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Ghia coming home
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halbug
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PostPosted: Fri Jan 05, 2024 5:54 am    Post subject: Re: Ghia coming home Reply with quote

Hi Ian, thank you. Yes multible pieces or strips is an option. I will try to figure something out on the weekend Razz . Cheers.
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Ian Godfrey
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PostPosted: Thu Jan 04, 2024 2:14 pm    Post subject: Re: Ghia coming home Reply with quote

quite trick metal forming...
I'd cut a strip of steel 50mm wide and roughly 250 long, curve it in the middle and shape the edge to fit the bottom of the tank. Then cut another strip 50mm in the middle but tapered down at the ends, curve in the middle and tack to the the first strip. continue adding more strips. Google pie cuts or lobster cuts. obviously yours will be a semicircle not a full tube. It would be slow but should work.
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halbug
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PostPosted: Thu Jan 04, 2024 8:31 am    Post subject: Re: Ghia coming home Reply with quote

Happy New Year Antoine!

I really appreciate your offer to help, thank you. The problem is creating an arch that is bent in two directions (blue plus red line) and I have no idea how to generate this with the existing tools and limited experience I have Embarassed


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TRS63
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PostPosted: Wed Jan 03, 2024 12:37 am    Post subject: Re: Ghia coming home Reply with quote

Happy new year to you!

Like Ian, I would assume, that heat shrinking can help for the warping. Fingers crossed !

For the steering gear : an arch would sure be the nicest version, I am sure, you have an idea what you would like to do. You can maybe try a carton version and see how it looks/post it here so that we can help if needed ?

Bests

Antoine
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halbug
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PostPosted: Wed Jan 03, 2024 12:05 am    Post subject: Re: Ghia coming home Reply with quote

Hi Ian, thank you. The steering gear does not go through the tank. The hole is a starting point. I like to create an arch of some kind to close the tank and clear the steering...
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Ian Godfrey
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PostPosted: Tue Jan 02, 2024 2:29 pm    Post subject: Re: Ghia coming home Reply with quote

excellent work here Lars Smile
re the warping, have a look at https://www.youtube.com/watch?v=EBcfhaNwg4Q on heat shrinking, essentially you heat up circle red hot until a bump forms then shrink it with a hammer and dolly or against your steel table. The trick is working out the right spot to heat. You may need to do it in a few places.
I'm a bit puzzled by the steering, does it come up through the tank? if so do you need to make an arch and weld it into the tank so the tank can be removed without disconnecting the steering?
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halbug
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PostPosted: Tue Jan 02, 2024 12:15 pm    Post subject: Re: Ghia coming home Reply with quote

All mesurements worked out, the tank fits in. Not sure yet how to close it arround the steering gear.
Image may have been reduced in size. Click image to view fullscreen.


I had to dimple it in towards the firewall to clear.
Image may have been reduced in size. Click image to view fullscreen.


The bottom center area got slightly warped and is now the highest point of the bottom surface. Not good! How can I get this turned arround??? Heat? How?
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halbug
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PostPosted: Mon Jan 01, 2024 6:22 am    Post subject: Re: Ghia coming home Reply with quote

WrennMetallWerks wrote:
Love all the new ideas and execution. Keep it up 🤩


Wow, thank's man Sometimes I wish and had someone arround here with your skills. Cheers
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WrennMetallWerks
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PostPosted: Sun Dec 31, 2023 9:27 am    Post subject: Re: Ghia coming home Reply with quote

Love all the new ideas and execution. Keep it up 🤩
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halbug
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PostPosted: Fri Dec 29, 2023 1:04 pm    Post subject: Re: Ghia coming home Reply with quote

Corners...

You guys will be laughing at me. I did not know how to mark the sides because of the multi angeled surfaces. I ended up using a laser Laughing
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Cut the sides off:
Image may have been reduced in size. Click image to view fullscreen.


And formed the corners:
Image may have been reduced in size. Click image to view fullscreen.


