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My 69 Ghia... Project ReStart, Seven Years Later
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djkeev
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PostPosted: Wed Feb 28, 2018 2:39 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

TDCTDI wrote:
c21darrel wrote:
Congrats. Now you cant avoid eye contact. Very Happy

Yeah, from the asshole neighbor that can't mind their own business.


Fortunately, I am a fair distance from neighbors. There is only one even close to me and when the leaves bloom, he can't even see my yard.

I am careful about noise at late hours, no sense in being rude!

Dave
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http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

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djkeev
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PostPosted: Wed Feb 28, 2018 2:51 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

I had forgotten a fairly significant fact!

My nose is NOT dented and never has been dented! Dancing

(I need to grab onto little crumbs of good news......)

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


There is rust below the bumper holes and below the horn in the spare well area, but that is easily fixed......
And when I do fix it, those stupid rubber gaskets you see hanging out? They are going "Bye Bye" and will be replaced with a 21st Century elastic polymer.

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Dave
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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

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djkeev
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PostPosted: Wed Feb 28, 2018 4:09 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

As amazing as this may sound seeing the condition of the 70 Convertible, that nose is also virgin, undented!

There is rust down in the bumper areas.

Essentially from the nostrils over is in great shape!
(I'm harvesting the nostrils for my 69 repair)

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Here is inside view, no distortion, no pounding evidence.....

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The bottom of the nose showing the rust.....

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In the Vanagon forum we have a "good karma, pay it forward" thread where we offer up stuff to fellow members for free, too good to throw away and in the spirit of good neighbors w give it away. They most often pay shipping.

In that giving Vanagon spirit...... if anyone needs a virgin nose, let me know.

Dave
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djkeev
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PostPosted: Wed Feb 28, 2018 4:41 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

First day of really doing anything........

6 hours invested.

Dave
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PostPosted: Wed Feb 28, 2018 4:44 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

There is a Nor'Easter blowing in.....

Funny how I tarp it now but it sat outside for Hurricane Irene and Superstorm Sandy...... Rolling Eyes

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I have a box fan in there and some open window trying to dry things out.

Dave
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PostPosted: Wed Feb 28, 2018 5:49 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

I just stumbled across this excellent thread documenting the interior trim and finish of late 69 and up convertibles.

Thought I would link it in here for future reference.

It has answered many questions for me already. I have nothing but an empty rusty shell. I will need to rebuild what was there.

https://www.thesamba.com/vw/forum/viewtopic.php?p=8702744#8702744

Another good thread

https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

Dave
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PostPosted: Wed Feb 28, 2018 7:00 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Dave,

The first of the 2 threads you mention in your post belongs to Phil - in Edinburgh, Scotland. I've had the privilege of spending a day with him driving through the areas around his city. Top down, wind in our hair, stopping at interesting places. Many, many golf courses in what appeared to me to be a windswept landscape.

Magic place, Scotland, and a great Karmann Ghia. My best Karmann Ghia day by far.

Chris M
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PostPosted: Thu Mar 01, 2018 5:32 am    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

djkeev wrote:
There is a Nor'Easter blowing in.....

Funny how I tarp it now but it sat outside for Hurricane Irene and Superstorm Sandy...... Rolling Eyes

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


I have a box fan in there and some open window trying to dry things out.

Dave


Fortunately the Nor'Easter arrival has been pushed back to mid afternoon today.
Why is that good?
I left my convertible top bow outside which has a very old but still serviceable rear wood bow on it! $$$'s
And
I had bagged and boxed various interior trim bits and tarboard, set them by the outside basement door and left them there overnight!
And
The Left Rear quarter window and all of it's related pieces were left out in a cardboard box too!

BTW same offer as with the undented nose, if anyone wants the operating quarter windows with trim, hardware and seals from a 69 Coupe, let me know... freebies!

I'll have the rear glass and trim available soon too.......

Dave
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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

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PostPosted: Thu Mar 01, 2018 12:47 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Noticed you had offered up some parts. This is the Give away thread. Use it at your leisure.
https://www.thesamba.com/vw/forum/viewtopic.php?t=692226
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PostPosted: Fri Mar 02, 2018 9:06 am    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Slow day today, sleeping under a blanket, the Nor'Easter is blowing in with Snow instead of rain......

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


Yesterday I did some cleanup inside, removed the back seat back, carpet and vinyl trim along the metal that abuts the seat.

