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Late 1969 Ghia vert preservation/ restoration
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mcdonaldneal
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PostPosted: Wed Feb 18, 2015 8:36 am    Post subject: Reply with quote

So, to the fuel tank. I'm slightly nervous about this, I've been a bit wary of petrol ever since I tried to light a garden bonfire with it many years ago! The blast rattled the windows of houses a mile away Embarassed
The sender unit in the top is 'sealed' with a waxy substance, which I cut around and levered off. Not sure if that is original, or if someone was trying to fix a leak? Maybe I can melt it back together (with a non-naked flame heat source when I'm done?

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Difficult to get a good view inside, but the phone camera reveals what I would say is a little light rust. I do have a fuel tank sealant kit, and on balance it might be better to treat and seal the tank while I have it out anyway. At least then I can forget about it!

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I then struggled to get the tank out, mainly because the two hoses are stuck fast. They both look pretty old, and I'm guessing both are replacements, as the small one has non standard hose clips, and the large one looks like it is sheathed in an old sock (and one of the hose clips is not vw!)

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I might have to cut them off, but I'm going to make sure I have the replacements on order before I go much further!
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mcdonaldneal
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PostPosted: Wed Feb 18, 2015 8:53 am    Post subject: Reply with quote

Mind you, just found this pic in the dictionary on the Samba! Under 'Gemi clamp'. Same knitted sock, must be the original type. Where on God's earth am I going to find one of those!? Maybe I can salvage the sock and put it over some new hose!

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Last edited by mcdonaldneal on Wed Feb 18, 2015 9:14 am; edited 1 time in total
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mcdonaldneal
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PostPosted: Wed Feb 18, 2015 9:06 am    Post subject: Reply with quote

Another couple of pics from the gallery (thanks to a.wilson). Can't find any forum posts about it though. Maybe I should make special efforts to get it off intact and see what it looks like inside. (And brace myself for the links to aircooled fuel fires!?)

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paul_round
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PostPosted: Wed Feb 18, 2015 9:47 am    Post subject: Reply with quote

On that note, has anybody ever tried the reservoir in a different location.
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c21darrel
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PostPosted: Wed Feb 18, 2015 12:15 pm    Post subject: Reply with quote

Quote:
has anybody ever tried the reservoir in a different location.


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Good work mcdonald, the sealing on the gas sender unit is a po hack. Just use the proper seal upon reassembly. Your tank looks pretty good Very Happy much of the rust appears to be debris. Your tank kit should handle that one with ease. Keep us informed.
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mcdonaldneal
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PostPosted: Wed Feb 18, 2015 12:44 pm    Post subject: Reply with quote

Finally got the filler hoses off, and saw why they were so tough! Whoever fitted them has used a bucket of some kind of sealant instead of the rubber sleeves to seal each end. Don't think I can reuse the knitted hose, but I'm tempted to maybe clean it and split it and use it to cover the new hose I'll put on! We'll see!

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Bleyseng
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PostPosted: Wed Feb 18, 2015 5:00 pm    Post subject: Reply with quote

Mine had the old sock on it too when I replaced it as it was cracked and when the tank was full leaked and filled the cabin with gas fumes. My wife hated it!!
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mcdonaldneal
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PostPosted: Thu Feb 19, 2015 9:25 am    Post subject: Reply with quote

I'm obsessed by the fuel filler hose.
Clearly I can't reuse the hose I've got, but it would be glaringly obvious to use a plain rubber hose.
I spent all day yesterday looking for some sort of cotton covered 50mm fuel hose with no success, then I had a brainwave! Why not use modern, rated fuel pipe and cover it with an actual glorified sock? I found some rib knitted tubular fabric, available in black, apparently the right size to fit over a baby's leg (according to the Amazon review!) and very reasonably priced by the metre!

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I'll probably use black, rather than pink, but you get the idea! I'll see what it looks like, and post some pics.
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kingkarmann
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PostPosted: Thu Feb 19, 2015 10:00 am    Post subject: Reply with quote

mcdonaldneal wrote:
The sender unit in the top is 'sealed' with a waxy substance, which I cut around and levered off. Not sure if that is original, or if someone was trying to fix a leak? Maybe I can melt it back together (with a non-naked flame heat source when I'm done?

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Wow, what a hack job!
A simple gasket goes between the sender and tank. No sealant and more importantly NO HEAT!!
Sender Gasket

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mcdonaldneal
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PostPosted: Thu Feb 19, 2015 11:53 am    Post subject: Reply with quote

Have already ordered the gasket.
Thanks!
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mcdonaldneal
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PostPosted: Thu Feb 19, 2015 1:35 pm    Post subject: Reply with quote

Having painted the exhaust parts with POR15 high temp paint, it needs to be cured. At 300F (150C) for 20 min. Sadly they won't fit into our oven (no surprise there!)
My first attempt at getting them up to temp is this...
Cast iron simmer plate onto the hob. Grill rack on top. Heat exchanger on top of that, aluminium foil and tea towels to try and keep the heat in. Oven thermometer inside...

