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pans of a 63 ghia
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ELFRIED
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PostPosted: Sat Mar 10, 2018 8:08 am    Post subject: Re: pans of a 63 ghia Reply with quote

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well finally having travelled for a 10000 miles or something our ghia is home
picked him up in Rotterdam drove through our Flemish polder and here we are

took about 5 months from the first contac till now.
first time doing this ,learned a lot...
hapilly the vendors where nice honest people

we re happy now the questions will come

allready checked , no bondo at all Very Happy
rockers are feeling hard ,how check the heater channels?
pans and headliner will have to be changed , need the windows to come out to change the headliner?
motor is turning around

first impressions...
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TDCTDI
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PostPosted: Sat Mar 10, 2018 8:20 am    Post subject: Re: pans of a 63 ghia Reply with quote

NICE!!! That's a hell of a commitment to get a car, unseen, from another country, especially when there's large bodies of water involved.
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Inchpincher61
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PostPosted: Sun Mar 11, 2018 11:51 am    Post subject: Re: pans of a 63 ghia Reply with quote

Welcome!

Congratulations...seems to be a solid car from the first view. I am looking forward for more pictures and I hope there are no big issues with the heater channels.

I am planning a US-purchase-trip as well..good to have somebody to ask regarding the transfer. Cool
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ELFRIED
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PostPosted: Mon Mar 12, 2018 12:57 pm    Post subject: Re: pans of a 63 ghia Reply with quote

no problem feel free to ask...

admiring your skills
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ELFRIED
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PostPosted: Tue Mar 13, 2018 10:02 am    Post subject: Re: pans of a 63 ghia Reply with quote

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headliner is pretty ok untill I pflapped down the passengers sun visor,hrmmm....


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strange way of repairing floor pans, PO did vertically put in metal pieces and made a layer of black shinny kind of tarr plastic over it.... it s about 2 inches thick and weighs a lot very peculiar


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is this the original sound deadener ?


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are the antenna and mirror in the correct place? is this the correct mirror anyway?
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c21darrel
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PostPosted: Tue Mar 13, 2018 10:44 am    Post subject: Re: pans of a 63 ghia Reply with quote

A 63 would typically have a cowl mounted swan neck rear view mirror, antenna looks aftermarket too. These were dealer installed items so there were variations but those appear to me to be previous owner modifications.
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ELFRIED
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PostPosted: Wed Mar 14, 2018 12:31 am    Post subject: Re: pans of a 63 ghia Reply with quote

Thx Darrel,

i assume putting the mirror in place of the antenna will work . But where putting the antenna then?
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PostPosted: Wed Mar 14, 2018 1:28 am    Post subject: Re: pans of a 63 ghia Reply with quote

ELFRIED wrote:
Thx Darrel,

i assume putting the mirror in place of the antenna will work . But where putting the antenna then?


Does either of these help?
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Nicholas
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ELFRIED
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PostPosted: Wed Mar 14, 2018 1:46 am    Post subject: Re: pans of a 63 ghia Reply with quote

great Nicholas

thanx
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ELFRIED
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PostPosted: Wed Mar 21, 2018 2:45 am    Post subject: Re: pans of a 63 ghia Reply with quote

nice way to fasten the front emblem but how was it origenally?
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PostPosted: Wed Mar 21, 2018 11:33 am    Post subject: Re: pans of a 63 ghia Reply with quote

^^^NICE! Looks like they worked!
Originally they used a spring clip very much like these....
https://www.thesamba.com/vw/classifieds/detail.php?id=2043538
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PostPosted: Wed Mar 21, 2018 11:55 am    Post subject: Re: pans of a 63 ghia Reply with quote

Thanks for keeping us updated.

Those bottle caps are a clever bit of good old fashioned American ingenuity!

The tar on the floor boards? Not so clever........