Pulled out the piece of masonite which was soaked and hid a treasure trove of mice hoarding......

Removed the inside rear view mirror and visors. The visor clips turned to fragments when I unhooked the visors!

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Spent about three hours total.

Today has been plowing snow and shoveling, falling about an inch an hour and have 5" already ....... Rolling Eyes

I also spent this Month's Ghia budget on a Refrigerator for the other house!

They had a dented $3000 unit but was only marked down to $990. A new door panel is $300.
Weeks went by, I walked in this morning to get something and BAM ! Last night it dropped to $550, brought it home.

I'll take off the door and get out my body work Dollies to smooth it out. It is stainless so I'm not sure how it will come out, never worked stainless sheet metal before.
I wonder how it reacts to being massaged back into shape?

It is our "vacation" home so perfection isn't required but "darn nice" would be..... well...... Darn Nice!

Dave
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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

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crocteau
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PostPosted: Fri Mar 02, 2018 9:42 am    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

djkeev wrote:
Snow instead of rain......
Big flakes melting on contact down here in the balmy south.

djkeev wrote:
I'll take off the door and get out my body work Dollies to smooth it out. It is stainless so I'm not sure how it will come out, never worked stainless sheet metal before.
I wonder how it reacts to being massaged back into shape?
Likely it'll stretch if you work it much, but while you're snowed in you can always go at it with the Mothers metal polish and get it looking mirror-like.
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PostPosted: Fri Mar 02, 2018 11:12 am    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

I mentioned that I cleaned up the Coupes' interior yeaterday.

A few photos of the mess.
Sadly I CREATED THIS MESS by storing the vehicle poorly for seven years.

There is rust that needs fixing, seven years ago it was solid metal!

I'm beating myself up but then again, the experience I gained in welding and repair on the Beetle and the Vanagon is a major factor in me being able to bring this vehicle back to life.
Seven hears ago I was overwhelmed.
Today I am excited at the prospect of doing this task.

The repairs I need to do due to my own fault are probably three to four days (hobby days, not full work days, hobby days are only a few hours)

It may be a price I need to pay that may be well worth it?

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You can see the wet masonite towards the right in this photo. You can see the vinyl that covered it in some of the earlier photos above....

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Rust on the Luggage area that needs repair, fortunately the Convertibles rear firewall is solid and will probide the OEM donor metal......

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Removed the masonite panel that was covering the small space behind the seat back, it was covered with vinyl and exposed after I removed the strip of vinyl.
My Masonite was sopping wet, it broke in half at the nail when I tried to remove it.

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The tar board in there was decomposed into mush..... look at the rusty nail that was holding it in (Yes VW nailed into metal for securing carpet and similar items)

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Pretty well cleaned out, now to dry it and analyze the damage.....

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Dave
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http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

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djkeev
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PostPosted: Sun Mar 04, 2018 3:53 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Well, once the Nor'easter pounded us and dropped a foot of snow on us,
Then the high winds knocked trees and power wires down like dominoes,
And the power was out for 30 hours, and my generator quit, power restoration time frame forecasts were for midweek, after cleaning and plowing we got out of Dodge and headed to our Pennsylvania house.
47° Sunny, woodstove, electricity...... Spring like! ..... life is good!

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


Suffice to say that NOTHING but thinking has been accomplished since Thursday.

I think we settled on a body color though...... 👍

https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

Now.... a Nor'easter is forecast for Tuesday into Wednesday with "plowable" snow fall. Shocked

Dave
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PostPosted: Mon Mar 05, 2018 6:25 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

With the snow cover I haven't done a lot.
The electricity is back on, I did some shopping.

I picked up a quart of POR 15, I have used many rust products IMHO .... six of one, half a dozen of another as far as quality goes. They are all similar.

Anyway, if you open a can and get a DROP on the lid seal and then reseal the can, that can will never open again!

I picked up a case of cheap 4oz Mason Jars.

I will NEATLY pour the POR 15 into these small jars. This way once opened I have a high chance of using it all and have no worries about resealing the container. One use quantity should really reduce the waste, this stuff isn't cheap!

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Dave
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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

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PostPosted: Tue Mar 06, 2018 5:04 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Today was mainly preparation for another Nor'easter.

But it was a BEAUTIFUL DAY!!!!!

After making sure the generators all worked, made repairs to various pieces of equipment and filling everything and every fuel can with gas, I played with the Ghia.

