| Author |
Message |
kiwighia68
Samba Member
Joined: October 20, 2013
Posts: 2916
Location: Auckland, New Zealand
|
 Posted: Sat Mar 15, 2014 2:40 pm Post subject: |
 |
|
Nice work and a good example for me to follow, Dorian. What shocks are you using, if you don't mind sharing that with me?
_________________
Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015 |
|
| Back to top |
|
 |
DorianL
Samba Member
Joined: June 06, 2013
Posts: 717
Location: Belgium
|
| Posted: Sun Mar 16, 2014 11:12 am Post subject: |
|
|
Putting in rear dampers now. It was too tight to fit. Presumably when torqued it pinched the cup gave a bit, A bolt, a couple nuts and washers to expand it back out. I would have preferred a larger bolt - but it's all I had within reach and it worked.
Front sway bar was tougher than I thought. I used a strap to hold it in place and crescent wrench and a clamp to get the fittings on there, Tough! I wish I had one of you guys here to help me as well  This is a plus-sized bar. There was no stock rear bar; I will add one.
Bar is touching the locknut. Not too happy with that, but I think it'll be fine. I kept nut up and inboard to stay cleaner and not touch the steering knuckle. May or may not make a difference. Not too found of these clamps. Not exactly sure how much to tighten. TIP: "shape" your clamps to conform before placing… it'll be much easier to thread the nut and tighten.
Useful clamp
Pinning the bolt
On to rear bar. This one was much easier to install. Line up was good. First L brackets. Two holes only were available. I'll leave it at that and wind drill a third. I Think it'll be fine. But I'll keep an eye on it.
Always worried about over tightening and breaking these clamps…
I've been waiting for this bit…
FWIW, it rolls and turns very nicely.
Last edited by DorianL on Sun Mar 16, 2014 1:38 pm; edited 1 time in total |
|
| Back to top |
|
|
DorianL
Samba Member
Joined: June 06, 2013
Posts: 717
Location: Belgium
|
| Posted: Sun Mar 16, 2014 11:22 am Post subject: |
|
|
| kiwighia68 wrote: |
| Nice work and a good example for me to follow, Dorian. What shocks are you using, if you don't mind sharing that with me? |
They are Koni adjustable. The performance guru here recommended them for all around handling. I'll get PN for you... |
|
| Back to top |
|
|
DorianL
Samba Member
Joined: June 06, 2013
Posts: 717
Location: Belgium
|
| Posted: Sun Mar 16, 2014 1:36 pm Post subject: |
|
|
Working on my trans in my new cave… 
The cap came off easy enough…
I hate those kind of snap rings…
Easy enough - lots of grime under there… And an oil seal to pro out...
Tap it in on one side…
Pry it out with this… Seems to work…
Now this is interesting and likely an issue. The second snap ring under the axle flange was just hanging there. It is too big to snap on to the output shaft. I don't think I can resize it to fit. It looks too big. In theory it should be the same size as the one holding back the axle flange. Hmmmmm… I'll have to think about this one. Not going to be able to reassemble this tonight, for sure.
No 22 is the problem…
Hmmm
Off goes broken clutch return spring… That looks like locating marks… maybe...
Rats - forgot to snap a pic of input shaft. Considering replacing the seal here as well. WOW it's TINY. That seal looks tough to get at… but not now… I'm calling it a night. Note the gunk in the clutch bearing guide sleeve.
|
|
| Back to top |
|
|
karmann1st
Samba Member
Joined: September 12, 2010
Posts: 93
Location: Florida
|
| Posted: Mon Mar 17, 2014 3:39 pm Post subject: |
|
|
WOW! pan looks AWESOME!!!!
_________________
Questions? Email me, I always answer all emails, same day or next. |
|
| Back to top |
|
|
DorianL
Samba Member
Joined: June 06, 2013
Posts: 717
Location: Belgium
|
| Posted: Wed Mar 19, 2014 4:00 pm Post subject: |
|
|
And now…
Snap ring goes back on…
And cap
The input shaft seal however was a XXXXXX. It took me a few hours to get it out… and only minutes to press the new one in. Started at 2100 - 0000, now. It's wide and deep in there. I didn't have correct tool to pry it out with… so careful tapping, tugging and prying. I think the damage is minimal and there will be no leaks. Just slight scuffing outside when i realized how malleable magnesium is…
|
|
| Back to top |
|
|
kiwighia68
Samba Member
Joined: October 20, 2013
Posts: 2916
Location: Auckland, New Zealand
|
| Posted: Wed Mar 19, 2014 4:12 pm Post subject: |
|
|
Dorian, I am old enough to know that the degree of satisfaction is in direct proportion to the difficulty of getting the job done. You must be very pleased.
Wel gedaan.
Time for some of that famous Belgian chocolate?
