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Ghia coming home
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halbug
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PostPosted: Sun Jul 12, 2015 12:56 pm    Post subject: Reply with quote

Fitting the Mendeola Bulkhead

Finding the center... sounds easy doesn't it? Rolling Eyes It took me the better part of the morning until I felt I had found it Twisted Evil
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Cutting: The two cuts parallel to the tunnel help to position the bulkhead straight and in line with the chassis center line.
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Some more fitting, grinding, hammering, bending: snug fit...
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... until everything is ready to be welded in place
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hours later ==> Done!
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I will tack weld in place later, but first I will need to find what I call "the perfect place for the steering rack". More to come...

Cheers
halbug
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halbug
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PostPosted: Sun Jul 12, 2015 12:32 pm    Post subject: Reply with quote

Thanks!!!

At least somebody's reading Smile Smile Smile
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CiderGuy
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PostPosted: Sat Jun 27, 2015 2:53 pm    Post subject: Reply with quote

Very nice job. Looks like he may have competition.
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Cars Currently Owned:

1970 Karmann Ghia Coupe
1973 Karmann Ghia Coupe - Project car for sale
1970 Karmann Ghia Convertible (Body off restoration)

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halbug
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PostPosted: Sat Jun 27, 2015 1:57 pm    Post subject: Reply with quote

OEM Spindles on Mendeola Chassis

To get my project legalized for street use in Germany I cannot use the welded spindles that came with the Mendeola set. The first Mendeola sets utilized stock spindles too, but they are no longer available.

I digitized the two different spindles to be able to compare the geometries on a computer. The upper ball joint had to be moved inboard, to get back to the steering axis inclination as Mendeola had designed it. The eccentric cone was digitized to be able to design the new adapter.

My first thought was to weld a cone in place of the eccentric into the spindle and ream the cone and spindle to get to the correct geometry. But I found out, that the spindle material contains sulfur – so I decided not welding them!!!

I’ve come up with a special adapter to make stock spindles a pure bolt on!

The CAD data are shown earlier. The angled washer is keyed to the eccentric cone, so that the washer is not pushed away when torque is applied to the nut.

All parts are CNC machined for tight tolerances. I am using high grade tool steel for those parts.

The steering axis inclination is exactly the same as Mendeola’s. Camber, Caster, Toe are adjusted just as with the welded spindles. Track width is reduced and scrub is slightly less, due to the higher axle location on stockies. Both works well with the wheel combo I plan on using.

Some pictures:

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Thanks for your interest
halbug

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halbug
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PostPosted: Sat Jun 20, 2015 1:02 pm    Post subject: Reply with quote

Sway bar for Type 181 / Thing Chassis

I wanted to keep the stock reinforcement bar under the torsion spring tubes and maintain the right geometry as Kevin had designed it.
This solution puts the sway bar where it needs to be, without lowering it.
Just as is sits in a bug Wink

Making parts:
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Space for a solid insert:
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Insert generates flat with threaded hole, this will hold one side of the bracket:
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Custom mount for the other side, shown with 2 brackets for sway bar:
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Clearance for the sway bar:
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All welded up:
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Everythings clears and fits Cool Cool Cool Cool :
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Cheers
halbug
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halbug
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PostPosted: Sat Jun 20, 2015 12:25 pm    Post subject: Reply with quote

Brackets to mount Berg Transmission mount:

Used a piece of square tube:
Image may have been reduced in size. Click image to view fullscreen.


Made to fit and welded to the chassis:
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These will clear the Mendeola rear trailing arms Very Happy !
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halbug
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PostPosted: Mon May 18, 2015 12:38 pm    Post subject: Reply with quote

Lots of grinding on the weekend:

The cast-in hard stops are cut back to clear the spring plates:
Image may have been reduced in size. Click image to view fullscreen.


Shock towers cleared for Mendeola (Fox) struts with a minimum preload of 1/2". Less preload is propably not required and not a good idea anyhow:
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Voila:
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Stabilizer bar attachments are next. This will be fun too, because of the Kübel (Type 181) truss bar under the torsion spring tubes Twisted Evil

Cheers
halbug
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halbug
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PostPosted: Sun May 03, 2015 11:01 am    Post subject: Reply with quote

Thanks!

First try fit of the Mendeola rear trailing arms yesterday – looking cool on my own chassis Cool

The rubber mount for the Berg 5-Speed did interfere with the arm, so I cut the lower tube off the mount to realign to the chassis and fit further rearward.

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I made slots to move the rubbers further inboard.

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Everything clears now, but I will have to make my own brackets to the frame horns.

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I experienced the first surprise with my Kübel chassis – even thought, I was told it should fit all right Rolling Eyes – the rear shock towers are different to bug or Ghia. Kübel tower left. Most obvious is the lower hard stop (arrow) and the different angle of the upper shock mount hole Crying or Very sad

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After a lot of comparing and measuring, I am hoping that the body mounts are in the same location, so I will grind off all the ribs below the red line and keep my finger crossed to not see more of those kind of surprises...