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After about 20min, the temp has made it up to 100C, that's with the gas ring on low. I'll turn up the heat...

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mcdonaldneal
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PostPosted: Thu Feb 19, 2015 1:48 pm    Post subject: Reply with quote

40 mins, nearly there! 140c
Heat turned up a bit more...

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mcdonaldneal
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PostPosted: Thu Feb 19, 2015 2:08 pm    Post subject: Reply with quote

1 hour, Yay! 150deg plus, even at the edge.
15 min wait, cool, onto the next bit!

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Who needs a big oven?
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PostPosted: Fri Feb 20, 2015 12:28 am    Post subject: Reply with quote

That's so cool. Errrr I mean hot. Probably OK to do in Scotland in the last month of winter but I would't enjoy the extra heat down here in Oz with the summer time temperatures we get.

Nonetheless this is a nice display of your ingenuity!

Nicholas
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mcdonaldneal
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PostPosted: Fri Feb 20, 2015 3:34 am    Post subject: Reply with quote

Couple of pics of the finish you get with the POR15 Manifold Grey high temp paint (after an evening of curing various bits!) My ever tolerant wife was out!

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Good enough to eat?

Apologies for the oven based 'joke'! Laughing
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mcdonaldneal
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PostPosted: Fri Feb 20, 2015 9:05 am    Post subject: Reply with quote

Managed to get the fuel tank out. Not surprised to see a bit of rust on the underside. Will be able to treat and paint while its out. The plan would be for black POR 15 on the underside, and just clean up and polish the visible top surface (and maybe clear POR15 the edges if needed).The was a labelled piece of tape underneath 'Beetle clinic'. Made me think maybe the tank is a replacement. Would fit with the botched sender fitment and the shonky filler hose sealing! I presume it is aftermarket, as I can't see a VW part number on it?

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mcdonaldneal
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PostPosted: Fri Feb 20, 2015 9:18 am    Post subject: Reply with quote

Well, looking in the trunk now I see the task that lies ahead. Bear in mind I am non- mechanical beginner at virtually everything I am attempting to do in this car!
Looking past the dirt and grime, the paintwork at least doesn't look horrendous. Peeling and rusted at the tank ledges though.

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What lies beneath is totally unfamiliar territory! Thanks to the Samba I have a vague idea of what some of the things are, but I see the brake master cylinder is pretty rusty. Any suggestions as to what I should do? I haven't done a search yet, but I'm guessing the options range from doing nothing to cleaning externally to replacing the MC and brake lines. (Does that mean just the flexible lines??) happy for comments while I go and do some searching!

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Clearly, I'd rather not get stuck into too many jobs at the same time, as there is a risk that they don't get finished! I suspect braking system integrity ranks pretty highly on my list of priorities!?
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PostPosted: Fri Feb 20, 2015 10:18 am    Post subject: Reply with quote

Nah shouldn't have to replace the brake likes unless they are in bad shape, and if you do replace them it would be an easy job either way. I wouldn't mess with the MC unless it needed to be messed with - but that's just me Wink also while you're working on it you can put one of those Volvo reservoirs on there if you choose to do so.

Great work, and great ghia!
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PostPosted: Fri Feb 20, 2015 10:47 am    Post subject: Reply with quote

Use a brass wire brush and knock the rust off and paint the MC with Ospho rust converter. All the rest of the rust has to be sanded down to clean metal and painted with epoxy primer, primer and single stage paint. Mine looks the same but black, everything was shot with black over the orange including the wiring. Talk about a nightmare to fix the wiring as it all had to be cleaned of black paint so I could see the color coding of the wires to fix stuff.
Does your gas tank have the little port near the front for the gas vapor to the charcoal canister? It does look like a replacement tank as the filler and overflow ports don't line up that well since they are for a Beetle.
You also should have a foam seal under the tank which you can order.
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70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!(sold)
76 Porsche 914 2.1L L20c, 120hp Djet (sold)
87 Syncro Westy Titan Red 2.1L 2 knob 100k miles
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PostPosted: Fri Feb 20, 2015 12:36 pm    Post subject: Reply with quote

^^^Good advice.
Your right, you can do nothing...or everything. If your rubber brake lines are older/hard, now is the time to replace them. Check the ragjoint (that disc between the steering shaft and steering box. Again if old or cracked, now is the time.
For someone that claims "non-mechanical beginner" You are doing a GREAT job!!
Since the tank is out, clean, wire brush/sand, treat and paint as much as you can, your car will thank you in the long run and you two will continue to bond Smile
They are going to get to know your face at the hardware store Razz
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