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halbug
Samba Member
Joined: March 09, 2006
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: Sat Sep 16, 2023 1:44 pm Post subject: Re: Ghia coming home |
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i vote for the complete top, I think it will look better, welds will be less obvious and less risk of warping around the sender flange.
What tank sender do you use with the bigger tank? |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Sat Sep 16, 2023 12:11 pm Post subject: Re: Ghia coming home |
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Thanks for the flowers Antione. 
I bought a larger gas tank for my Ghia. The quality is pretty poor. I spent hours to correct the flange that the tank lies on. Its ok now. The stamping tool for these is badly made.
That is the reason I am thinking about replacing the complete top with one from an original tank. For sure I like to replace the filler neck and the sender mounting surface. What do you guys think? Complete top or partial replacements???
Corrected Flange:
Clearance for the steering joints:
Cheers halbug
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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: 999
Location: Stuttgart - Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Wed Sep 13, 2023 10:29 am Post subject: Re: Ghia coming home |
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Hi Ian, thanks! The joints and intermediate shaft are from Borgeson. Theses are ball bearing joints allowing a theoretical angle of 35 degree, I am using approximately 30.
I made and placed a plastic sleeve with a press fit between the intermediate shaft and the ball joint to take all clearance out. This made a very big differnce in the smoothness of the system.
The Golf rack and the super beetle steering column have the same spline, Borgeson joints are available to fit.
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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 12, 2023 3:15 pm Post subject: Re: Ghia coming home |
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Wow, that's impressive, the ball joint in the middle is genius. 
What brand of joints are they?
I assume the have the correct splines for the Golf rack and steering column. |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Tue Sep 12, 2023 10:55 am Post subject: Re: Ghia coming home |
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It's working! I had some trouble finding the right geometry for the three joints. They are somewhat borderline but I did not want to add a forth.
After a lot of try out, I found a tip about de-phasing the joints slightly. And this plus taking all loosness out of the system did it for me...
Lock to lock even forces, no binding, no hard spots. The system needs to loosen up a bit, but this will happen over time.
Only four little 1/4 holes in the body and no real visible change on the steering column inside for this conversion. 
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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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| Posted: Thu Jul 13, 2023 7:10 am Post subject: Re: Ghia coming home |
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Hi Emil, sure no problem. I am happy for any help or details one may be interested in, reading my build.
I assume the front stiffy is straight forward? Let me know if not. Rear picture is confusing because the reinforcement bracket is in the wrong location in my picture. It needs to slide forward underneath the existing stock cross beam.
I will post more pictures once all the brackets are welded in place.
This may take a while because the body has to come off again to weld the brackets in place and modify the tunnel. And before that I want to finalize the steering system.
Cheers halbug
_________________
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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Evil_Fiz
Samba Member
Joined: May 06, 2011
Posts: 1049
Location: Jacksonville, FL
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| Posted: Wed Jul 12, 2023 3:16 pm Post subject: Re: Ghia coming home |
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| halbug wrote: |
| ...Back in my garage I fabbed some additional brackets to increase the torsional stiffness of my vert. The front is copied from the super beetles. Final welding after the body is separated from chassis again. |
I have a really hard time making out your pictures because of the low contrast and my VERY poor eyesight. Any wide, establishing shots of the bracing would be much appreciated. I too would like to increase stiffness in my vert and your ideas are always spot on.
Cheers,
Emil
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It's not just about what's interesting. It's also about what's helpful, and it's helpful even if it helps just one other guy working on a Ghia.
kiwighia68
See my build on TheSamba at:
The K_R_A_K_E_N_N : a 70 Ghia Convertible reinterpreted |
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halbug
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Joined: March 09, 2006
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: Sun Jul 09, 2023 2:22 am Post subject: Re: Ghia coming home |
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That steering column is a big step forward 
Would a business like GKN driveline be able to make you a splined shaft locally?
for your application a machined spine would be quite strong enough so a gear cutter could make one too.
good luck |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Sat Jul 08, 2023 11:17 am Post subject: Re: Ghia coming home |
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| halbug wrote: |
Next I will have to proove to myself that the 3 link CV system for the steering will work as planned  |
It seems to be working!!! Mendeola front sunspension with stock location, altmost original steering column... I am happy!
Installing bottom end of steering column:
Temporarily put the shaft together:
Assembled and in the car. Of course still much too long, but ok for try out.
Joints lined up without binding.
I need to get a splined shaft. Can't find one in Europe. Summit has them, ships to Germany but at a rate of 50$... double of what the shaft is 
_________________
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: 999
Location: Stuttgart - Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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halbug
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veltror
Samba Member
Joined: December 05, 2013
Posts: 90
Location: UK
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| Posted: Tue Jul 04, 2023 2:37 am Post subject: Re: Ghia coming home |
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| This is a stunning build, kudo's to you. |
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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 Jul 02, 2023 3:43 pm Post subject: Re: Ghia coming home |
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Good to see you 'back at it'.
I like the design of the stiffening brackets, what thickness is the steel?
Are you going to drill and bolt the rear one to the tunnel similar to the front one after you have welded it to the cross member?
many thanks for the photos |
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halbug
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Location: Germany
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thank you!
