original stainless clamps.

This is the other side

And in those cardboard boxes are a present from Santa Claus...front and rear disk brakes, 20.5mm diameter master cylinder and 2inch dropped spindles from CSP. I look forward to mounting those up during the upcoming weekends.

Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[hpw]

Nicholas, good job Looking GOOD
_________________
http://www.youtube.com/watch?v=3SLIzSCt_cg&list=FLIX26sGa8__1F1loczLPTtg&index=2

[slafa]

Wow, I like the looks of a brand new car Nicholas, your managing of this entire process is very inspiring, it is so obvious how much energy you put into preparation which is paying huge dividends all along the process. Very nice
_________________
'63 KG Roadster proj.
1973 Mercury Montego MX Brougham
1977 Dodge Tradesman 200 "shorty" Van
1983 Ford 350 Econoline Ambulance
1997 Mercedes S500 W140
1976 BMW 75/6 bike
various Honda, GMC daily drivers

[sputnick60]

Finally I've got her back paws on the ground after how many months? Here are the new CSP rear disk brake set up with shocks mounted and calipers painted red. Red? Yes, because red paint makes them stop better! Everyone knows that!

Here is the view showing teh transmission and axle tube

This shows the hand brake mechanism which acts on the disk piston in a mechanical action. I'm yet to tidy up all the cables. that will happen once I get the fluid in there and tension up the hand brake... that can happen latter.

Finally I've fitted a set of 356 rims to check how the centres look. I'm planning on using these centres with other outer rims. Probably will use 5.5 or 6 inch rims that I can fiddle with and find the optimal offset. and then get the lot rechromed.

I plan on using the Moon Style caps. Anyway the calipers are easily visible through the slots which confirms the "Look" I'm after is possible.

Soon to come .. the front paws

Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[slafa]

Very nice
_________________
'63 KG Roadster proj.
1973 Mercury Montego MX Brougham
1977 Dodge Tradesman 200 "shorty" Van
1983 Ford 350 Econoline Ambulance
1997 Mercedes S500 W140
1976 BMW 75/6 bike
various Honda, GMC daily drivers

[sputnick60]

Despite being in Western Australia at the moment I have more photos to show progress has been happening. Chris has been busy and has sent a steady stream of invoices.

Here is the underside of the Left rear guard before primer showing the extent of repairs in there

This shows the outer wing and how the skin now looks

This is the other guard looking pretty good too

And later the same afternoon shown here is the LHS guard with primer on it prior to sanding

More progress photos to come.

Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[sputnick60]

So I've had a chance to look back and noticed that a few things haven't yet been posted up.

During my research I discovered LHD cars have the centre two posts in a different position.
To show the difference here is a picture of a factory RHD. See how they are over to the left.

and here is a picture of a factory LHD showing them near the steering column ridge, towards the left side of the car

That's quite an interesting difference and a detail I couldn't let slip. So here is my car with the changes in the pillars

Now some more details about the rear quarter that was involved in a serious shunt all those years ago. This photo show how far we pulled it apart before starting the rebuild.

The next lot of photos show how it stands as of yesterday.

the engine bay floor and rear valance was supplied by Mike Gregory from House of Ghia. I had ordered several versions of repro engine bay tin from other suppliers and it was all wrong or at least similar but too different to use. I had to resort to a clip mainly because I'm too damn fussy. Thanks Mike I'd be lost without you!

That's a fair amount of work. I think at this stage the metal work is done and we are starting to do the prep for the first layers of paint

At home I've been busy with the chassis and I'll post the photos of that soon.

Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[hpw]

unbelievable attention to detail
_________________
http://www.youtube.com/watch?v=3SLIzSCt_cg&list=FLIX26sGa8__1F1loczLPTtg&index=2

[Ian Godfrey]

Nicholas, great work, I am picky but you're more picky than me.
A few thoughts.....
The shift rod bushing in the tunnel should have the slot towards the left side of the car, not up or down.
Did you put loctite on the nut that holds the bracket for the rear brake hard/soft line connection.
If you chrome rims do the inners and outers separately then weld together, as the copper, nickel and chrome doesn't 'throw' well into narrow gaps. This way the rims look good from the outside at least. Seal around the welds with zinc rich paint and cavity wax. If you plate after assembly the welds look good but rust starts where the center and rim join where the plating hasn't reached.
Did you find a cover for the accel lever on the left front of the tunnel.
Keep up the inspirational work
Ian G
Melbourne

[sputnick60]

[sputnick60]

I got the Chassis off the jack stands and so all four paws are on the ground.

Here is a photo of the CSP disk brake adaptors for the CB performance drop spindles.

Here's the view of the CSP set up before all the bolts are tightened.

the view from the front

the Shockex shocks weren't supplied with the correct bushes for the ball joint suspension tower. I've got to sort that out but for now only the one is mounted but just hanging there by the bolt at the bottom.

the view from the side

and these Mangels show the "look" works just fine at the front

For me this point is a significant mile stone ahead of joining the body and chassis. I'm so looking forward to that!

Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!

[Toddball]

Super Cool! Your pics are great for reference. I really like the look you are going for with the wheel set up! Keep up the awsome work, I will be looking forward to more posts.