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halbug
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Joined: March 09, 2006
Posts: 455
Location: Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
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: 1137
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: 455
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
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Posts: 455
Location: Germany
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1137
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: 455
Location: Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
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
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Joined: December 17, 2017
Posts: 1000
Location: Stuttgart - Germany
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1137
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
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Joined: March 09, 2006
Posts: 455
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: 455
Location: Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 1000
Location: Stuttgart - Germany
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halbug
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Posts: 455
Location: Germany
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Ian Godfrey
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Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Sun Sep 04, 2022 3:04 am Post subject: Re: Ghia coming home |
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Excellent work
if some one could hold a steel dolly from the inside you may be able to tidy up some of the bits what are creased.
and/or heat them up 'cherry red' and flatten them against a dolly with a shrinking hammer, to shrink the metal a bit where they are creased.
You did excellent work retaining the edge of the body where it meets the pan. |
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halbug
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Posts: 455
Location: Germany
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| Posted: Sun Sep 04, 2022 12:45 am Post subject: Re: Ghia coming home |
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Metal forming day
My attempt to keep the body flange in shape and put some sand over the forming area
Right at the start I had issues with creases in the areas that where not even to start with. They stretched out but somehow continued into the sides and created issues
This is how it looks now... lots of beating! I used a dead blow hammer with a rounded off tip to generate enough energy
Here you can see how close to the body flange I had to go
Tranny should clear
Inside shots
I am somewhat happy that it is done now, but it looks kind-a-ok... I know, not really visible to anyone, but still... I have started to make it look better, but its extremely difficulf because of the tray above it.
_________________
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
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Posts: 455
Location: Germany
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TRS63
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Joined: December 17, 2017
Posts: 1000
Location: Stuttgart - Germany
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halbug
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Posts: 455
Location: Germany
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