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xzener
Samba Member
Joined: June 03, 2006
Posts: 1777
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 Posted: Tue Feb 28, 2017 4:46 pm Post subject: Re: Had some time for my '58 low light today |
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Still a bit damaged... But with the rarity of parts, you can't be too choosey. Looking great.
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My 70 beetle was totaled Now to build the Ghia I always wanted. Rest in peace Ruby, I will miss you. Hello <insert Ghia name here>! |
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c21darrel
Samba Member
Joined: January 22, 2009
Posts: 8211
Location: San Dimas
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noslzzp
Samba Member
Joined: September 19, 2011
Posts: 147
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| Posted: Thu Mar 02, 2017 11:24 am Post subject: Re: Had some time for my '58 low light today |
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Dave, where did you get this rear lower fender panel? We ordered some from CIP but they look different. Yours seem to have a "flatter" bottom whereas the ones we received have more of a "curve" to them:
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Introducing the Basilari 306R.. A low light Ghia, performance chassis and 300HP boxer six.
http://www.basilari.com/category/buildupdates/ |
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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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| Posted: Thu Mar 02, 2017 12:27 pm Post subject: Re: Had some time for my '58 low light today |
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| noslzzp wrote: |
| Dave, where did you get this rear lower fender panel? We ordered some from CIP but they look different. Yours seem to have a "flatter" bottom whereas the ones we received have more of a "curve" to them |
| Porschedave wrote: |
| My next step was to look at some of the right-rear fender rot, and replace it with pieces that I bought from CIP. |
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1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon) |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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| Posted: Tue Mar 07, 2017 5:55 pm Post subject: Re: Had some time for my '58 low light today |
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Hey Guys
Gosh it's snowing again up here in the Pacific Northwest - it's not supposed to keep coming down like this. Gee wiz.
Anyhow, I spent a morning making templates from cardboard and then making them out of metal so that I could plug these holes. It was a lot of work and time consuming but the progress is satisfactory - at least I feel that I am moving forward with this resto ...
Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139 |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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Exaktaphile
Samba Member
Joined: October 01, 2010
Posts: 151
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| Posted: Sat Mar 18, 2017 1:59 am Post subject: Re: Had some time for my '58 low light today |
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You're doing nice work! 
Your hinge area looks like a near twin to my car.
Here's a few pictures I took while chopping that area up.... It was a bit daunting until I fully understood the geometry.
https://www.thesamba.com/vw/forum/album_search.php...t_dir=DESC |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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| Posted: Tue Mar 21, 2017 3:50 pm Post subject: Re: Had some time for my '58 low light today |
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Hi Exaktaphile
Thanks for the complement and thanks for the link to your thread. Nice to know that I'm not the only one trying to bring one of these back from the trash.
Today I tackled the back end of the driver's side rocker and found similar issues you showed in your thread. One item in particular was the reference to the reinforcing plate that had the carefully engineered reinforcement bead designed to catch dirt and water. When I tapped mine it simply turned to dust and fell away. I'll have to cut away not only what's left of the reinforcement piece but also the material under it as it was rotten as well.
I'll get some photos up, perhaps tomorrow.
Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139 |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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| Posted: Thu Mar 23, 2017 5:04 pm Post subject: Re: Had some time for my '58 low light today |
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hey
I worked on both ends of the car today. First, I completed the repair to the rear section of the body, including replacement of the while inner section as well as reinforcing plate.
I then moved onto the front A pillar. This is a challenge but the initial fit has not been too terrible. There are some alignment and gap issues that I'll have to tackle before it gets welded into place.
I'll also need to get the new rocker into place before this is welded up.
Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139 |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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| Posted: Fri Apr 14, 2017 5:36 pm Post subject: Re: Had some time for my '58 low light today |
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I'm continuing the work on the driver's side.It's been more complex than I imagined. The rust rot was pretty extensive. I've worked on the A pillar and think that it is partially sorted. But first I need to get the rocker sorted. It turns out that the aftermarket rocker does not have the same profile as the low-light rocker, especially on the inside. I made a wood buck and made my own inside section. This will be a skin over top of the after-market rocker. Of course, I need to sort out the heater tube attachment. And since the wheel well was toast I also needed to fix that. But there's progress. here's some pics:
rotten rear quarter
mostly repaired:
wood buck for new profile:
completed new skin:
Happy Easter all
Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139 |
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Exaktaphile
Samba Member
Joined: October 01, 2010
Posts: 151
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| Posted: Sat Apr 15, 2017 5:33 am Post subject: Re: Had some time for my '58 low light today |
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You're doing a great job - kudo's! I did similar repairs on my channels and was surprised as well at how much time disappeared. It's totally worth it after you lay down that last puddle and see what you've accomplished.
