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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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 Posted: Thu Apr 18, 2024 10:04 pm Post subject: Re: Ghia coming home |
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Thank you Ian!
After many rounds of grinding off the CuSi and re-welding I finally got the filler leak proof. The thing with Cusi is, that it wants much more power than what my welding machine is recommending. That is something I had to figure out the hard way. At least it's easier to grind off CuSi than steel 
If there is not enough welding power the CuSi just drips on the metal creating build up and holes in the weld material. More power and it started to melt and flow evenly onto the metal. Exactly how I wanted it to seal the tank joints. They are next.
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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
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Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Sat Apr 13, 2024 2:51 pm Post subject: Re: Ghia coming home |
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| you're welcome. You have done it very neatly reshaping the top of the tank like that. excellent work |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Sat Apr 13, 2024 9:15 am Post subject: Re: Ghia coming home |
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Thank you Antoine!
Today I finished the top before closing the tank next. Sorry Ian, I stole another idea from you. Jep! Phantom in-tank pump and return from Aeromotive. I just couldn't find space for the swirlpot.
I wanted to mount it to a flat so I took out the ribs from the tank top partially. After some trails on the old tank I decided to make some cuts and heat to minimize warping. It worked! CUSI welding is very different. The filler needs a lot of cleaning...
Here are some pics.
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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: Sat Apr 06, 2024 5:40 am Post subject: Re: Ghia coming home |
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Did you ever notice that VW has been using tapers to fit together the fuel filler neck?
I cut the top piece off and turned the access material away, creating back the original 5 deg. taper. Than shortened the neck by the amount the tank gets taller.
I made a little stretching tool with the same taper and pounded it into the remaining tube on the tank.
It worked actually without heat, very easy. It's all about the right tools, right? 
The two pieces fit perfectly into each other. Looks like VW did it
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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
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Ian Godfrey
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Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Tue Apr 02, 2024 1:41 pm Post subject: Re: Ghia coming home |
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That looks really good, no warping either  |
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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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Evil_Fiz
Samba Member
Joined: May 06, 2011
Posts: 1047
Location: Jacksonville, FL
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| Posted: Sun Mar 31, 2024 5:04 pm Post subject: Re: Ghia coming home |
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| halbug wrote: |
Emil, all right - I will find more custom brackets to be made thanks man!
How about your project, are you still working on it?
Cheers halbug |
yes I am. I have been prepping the body for epoxy. I have spent A REALLY LONG TIME researching, learning, and undoing mistakes. If all goes well my wife will epoxy the doors, hood, and engine cover next weekend. With luck, the entire car will be epoxied the following weekend. She has to do the paintwork because my eyesight has degraded too much for me to do it. Look for a lengthy and detailed post in my thread in the near future.
If you haven't already, check out "Project Binky" on YouTube. Those two guys are the British version of you and Antoine (TRS63).
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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Posts: 455
Location: Germany
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Evil_Fiz
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Joined: May 06, 2011
Posts: 1047
Location: Jacksonville, FL
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| Posted: Fri Mar 29, 2024 3:41 pm Post subject: Re: Ghia coming home |
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This is turning into "Project Binky", the German Edition.
We need more custom brackets.
Loving it,
Emil
_________________
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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halbug
Samba Member
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Posts: 455
Location: Germany
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halbug
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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: Thu Jan 04, 2024 2:14 pm Post subject: Re: Ghia coming home |
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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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TRS63
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Location: Stuttgart - Germany
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halbug
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Ian Godfrey
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Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Tue Jan 02, 2024 2:29 pm Post subject: Re: Ghia coming home |
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excellent work here Lars
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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. Cheers.
