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Ghia coming home
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Ian Godfrey
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PostPosted: Tue Nov 01, 2022 12:39 pm    Post subject: Re: Ghia coming home Reply with quote

I also don't run heater boxs, will you be using them in your build?
I notice you got the fancy starter now Cool
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Ian Godfrey
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PostPosted: Tue Nov 01, 2022 12:37 pm    Post subject: Re: Ghia coming home Reply with quote

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 Embarassed
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
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PostPosted: Tue Nov 01, 2022 10:37 am    Post subject: Re: Ghia coming home Reply with quote

Working on the rear end, trying to sort out what to put where Rolling Eyes 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 Laughing
Image may have been reduced in size. Click image to view fullscreen.


Forward bars are angled in a way to give most sideway support to the shock towers now.
Image may have been reduced in size. Click image to view fullscreen.


Debating with myself on how to do the rear bars next? Confused
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halbug
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PostPosted: Mon Oct 03, 2022 12:56 am    Post subject: Re: Ghia coming home Reply with quote

Ian, company is AKG, a well known maker of instrustrial HD coolers. They have been arround for ages. Used to be THE set up for front oil coolers on bugs and rally cars in the 70/80ties, until the market got flooded with much cheaper ones.

But you would not use it, I am sure, because it is HEAVY! Laughing

I am hoping it will work fine as a heat sink for hot foamy oil during city traffic or highway jams.
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Ian Godfrey
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PostPosted: Sun Oct 02, 2022 5:09 pm    Post subject: Re: Ghia coming home Reply with quote

Lars, who makes that cooler?
a very well thought out fitting solution.
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halbug
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PostPosted: Sun Oct 02, 2022 1:30 am    Post subject: Re: Ghia coming home Reply with quote

Thanks Antoine, keep in mind the perspective of the photo. Lens is at the same heights as headlamps Wink
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TRS63
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PostPosted: Sun Oct 02, 2022 12:00 am    Post subject: Re: Ghia coming home Reply with quote

Nicely done Very Happy m'y first reaction was about it being too visible but for sure after paint & bumpers this will be ok Very Happy

Antoine
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halbug
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PostPosted: Sat Oct 01, 2022 11:54 pm    Post subject: Re: Ghia coming home Reply with quote

Engine oil cooler...

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

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

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


I made brackets that allow the cooler to swivel back on enemy contact... After it has been painted black and the bumpers are in place it should be barley visible.

Large size is to compensate for foamy oil from dry sump pump, partial air blocking and large motor.
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halbug
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PostPosted: Fri Sep 23, 2022 1:26 am    Post subject: Re: Ghia coming home Reply with quote

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:

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


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 Wink

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 Rolling Eyes

Cheers
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Ian Godfrey
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PostPosted: Tue Sep 20, 2022 5:37 pm    Post subject: Re: Ghia coming home Reply with quote

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 Crying or Very sad

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
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PostPosted: Tue Sep 20, 2022 8:33 am    Post subject: Re: Ghia coming home Reply with quote

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

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


This was not the case with the old chassis. Any advice is welcome.
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halbug
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PostPosted: Sun Sep 18, 2022 10:05 pm    Post subject: Re: Ghia coming home Reply with quote

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.
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Ian Godfrey
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PostPosted: Thu Sep 15, 2022 12:57 am    Post subject: Re: Ghia coming home Reply with quote

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
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PostPosted: Tue Sep 13, 2022 3:14 am    Post subject: Re: Ghia coming home Reply with quote

TRS63 wrote:
Wow, such a good and relaxing news when everything comes as planned ! Can't wait to follow the rest of the project, definitely one of my favorite on theSamba !

Grüße,

Antoine


Thank you for the flowers Antoine

Cheers
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halbug
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PostPosted: Tue Sep 13, 2022 2:37 am    Post subject: Re: Ghia coming home Reply with quote

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. Very Happy
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
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TRS63
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PostPosted: Tue Sep 13, 2022 12:56 am    Post subject: Re: Ghia coming home Reply with quote

Wow, such a good and relaxing news when everything comes as planned ! Can't wait to follow the rest of the project, definitely one of my favorite on theSamba !

Grüße,

Antoine
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Antoine
My 62 ragtop daily driver:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728873
My 914 restoration&lightweight project :
https://www.thesamba.com/vw/forum/viewtopic.php?p=9698432#9698432
Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
My 52 Standard Zwitter :
https://www.thesamba.com/vw/forum/viewtopic.php?p=10086685#10086685
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Ian Godfrey
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PostPosted: Mon Sep 12, 2022 3:14 pm    Post subject: Re: Ghia coming home Reply with quote

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. Very Happy
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
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PostPosted: Mon Sep 12, 2022 12:22 pm    Post subject: Re: Ghia coming home Reply with quote

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 Evil or Very Mad

They became much thinner umtil they fit.
Image may have been reduced in size. Click image to view fullscreen.


Good news: 205-16" on 6.5J rims with IRS do!! fit under the body without any modifications (to the body Laughing ).

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


BTW, the clearance for the Berg5 works out just fine and I was able to smoothen it out somewhat in a third attempt.
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halbug
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PostPosted: Mon Sep 05, 2022 11:30 am    Post subject: Re: Ghia coming home Reply with quote

Ok guy's, I tried for some hours. I have given up... just can"t get to the spots with that tray in place. I will have to leave it as is for now. Maybe the body guy will improve it a little once I get to redo the body paintwise.

Cheers
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halbug
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PostPosted: Mon Sep 05, 2022 2:46 am    Post subject: Re: Ghia coming home Reply with quote

Thanks Antoine!

Theses are the areas I would like to see a little ironed out Rolling Eyes
Image may have been reduced in size. Click image to view fullscreen.


I expect this to become difficult.
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