1969 Karman Ghia Build (UK)

djway3474 · Posted: Thu Oct 09, 2014 9:53 pm Post subject:

I have seen that same "floater" problem several times. Ultra fine piece of metal in the float bowel would move up into the jet after a little run time. Stop a bit and ran fine again, for a while. Each time I found a small piece of metal that the light had to hit just right, after much frustration
Once in a Merc inboard boat and twice in webbers.
The last set of carb I recently installed I deburred all machined areas inside the carbs and cleaned, rinsed and repeated. No trouble this time.

carl4x4 · Posted: Mon Sep 28, 2015 3:31 pm Post subject:

The Ghia is getting some good mileage, this weekend we took a trip down to the New Forest today in the Autumn sunshine with some mates in a 308 on some great driving roads Smile

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

Definitely need taller gears to keep up with the 308 Wink

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1969 UK Karmann Ghia build http://www.thesamba.com/vw/forum/viewtopic.php?t=518789&highlight=

John Moxon · Posted: Tue Sep 29, 2015 12:34 am Post subject:

carl4x4 · Posted: Thu Oct 08, 2015 10:18 am Post subject:

Not sure I took notice of the names sorry John, we were mostly near Ringwood for the day here for an open day:

http://www.classicconnection.co.uk/index.php
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1969 UK Karmann Ghia build http://www.thesamba.com/vw/forum/viewtopic.php?t=518789&highlight=

John Moxon · Posted: Thu Oct 08, 2015 10:55 am Post subject:

carl4x4 · Posted: Thu Oct 08, 2015 1:49 pm Post subject:

The solution to my old carbs problem has arrived Very Happy

Only thing is I can't bear to take it off the road yet as it's running sweet at the moment!
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1969 UK Karmann Ghia build http://www.thesamba.com/vw/forum/viewtopic.php?t=518789&highlight=

giraffeinbath · Posted: Thu Oct 08, 2015 2:03 pm Post subject:

Would you say you have the suspension and steering geometry nailed now?

I'm trying to work out what to do with the front end of mine, did the Fuchs you had early on cause you issues?
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carl4x4 · Posted: Thu Oct 08, 2015 3:18 pm Post subject:

Nailed? well more or less, the rear I have sussed once I realised how to adjust the toe & camber that solved the instability at speed.

Front suspension is almost perfect, but needs raising a little as when you have two big adults in the car it rubs a tiny bit on full lock.
I can either raise it a little on the suspension or fit slightly bigger lock restrictors in the rack.

But the ride & steering is so compliant & precise with the Red9 front I'm glad I stuck with it.

With regards to wheels, I quickly learnt that OEM was the best hence the ATS wheels from the 1303s Cabriolet = best all round. The Fuch replicas did rub both sides on full lock unless I added 9mm spacers to the front, which meant changing from bolts to extra long studs & nuts.

edit: Forgot that the Fuch replicas mean you can't fit centre caps on the rear wheels until you make up some sort of cap spacer which looks a bit rubbish unless you do it properly!
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1969 UK Karmann Ghia build http://www.thesamba.com/vw/forum/viewtopic.php?t=518789&highlight=

carl4x4 · Posted: Thu Oct 29, 2015 3:10 am Post subject:

Who needs a wind tunnel ? Simply let the dew settle on your car then take it for a drive. Aerodynamics old skool style Smile

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carl4x4 · Last edited by carl4x4 on Wed Nov 04, 2015 11:59 am; edited 1 time in total

As the weather is getting damp and the nights are getting longer I decided this weekend was a good time to start the winter rebuild. Gearbox needs a rebuild with different ratios, plus conversion to EFI with new fuel lines etc. I forgot how quick it was to remove the engine, even on my own & with all the extra oil line plumbing etc it only took me 2.5hrs start to finish. Not bad considering I'm a bit out of practice Smile

lets hope the rest of the work goes as smoothly!