Inserting remaining plates should be relatively easy. Clearancing the steering shafts not so.
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TRS63
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PostPosted: Thu Dec 28, 2023 11:13 pm    Post subject: Re: Ghia coming home Reply with quote

Great corner! For the closing pieces, the corners will be tricky but I am sure that you will achieve it. If too hard, shrink them with heat !

Keep us informed,
Antoine
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Resurrecting a 60 ghia : https://www.thesamba.com/vw/forum/viewtopic.php?t=713906
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Ian Godfrey
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PostPosted: Thu Dec 28, 2023 1:53 pm    Post subject: Re: Ghia coming home Reply with quote

No tips, but i am enjoying the pixs. Thats a lovely solid steel bench to work on, that heavy flat surface is excellent.
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halbug
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PostPosted: Thu Dec 28, 2023 1:11 am    Post subject: Re: Ghia coming home Reply with quote

First time I'm building something new from a sheet of metal, not repairung it.

Home style bending, the anti slosh plates served as templates
Image may have been reduced in size. Click image to view fullscreen.


The tank frame attached to the new lower.
Image may have been reduced in size. Click image to view fullscreen.


My plan is to spot weld from the inside and CUSI weld the seam again from the outside to seal. So the plan...

But lower sider walls are first and they are a the next challenge for me. And as always, if you have comments or tips please let me know. I just do as I think... never done before.

Cheers
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PostPosted: Thu Dec 21, 2023 1:03 pm    Post subject: Re: Ghia coming home Reply with quote

Finished the anti slosh panels today:
Image may have been reduced in size. Click image to view fullscreen.

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


They will be the template for the new underside of the tank. I messed up the lower so I cut it off. Now I have to build instead of modifying a tank Rolling Eyes

Not much left:
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halbug
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PostPosted: Thu Oct 26, 2023 10:44 am    Post subject: Re: Ghia coming home Reply with quote

Antoine, here are some details

Based on my trail MIG braces, I think an overlap joint with a 2mm gap between the step and the sheet will make a nice joint for the tank:
Image may have been reduced in size. Click image to view fullscreen.


Stepped the top:
Image may have been reduced in size. Click image to view fullscreen.


Forming the corners to make the two fit:
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TRS63
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PostPosted: Fri Oct 20, 2023 10:48 pm    Post subject: Re: Ghia coming home Reply with quote

Now you're in for the next challenge ! I never brazed so looking forward to your feedback on how it worked!

Bests

Antoine
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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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halbug
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PostPosted: Thu Oct 19, 2023 3:49 am    Post subject: Re: Ghia coming home Reply with quote

Ian, yes anti slosh panels are on the list.

And in addition these reason to cut off the top:
Clearance for fuel swirl pot with pump
Original fuel filler neck and lid
Decent flange for sender
Venting valve
Finding some more volume?
The original top simply looks much better and has a channel for the fuel level sensor cable.

Cheers
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Ian Godfrey
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PostPosted: Mon Oct 16, 2023 1:26 pm    Post subject: Re: Ghia coming home Reply with quote

No going back now, good luck with the brazing, I'm looking forward to seeing the pictures.
Are you adding any 'anti slosh' baffles while the tank is open?
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halbug
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PostPosted: Mon Oct 16, 2023 3:23 am    Post subject: Re: Ghia coming home Reply with quote

So I did it! I cut the top of the 60l tank off:

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There are some benefits of using the top from an original tank.

However, it will be a huge challenge for me joining the two halfes, as the contour is quite different. For the joining I have opted to MIG brace the seam with CUSI3. I converted my welder and have done some testing. Looks promising.
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halbug
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PostPosted: Tue Sep 26, 2023 10:00 pm    Post subject: Re: Ghia coming home Reply with quote

Ian Godfrey wrote:
to stretch that area I would quickly heat up a small section (30 - 40mm circle) to cherry red with oxy acetalene and work that area with a ball peen hammer. I'd start in the middle and work out a bit at a time

to cold form it you would need something behind it which you can't do Sad

Or, when you cut the top of the tank you could possibly support the creases with some wooden blocks Smile


Ian, i agree, I should wait until I open the top of the tank.
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