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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1135 Location: Melbourne Australia
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Posted: Tue Nov 01, 2022 12:39 pm Post subject: Re: Ghia coming home |
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I also don't run heater boxs, will you be using them in your build?
I notice you got the fancy starter now |
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1135 Location: Melbourne Australia
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Posted: Tue Nov 01, 2022 12:37 pm Post subject: Re: Ghia coming home |
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Lars, some nice fabrication there.
I had noticed the same flex in the shock towers, so as well as the bars, I was thinking about a connection up to the parcel tray on each side. Though that would mean holes or welding
for the rear pair of bars, the choices seem to be attaching to the frame horns or to the gearbox cradle, I went for the horns. |
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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Posted: Tue Nov 01, 2022 10:37 am Post subject: Re: Ghia coming home |
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Working on the rear end, trying to sort out what to put where Everything seems to be interdependent to each other. The Käfer-Cup-Bar has the least ammount of flexibility finding straight lines to the supporting points. So I made this my first priority.
I was surprised how weak the shocktowers are sideways. Ok, the body will support somewhat, but still... You can move them some mm by hand easily. I believe if you run coil overs, a stiffy or 5 piece käfer bar is a must.
No body modifications allowed
Forward bars are angled in a way to give most sideway support to the shock towers now.
Debating with myself on how to do the rear bars next? _________________ Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1135 Location: Melbourne Australia
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Posted: Sun Oct 02, 2022 5:09 pm Post subject: Re: Ghia coming home |
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Lars, who makes that cooler?
a very well thought out fitting solution. |
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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TRS63 Samba Member
Joined: December 17, 2017 Posts: 992 Location: Stuttgart - Germany
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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Posted: Fri Sep 23, 2022 1:26 am Post subject: Re: Ghia coming home |
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Hi Ian, thanks for your help! The front is properly seated. The Napoleon hat is evenly compressing and the seal and the bulkhead is clear everywhere. And no, I did not cut the body LOL:
The door gaps are as perfects as they can be for a Ghia and I fixed the body with the braces this way. The doors open and close like before, but I have not taken off the braces.
Meanwhile I have the rear attachment points of the body, to the torsion housing within 2 mm. The torsion housings have been my reference point for all measurements on the pan before. BTW, the 2 attachment points on top of the torsion housing are missing on the Thing pan. One more issue to fix
Sealing surface (green arrow) is still somewhat off, but may improve with torqueing all the body bolts later. The offset of 8 mm in the area of the upper shock attachment is maybe due to the tolerances within the body? It was not like this before on the old chassis for sure...
I will concentrate on other things now first, to get back to this later
Cheers _________________ Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1135 Location: Melbourne Australia
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Posted: Tue Sep 20, 2022 5:37 pm Post subject: Re: Ghia coming home |
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I've fixed the link to the 'door gap alignment using shims under the rear body mounts'. But I can't find the 'sequence of tightening' for the pan bolts
now to your problems. It looks like the body is seated properly on the pan at the rear. I imagine you have checked that there is a gap where the body mounts to the top of the mendeola front suspension. Could the front 'fire wall' be hanging up on the steering rack? looking from the inside does it seat well over the 'Napoleans hat' and in the front corners?
Assuming it is sitting on the pan rubber all around, I think you need to try to determine whether the body is twisted or the pan is twisted. are you able to set up a laser to shine under the car so you can measure both sides of the pan at the rear and front? With the body on the pan do the doors fit well at the moment? So if the new pan is straight, is the old pan twisted, maybe the body took a 'set' to the old pan?
Normally I would put this down to 'every Ghia is hand made' but I think it should fit better.
let us know how you get on. |
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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Posted: Tue Sep 20, 2022 8:33 am Post subject: Re: Ghia coming home |
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halbug wrote: |
Hi Ian, thank you for the link, unfortunately it is not working for me. Maybe the document has been moved?
I rolled the chassis away from the body and had another close look. Seems like the drains in the heater channels still hit the pan. Found one or two other little highspots. Let' hope this will fix the issue. |
Nope! Still not even left to right. The RH side seems to sit high compared to the LH side.
Green arrow: looks like it is fully seated
Orange: maybe 5 mm higher compared to other side
Red: maybe 10 mm higher compared to other side
This was not the case with the old chassis. Any advice is welcome. _________________ Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1135 Location: Melbourne Australia
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Posted: Thu Sep 15, 2022 12:57 am Post subject: Re: Ghia coming home |
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Lars, have you come across this?
Door gap adjustment using packers under the body mounts
https://www.thesamba.com/vw/archives/manuals/1960_...l_Body.pdf
P.20
Good luck
[Mod edit] fixed the link
Last edited by Ian Godfrey on Tue Sep 20, 2022 5:17 pm; edited 1 time in total |
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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Posted: Tue Sep 13, 2022 2:37 am Post subject: Re: Ghia coming home |
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Ian Godfrey wrote: |
Great progress, you are going fast now
Congratulations on the wheels and tyres fitting. I'm sure you did all the measuring but it is reassuring to see it come together.
How much clearance is there between the rear of the tyre and the fender lip? |
Ian, only who has done this himself knows how rewarding it is to see that calculations are reflected in real live at the end... thanks
There is approximately 8mm clearance. The test tire mesures 213mm wide. I will be using 205 Michelin Pilots and they will be 209mm wide on a 6.5 rim. So I should see arround 10mm clearance at the end.
As you can see, there would be some mm to be gained grinding the flange of the wheelwell back or bending it slightly up.
Ian Godfrey wrote: |
Great progress, you are going fast now
Is the body 1/2" higher on the pan or is the suspension just high on one side? |
Both. Mostly noticeable at the suspension. I will bolt the bidy down to see it will level out the body.
When will you get back to yours?
Cheers _________________ Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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TRS63 Samba Member
Joined: December 17, 2017 Posts: 992 Location: Stuttgart - Germany
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Ian Godfrey Samba Member
Joined: September 25, 2006 Posts: 1135 Location: Melbourne Australia
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Posted: Mon Sep 12, 2022 3:14 pm Post subject: Re: Ghia coming home |
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Great progress, you are going fast now Lars....
those Thing shock towers are quite wide, but there is plenty of 'meat' left.
Congratulations on the wheels and tyres fitting. I'm sure you did all the measuring but it is reassuring to see it come together.
How much clearance is there between the rear of the tyre and the fender lip?
Is the body 1/2" higher on the pan or is the suspension just high on one side? |
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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Posted: Mon Sep 12, 2022 12:22 pm Post subject: Re: Ghia coming home |
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The KG body is fully seated on the Thing chassis!!!
It took me hours to make the chassis fit. Mainly the shock towers where much wider, compared to a bug chassis. Its a pitty I had to grind off so much of them. However the Kaefercup bar will stabilize those towers again and they are not weaker than original bug ones anyhow.
Somehow the body seems to sit 1/2" higher on the right rear corner... I can't figure out why
They became much thinner umtil they fit.
Good news: 205-16" on 6.5J rims with IRS do!! fit under the body without any modifications (to the body ).
BTW, the clearance for the Berg5 works out just fine and I was able to smoothen it out somewhat in a third attempt. _________________ Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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halbug Samba Member
Joined: March 09, 2006 Posts: 447 Location: Germany
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