Dave
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ELFRIED
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PostPosted: Tue Jul 17, 2018 7:52 am    Post subject: Re: pans of a 63 ghia Reply with quote

well the ghia is on the self made dolly and today I cut out the pans and removed the remains from the tunnel with a simple hammer and big srewdriver ,went allright for me
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looking at the chassis it was covered with a sort of soft tar-sand mixture ,very sticky ,not hard and not really soft.it was all over and a hell of a job to ge it off. For example the steering house was one clump of that mixture.
But it seemed to have protected the whole during the years standing in a barn;
everything seems remarcable solid ,just superfisious rust .
perhaps the specialists can throw an eye on my pictures?
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greetings from dry sunny Flaners
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ELFRIED
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PostPosted: Tue Jul 17, 2018 7:54 am    Post subject: Re: pans of a 63 ghia Reply with quote

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PostPosted: Tue Jul 17, 2018 12:17 pm    Post subject: Re: pans of a 63 ghia Reply with quote

Nice progress Elfried! Your chassis looks to be in pretty good condition, should be the typical rust removal on tunnel, a little grinding and you will be ready to weld the pans on. Keep up the good work.
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ELFRIED
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PostPosted: Wed Jul 18, 2018 5:22 am    Post subject: Re: pans of a 63 ghia Reply with quote

thanx, hahaha yes the welding
bought myseld a simple MIG welder now looking for the right gas cilinder to,fill it with argon co... and then indeed the welding never done it before elecrical yes but not the mig

I thik I will make every 5 cm a little hole and then point weld it in the hole on the tunnel lip- as in the you tube film

good idea?
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PostPosted: Wed Jul 18, 2018 5:55 am    Post subject: Re: pans of a 63 ghia Reply with quote

Pretty much, The biggest problem is that the flange on the tunnel is of thicker gauge than the pans so you have to start your weld in the hole drilled in the pan and build up a puddle & swirl that to fill the hole. If you don't, you'll just blow through the pan or not get enough heat to permanently attach the pan to the tunnel.

What I did was drill the holes, weld every 5th or 6th one, then using a drift or punch, beat the pan down around the weld to snug the pan as close to the chassis as possible & weld the next hole & repeat the process for each weld.
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Before you attach the pans to the chassis, fit them to the body. The forwardmost 15* bend in the outer lip doesn't match the original & will interfere with the lip on the heater channel as seen here...
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Since you did not retain the outer perimeter flange, I would STRONGLY suggest bolting the pans to the body, then setting the body back onto the chassis, bolting the body to the chassis & then welding the pans in place. Unlike a beetle, the Karmann Ghia has a very narrow channel for which the outer flange on the pan fits into the heater channels.
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GOFUNDYOURSELF, quit asking everyone to do it for you!


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Do something, anything, to your project every day, and you will eventually complete it.
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TDCTDI
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PostPosted: Wed Jul 18, 2018 6:41 am    Post subject: Re: pans of a 63 ghia Reply with quote

ELFRIED wrote:

perhaps the specialists can throw an eye on my pictures?
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Something doesn't look quite right here, are you sure that you didn't remove the upper flange of the tunnel? There should not be a gap between the tunnel & the flange since the metal of the tunnel is folded 90* to create the flange. There's supposed to be three layers, two thick (tunnel & bottom plate) and then the thinner metal of the pan (Which in some cases/places can be completely rusted away.).

It should look more like this when the unneeded pan material is removed...
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If so, then you are separating the bottom plate from the upper tunnel portion, you will need to replace this before going any further.
Here's one that I had to replace part of due to rust but the bottom plate was still in decent condition.
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Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.
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ELFRIED
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PostPosted: Wed Jul 18, 2018 7:30 am    Post subject: Re: pans of a 63 ghia Reply with quote

Jezus , you scared the hell out of me , I hurried to watch it but happily I did it all good. If you make the foto I took bigger you see the 2 layers of material which are still there. So everything is allright. No problem.

And thanx a lot for the instructions about the welding. I will surely do it as you suggested.
I go now for a month on holiday so it ll be for after holiday period. Time to think and concider...

Now I have nice access to everything I wonder what to change? Shocks for sure but what about
- tie rods is there a test to see if they are allright?
- king pin is there a test to see if they are allright?
-fuel lines for sure,and i ll make it a double system
- front axl ?
- rear axl?

it all looks pretty much in good shape .....

greetings
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PostPosted: Wed Jul 18, 2018 7:49 am    Post subject: Re: pans of a 63 ghia Reply with quote

Sorry about that, it just didn't look right.

Now would be an easy time to address suspension stuff. definitely a good time to replace transmission mounts & shifter bushings.
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GOFUNDYOURSELF, quit asking everyone to do it for you!


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Do something, anything, to your project every day, and you will eventually complete it.
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