_________________
Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015 |
|
| Back to top |
|
|
Altema
Samba Member
Joined: June 20, 2010
Posts: 2906
Location: Lower Michigan
|
| Posted: Wed Mar 19, 2014 4:58 pm Post subject: |
|
|
Work of art right there... 
|
|
| Back to top |
|
|
KGCoupe
Samba Member
Joined: July 01, 2005
Posts: 3580
Location: Putting the "ill" and "annoy" in Illinois
|
| Posted: Wed Mar 19, 2014 5:10 pm Post subject: |
|
|
| Altema wrote: |
Work of art right there...
|
X 1,000,000!
Stunning, really ... and quite an amazing amount of progress from this
in just 9 short months.
If I worked on my Ghia 18 hours a day for 9 months I couldn't accomplish 1/4 as much as you have.
Well done. |
|
| Back to top |
|
|
mountainkowboy
Samba Member
Joined: April 06, 2008
Posts: 951
Location: Socal
|
| Posted: Wed Mar 19, 2014 6:25 pm Post subject: |
|
|
Very nice.
_________________
Chuck in Socal
________________________________________
71 Super Convertible...DD
78 Honda CB750K
06 Honda CR-V (wifes)
63 IH Scout 80 "Beater" |
|
| Back to top |
|
|
DorianL
Samba Member
Joined: June 06, 2013
Posts: 717
Location: Belgium
|
| Posted: Thu Mar 20, 2014 2:27 am Post subject: |
|
|
Wow - Thanks, Gentlemen!
The deadline to be back on the road is July !. So I need to keep up the pace.
My goal is to pick up the body with a flatbed Friday and slap it on the roller-skate Saturday. i have a team of three so far to help me - then it's BBQ time 
Still to be done:
- Final clean and POR15 silver the trans (possibly and possibly tonight)
- Oil in trans… I lost a lot replacing the seals.
- install trans
- install CVs
. Make sure the body-to-rollerskate gasket fits. Temporally crew it down, as they have a life of their own. I have a set of tiny stainless self-tapping screws that need drilling for. The gasket will need sealant on both sides.
- Check all torques
- Connect brake hoses to calipers not sure if copper washers are required. I don't see any mentioned anywhere in Bentley/Haynes Anyone can comment on that? Is a copper washer needed?
- Possibly install pedals and bleed brakes. Unlikely. I want those pedals nicely cleaned up first and possibly modified to be wider apart
- Grease everything
- replace distorted bearing cover
- replace a tie-rod end with a missing locknut
- replace body-to-rollerskate rubber rests on rear (as missing)
- Adjust the shock to medium |
|
| Back to top |
|
|
c21darrel
Samba Member
Joined: January 22, 2009
Posts: 8223
Location: San Dimas
|
|
| Back to top |
|
|
DorianL
Samba Member
Joined: June 06, 2013
Posts: 717
Location: Belgium
|
| Posted: Sat Mar 22, 2014 1:18 am Post subject: |
|
|
| c21darrel wrote: |
From past experience...
I would complete everything on the pan...pedals, clutch/accelerator cables, trans oil, connect brake lines...everything before dropping the body back on. Once the body is on it will all be more difficult, time consuming.
I dont remember any copper washers on brake lines. They thread direct into the calipers on one side and hardline on the other. |
Makes absolute sense… I was putting oil in trans a figured it would be MUCH tougher with the body on the pan…
- - - - - - - - - - - - - -
Going to pick up the KG body… A harbinger?
And another! Wow, I haven't seen a KG on the road since I bought this one at the "bug-in"
(Saw this on the way as well, when I picked up the flat bed. NICE! Unusual here.)
Wheeling it around…
NOW. Can I swear here???? I think I am allowed to swear on this board. We're all adults here. Pay taxes. Stand up to pee. That sort of thing... IN-xxx-CREDIBLE. I made a mistake. My day job, to be quite honest, is a desk job. I decided to respectfully stay out of the way let the workers strap the KG down to the flatbed. They are more experienced than me; I am a mere white-collared nerd. MISTAKE! I should have done it myself. Fortunately, I drove VERY cautiously... but 2/3 of the way home… in the rearview I see a corner of the KG hanging off the flatbed. I pulled over immediately to straighten it out - a scary thing to do on the highway. I SHOULD have taken pics. Obviously the guys can weld or sand… but they were never Boy Scouts!!!! What a disaster I found under there. I was expecting they knew what they were doing. NO. Not a single recognizable knot. I mean a MESS!!! Compression straps cinching the flatbed rather the strapping the body down. UGLY! I should have take pics - AMAZED at what I saw. I should have checked. Fool I was to trust them. Even the door foams to keep them from rattling were gone. The granny knot they used slipped and the foams flew away allowing the doors to rattle in the wind. Anyway there was only a TINY nick 1/16 square. Lucky. Very lucky. And lucky I was constantly checking - this could have been a real disaster. I reset everything - not easy alone. Strapped down carefully and took small roads home. I am AMAZED!
Anyway… here we are:
Trans POR15ed. Hopefully easier to clean, now.