Cheers
halbug
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Basketcase
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PostPosted: Mon Apr 27, 2015 7:58 am    Post subject: Reply with quote

beautiful Ghia and Bug!
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halbug
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PostPosted: Sun Apr 26, 2015 10:24 am    Post subject: Reply with quote

Back from winter break:

Clearing the Berg5 to the Frame is complete:
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During the winter:
I received a new a differential from Gary Peloquin, what a difference in service to Quaife. And the technical things I did not like about the Quaife are all good here.

Mendeola stuff is still not complete, but I measured the welded spindles that came with the kit and developed adapters to make stock spindles work without the need of welding them. I cannot get welded spindles approved for street driving, so had to come up with a solution for stockies.
This is the CAD, parts will be made soon.
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More to come Cool

Cheers
halbug
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halbug
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PostPosted: Mon Oct 06, 2014 9:30 am    Post subject: Reply with quote

Kevin has sent most of the missing parts. At least I have the important stuff together now Cool .

Kuebel Chassis hanging off the hoist, waiting to become transfomred...

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Cheers
Lars
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halbug
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PostPosted: Sat Aug 16, 2014 1:38 pm    Post subject: Reply with quote

My Mendeola Stuff arrived Thursday Very Happy Very Happy Very Happy

Unfortunately some parts are missing Sad but Kevin promised he will send them right away.

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Today I built the frame for my body hoist Shocked

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I will use it to store the chassis above my bug, while I am not workin on it. This way I can still park my bug in my tight garage Laughing . It will also be used to lift the Karmann body off its old pan and lower it onto the new one...

Cheers
halbug
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halbug
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PostPosted: Mon Aug 11, 2014 1:35 am    Post subject: Reply with quote

Quick Update:

Diff. went back to the dealer. Quaife in England was very uncorporative and the thing had just too much clearance between splined shaft and drive flange.
I hope Gary Peloquin will have one for sale soon.

Medeola chassis kit is supposed to arrive any day now... Razz

Cheers
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halbug
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PostPosted: Fri Jul 11, 2014 10:51 am    Post subject: Reply with quote

kman wrote:
Funny. My daughter is in Osnabruck right now. She is unimpressed that the Ghia was made there. But she's a teenager.


Little does she know Laughing Hope she enjoys her time in Germany!
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kman
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PostPosted: Wed Jul 09, 2014 8:13 pm    Post subject: Reply with quote

Funny. My daughter is in Osnabruck right now. She is unimpressed that the Ghia was made there. But she's a teenager.
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halbug
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PostPosted: Wed Jul 09, 2014 1:51 pm    Post subject: Reply with quote

OK - No spacer needed according to Quaife. Now I have an issue with plenty of clearance between the drive flange and the splined shaft. Will see how this goes Evil or Very Mad

Good News: New Seats arrived today - Looking Great. Cool

Cheers halbug
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halbug
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PostPosted: Sun Jun 29, 2014 11:54 am    Post subject: Reply with quote

I went with a Quaife differential Twisted Evil

I have never set up a differential from scratch, so I decided to save the labor for assembling a super diff and install the already assembled Quaife myself. I got it yesterday. The set up of the drive flange to the splined shaft is different to the original, so will have to find out how to get this done right. Here's a shot:

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Anyone done it before?

Thanks
halbug
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halbug
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PostPosted: Mon Jun 16, 2014 1:12 pm    Post subject: Reply with quote

Thanks you guys!

I had some time over the WE and worked on my transmission.

I had Dave Folts build me a tranny with Gene Berg 5-speed kit during my stay in Michigan. I had it build for swing axle with a .88 fifth gear set. I need to change it to IRS now (see above) and decided to do the swap myself.

So I unpacked the B5 for the second time since I own it:

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I took the side plates off and the differential out:

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My bug has the same final drive as this Berg5 and I prefer something longer yet meanwhile. So, I took the end cover off:

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... and pulled the 5th gear set:

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... and had Dave Folts sent my a new set, a .82 this time. He ground it exactly to the same hight. This made the re-installation pretty simple. Except for me "dropping the ball" big time when pushing the little detent steel ball of the fifth shift rod too far, so that it fell into the main housing Embarassed . This made me having to pull the whole stack Evil or Very Mad . Well that was another lesson learned - the tranny is closed from that end again.

Next I will have to buy a new differential. IRS super diff or a Quaife diff, I will have to do some more research...

Stay tuned and thanks for your interest.

Halbug
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rcooled
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PostPosted: Mon Jun 02, 2014 2:42 pm    Post subject: Reply with quote

That should be a great foundation for your project...good score! Looks very similar to my old Oriel Yellow '69.


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PostPosted: Mon Jun 02, 2014 1:31 pm    Post subject: Reply with quote

Nice buy! Good luck on your build, already looks fun!
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