I like your buck! If you have time and energy in the future, you can help pay for your project by selling just the top section with the lowlight profile. People can use it for patches or do the whole graft onto a new later channel section. That might alleviate some of these angle-iron adaptations. Heck, you can bend them to order! |
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boinkffd
Samba Member
Joined: October 07, 2004
Posts: 231
Location: South
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| Posted: Sat Apr 15, 2017 5:33 pm Post subject: Re: Had some time for my '58 low light today |
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| Dave, keep up the good work. |
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kiwighia68
Samba Member
Joined: October 20, 2013
Posts: 2874
Location: Auckland, New Zealand
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| Posted: Sun Apr 16, 2017 3:00 pm Post subject: Re: Had some time for my '58 low light today |
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I'm enjoying your build Dave, partly because I've been down the same road, but with this difference: I had expert help.
The A-pillar repair is a devil. I was able to transplant a complete used A-pillar assembly - supplied by Dan in Seattle - on the R side, but had to repair the other. Some of the repair pieces had to be handmade.
Before:
During:
After:
I admire your resilience, tackling these jobs on your own.
_________________
Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015 |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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| Posted: Thu May 04, 2017 4:34 pm Post subject: Re: Had some time for my '58 low light today |
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Hey Folks
I'm continuing to work away at the driver's side. It's been a lot of work.
The first step was modifying the rocker to match the low-light profile - here's the finished piece.
And then I fit it to the car making sure all the bolt holes line up. The next step was to assemble the lower half of the A-pillar, the newly revised rocker and the outer skin. There was a lot of fiddling to get a good alignment. The aluminum flat bar was used to ensure that the back face was correctly aligned
And then I made another piece of flat bar with two very carefully drilled holes to match the hinge holes not he door itself. This would ensure the door would bolt straight on.
and of course I had to repair the rotten bits on the inner fender well. Here's a photo of the first pass.
And finally fitting the outer skin of the rocker. It took some modification especially at the front end. But overall, it looks good.
later
Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139 |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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xzener
Samba Member
Joined: June 03, 2006
Posts: 1777
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| Posted: Fri May 12, 2017 5:53 pm Post subject: Re: Had some time for my '58 low light today |
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Did you make that fender lip yourself?? Looking great.
_________________
My 70 beetle was totaled Now to build the Ghia I always wanted. Rest in peace Ruby, I will miss you. Hello <insert Ghia name here>! |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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| Posted: Sat May 13, 2017 3:22 am Post subject: Re: Had some time for my '58 low light today |
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| Porschedave wrote: |
Working on the left rear corner now...
Dave |
It looks like you used the repro lower fender repair section without modification - these are for 67-71 year models which have the different wheel arch profile. I was going to do this but then realised my early bumper would be too long for that profile - how are you going to address that?
_________________
1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon)
Last edited by Mellow Yellow 74 on Sat May 13, 2017 9:00 pm; edited 1 time in total |
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Porschedave
Samba Member
Joined: July 01, 2004
Posts: 454
Location: Vancouver, Canada
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| Posted: Sat May 13, 2017 7:25 pm Post subject: Re: Had some time for my '58 low light today |
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Made some more progress today - replace the rusty bits from the fender lip, both the inner and outer sections. The next steps will be to fabricate the section to the front of the torsion bar opening.
While some of the aftermarket pieces are not exactly the same as the original, one does not have many options for replacement pieces so we make due with what we can buy or make. And all of the aftermarket pieces need to be massaged in a any event.
Dave
_________________
1977 911S
1958 Karmann Ghia build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?t=571683
1965 Sunroof Notch build thread here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5600139&highlight=#5600139 |
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