A lot of snow had melted, I pulled back the tarp and gazed inside...... what to do?.....


The headliner is old, rotten, torn and mouse infested. It brushes my head everytime I climb in! Ewww!!!

I put on a mask (I hates mices! Just read my Vanagon experiences!) and got a pair of scissors to cut out the headliner.

It wasn't as bad as I expected and soon had it out, the bows out (anyone want them?) and cleaned up the mess.

I them turned my attention to the lower Luggage shelf area, the part behind that masonite board behind the seat.

It had dried completely, I had vacuumed up the mouse debris so I got out a scraper. And a wire brush and went to work.

I did good but there is a heavy bead of seam sealer there. To get at and treat the rust, this seam sealer needed to go "bye bye".

I used my torch, I use a MAP cylinder, it is my "restoration" go to tool.

Soon the Ghia was full of smoke as I scraped off 50 year old seam sealer.

Mostbof it was fine. There is an area on the right that needs some welding "love".

I was able to discern how the shelves on either side of the seat bottom are welded in. The Coupe shelf parts and the Convertible shelf parts are two different animals.
The Convertible ones are much wider, hence the rear seat is more narrow.
I need to remove the Convertible ones whole and transplant them.
I've pretty much figured out the "how to" For the task.

This isn't my car, this is a photo of Scott's car behind the rear seat, you can clearly see the huge besd of body seam sealer.


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Seam sealer removed, you can see the lap joint that was under it......

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Left side, no major repair needed, a small rust hoke to weld up.....

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A decent seam for the most part.......

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The right side is my problem area......

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When I removed the seam sealer, I uncovered the bolts holes that the Convertibles use to fasten to the pan......

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http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

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djkeev
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PostPosted: Wed Mar 07, 2018 2:04 am    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

When I do a vehicle build thread I will often do spin off threads of certain areas of interest.

On this Ghia, I'm installing an Air Conditioner. To keep the procedure in one place, I started an A/C thread......

https://www.thesamba.com/vw/forum/viewtopic.php?p=8708500#8708500

****************


Because I am joining a Convertible body with a Couoe Body, there are many structural design differences between the two body styles.

Reinforcement in the Windshield,
Reinforcement in the "A" Pillar,
Reinfircement in the Rocker Panels,
Different Body Mounting points,
Door / Glass differences,
And of course, the Convertible mechanism and related items.

Here is my thread on finding, documenting annd moving or recreating the needed changes in a Coupe body to support becoming a Convertible.....

https://www.thesamba.com/vw/forum/viewtopic.php?t=439808


Dave
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PostPosted: Wed Mar 07, 2018 3:25 am    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Because I am mating proprietary Convertible parts into the Coupe, I will need to remove the Coupe "B" Pillar.

Did some investigation on how the rear 1/4 panel is fastened to the "B" Pillar.

Again, using my torch I took to melting away the Pewter covering the factory seam.

What was exposed wrte simple stitch welds, I totally expected a series of spot welds.

This should let go fairly easily with some grinding......

I do wonder what I'll find on the right side, that is a replacement panel. I wonder how THEY fastened it and finished the door opening?
Probably screws and pop rivets! Laughing


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Welds circled for clairty......

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Dave
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http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert


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PostPosted: Wed Mar 07, 2018 5:19 am    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Oh....... maybe Three hours yesterday......
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PostPosted: Thu Mar 08, 2018 10:02 am    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Well.......
Nor'easter #2 blew through...... second one in less than a week.
The first one was light, only 12" of snow but the wind was vicious.
This 2nd one lingered and dropped 17 1/2" of snow but was fairly calm.
Went from 7 1/2" to 13" depth in 90 minutes!

Cleaning uo a foot and a half of heavy wet snow is exhausting, even when in a truck with a plow. It is just too much snow...... I did it in lifts, about four times during the storm.

No power outages this time.

So just when you get ramped up and excited...... you get buried... again.

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I won't be harvesting any bits off of this Dash clip for a few days either......

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But on the plus side...... I have made very real headway on emptying the garage! Laughing

Dave
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Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
Ian Godfrey is offline 

PostPosted: Thu Mar 08, 2018 3:33 pm    Post subject: Re: My 69 Ghia....... Round Two! Reply with quote

Dave, if you keep the jars of Por15 in the fridge they last much longer before 'going off'. Just needs a good relationship with other possible users of the fridge!
Dishwasher, fridges and ovens are very important 'tools' to have access to.
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