Oil at right level...
New return spring…
Now to get these pedals cleaned up…
Last edited by DorianL on Sat Mar 22, 2014 10:33 am; edited 1 time in total |
|
| Back to top |
|
|
CiderGuy
Samba Member
Joined: December 23, 2013
Posts: 1351
Location: Bucks County, Pa
|
| Posted: Sat Mar 22, 2014 2:25 am Post subject: |
|
|
| If I saw what you saw, after the many months of hard work you but into this car....... Let me say you're a better man that I am. I would have been looking for someone to bail me out of jail today. ... |
|
| Back to top |
|
|
sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 4040
Location: In Molinya Orbit
|
| Posted: Sat Mar 22, 2014 3:13 am Post subject: |
|
|
| DorianL wrote: |
| Can I swear here???? |
Yep you sure can! Been there done that. I thought I had it licked using a flat bed truck and having the body on its chassis. Oh no! that wasn't good enough. The dickhead with the truck has a wedding ring 'cos he's a decent married guy. Right?!
A professional knows that your don't push the car when there are bands of metal on your hands!! 
So yes, you can swear because it is rational and healthy to do so. I certainly did and look! I'm not waiting on death row.
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! |
|
| Back to top |
|
|
DorianL
Samba Member
Joined: June 06, 2013
Posts: 717
Location: Belgium
|
| Posted: Sat Mar 22, 2014 10:45 am Post subject: |
|
|
Grrrrr… I didn't lose my cool. Probably it was the shear amazement that they could screw this up so badly.  Then, since I was on the highway, I HAD to keep my cool. Making a mistake there would not be cool.
Anyway - I was a bit rushed this morning and I forgot to take pics of the body to pan seal. I drilled small holes and used 3mm self-tapping screws to hold the seal down. I used a tube of sealant under the seal, but not over it. Who knows, maybe one day I'll need to pull the body again.
I got the trans in there - but not the CV/shafts. Ran out of time.
After a big debate on where to grasp the KG and putting down jackstands… we simply put it straight on the pan. It fit immediately. I did use masking tape to hold the rubber mount pads in place i glad I did that. This turned out to be much easier that I thought. Four men + my son, 14.
|
|
| Back to top |
|
|
kiwighia68
Samba Member
Joined: October 20, 2013
Posts: 2916
Location: Auckland, New Zealand
|
| Posted: Sat Mar 22, 2014 11:09 am Post subject: |
|
|
Dorian, swearing is good for you. It's not good to keep anger of that magnitude bottled. That's why we throw tools around and kick the door. (Better without witnesses!)
You are doing a great job in more than one way: Your posts are also a guide for me because I am following in your footsteps, and I'm on the opposite side of the planet.
Lessons learned today:
Use self-tapping screws to hold the body to chassis rubber down (not nails)
Put sealant UNDER the rubber first
Put POR-15 silver (high heat?) on the transmission (and engine block and manifolds?)
Please remember to let me have the part number for your shocks.
_________________
Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015 |
|
| Back to top |
|
|
DorianL
Samba Member
Joined: June 06, 2013
Posts: 717
Location: Belgium
|
| Posted: Sat Mar 22, 2014 1:58 pm Post subject: |
|
|
Sure - will fish out those numbers tomorrow morning.
Another little tip: I used masking tape to hold the gasket on the rim. I drilled straight though the gasket. It worked fine.
Nicely done…
Starting with installing this. The last thing I want is that door swinging open and wrenching itself. I already had to pull a dent because the PO neglected to replace that strap. We are not going back there again...
|
|
| Back to top |
|
|
AlienJohn
Samba Member
Joined: February 23, 2014
Posts: 253
Location: Ohio
|
| Posted: Sat Mar 22, 2014 4:16 pm Post subject: |
|
|
TRULY INSPIRING !
I wave read this whole thread and my jaw has been hanging open for the last few pages.
Brother, best of luck. I hope it's all you dreamed 
Keep those updates coming ! Let's see it driven for the first time !
John in Ohio USA
74 Coupe
_________________
All Hail Snorkelstang !
72 Standard Beetle
74 Karmann Ghia Coupe
76 Fender Telecaster |
|
| Back to top |
|
|
karmann1st
Samba Member
Joined: September 12, 2010
Posts: 93
Location: Florida
|
| Posted: Sun Mar 23, 2014 10:54 pm Post subject: great job Ira.! I never imagine how great will look on pan! |
|
|
| DorianL wrote: |
Sure - will fish out those numbers tomorrow morning.
Another little tip: I used masking tape to hold the gasket on the rim. I drilled straight though the gasket. It worked fine.
Nicely done…
Starting with installing this. The last thing I want is that door swinging open and wrenching itself. I already had to pull a dent because the PO neglected to replace that strap. We are not going back there again...
|
_________________
Questions? Email me, I always answer all emails, same day or next. |
|
| Back to top |
|
|
|