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c21darrel · Posted: Wed Nov 04, 2015 11:46 am Post subject:

So with FI you will need to run a return line to tank, right? Higher pressure lines? What else? What are the issues you are solving and what are expectations? Sorry not much FI knowledge here. Embarassed

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carl4x4 · Posted: Wed Nov 04, 2015 12:28 pm Post subject:

The old fuel line is unreliable, so two new fuel lines running inside the car on the outside of the tunnel (as per the VW bulletin back in the day),

broadly speaking the list is:

- conversion to electric fuel pump & filter in the front of car
- two new fuel lines, plus vacuum controlled regulator
- convert fuel tank for bigger bore lines + return input
- install ECU & new loom
- convert to crank trigger ignition
- removal of mechanical fuel pump & distributor, blank off
- install fuel rails, injectors, throttle bodies
- various sensors to be installed, Lambda, temp, air flow etc.

I'm sure I've forgotten something Laughing

Why am I moving to FI? it's part of an on-going project to modernise the Karmann Ghia, I've done the interior, moved to rack & pinion steering, converted to front wishbone suspension. In order to get more power out of the 1955cc engine I need to move up a size in carbs as the ones I have now are running 28 venturis, plus upgrade the fuel system to electric & replace the suspect fuel line.
So now's an opportune time to modernise to fuel injection, my Vintagespeed exhaust is also Lambda probe ready anyway Smile

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kgj · Posted: Thu Nov 05, 2015 7:39 am Post subject:

Hi. I have been following this thread for a long time. nice car, good work.
you mention fuel line replacement as per VW bulletin. Which bulletin would that be?
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1958 coupe

carl4x4 · Posted: Thu Nov 05, 2015 8:42 am Post subject:

Thanks kgj, I'm somewhat envious of your garage & it's contents I must admit Wink

having read your rebuild thread.

Here's the bulletin, I spent a while dithering as to where to put the replacement lines, but then stumbled across this in another Samba thread. I believe it's a dealer bulletin issued for Beetles, presumably for replacement or supplementary fuel lines? If it's what VW recommended then who am I to argue!

The only alteration I'm going to make is to run it on the left hand side (passenger in the UK) This means I don't have to cross it over the section under the seat. That is probably OK on a Beetle, but on a Ghia coupe the rear seat practically sits on that section so wouldn't be an option.
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1969 UK Karmann Ghia build http://www.thesamba.com/vw/forum/viewtopic.php?t=518789&highlight=

kiwighia68 · Posted: Thu Nov 05, 2015 10:56 am Post subject:

Hi Carl, I've just finished reading your thread again and stumbled on to something that I have to do this weekend, which is to make a bracket for the numberplate on the front. I'm not it the mood to drill holes in my stainless steel bumper (yeah, the one that kept me busy for a week).

How did you do it, please, if you don't mind disclosing your (patented?) secret?
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Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015

carl4x4 · Posted: Thu Nov 05, 2015 2:08 pm Post subject:

carl4x4 · Posted: Fri Nov 06, 2015 4:45 am Post subject:

Another 1.5 hours last night and the gearbox is out, mounts removed etc. how come it took months to fit this stuff when I was restoring Poppet, yet only hours to take out ?

Now there's a bit of a wait as a local gearbox specialist are going to take my 1302s box and an eBay 1303s box I bought ages ago and make one good one out of the two. The 1302s box I've been running needs much more legs, so he's mixing the final drive from the 03 with the ratios of the 02.

Hopefully I'll end up with:

3.80 (1st) 2.06 (2nd) 1.26 (3rd) 0.89 (4th) 3.875 (final drive)
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bhartwell59 · Posted: Fri Nov 06, 2015 7:23 am Post subject:

easy e · Posted: Fri Nov 06, 2015 8:27 am Post subject:

carl4x4 · Posted: Fri Nov 06, 2015 10:58 am Post subject:

That reminds me I must put one of those Pegasus safety signs on my Christmas list Smile

(Thanks for the pics easy-e) I put the Pegasus stickers on as a nod to the old race cars of the time
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