Restoration thread: my 60 strato blue coupe

[TRS63]

So, I think the next update is really overdue!

As mentioned before, I turned my attention a bit to the back of the car..

My parcel shelf was really rusted:

So I removed it:

Which was the best decision judging the rust that was also hidden under it:

I fixed these issues (all pictures before final grinding):

Then I cleaned/blasted some parts:
Before:

After:

Oh, and because a restoration isn’t only about working on the car but also looking for the right parts and all the history around the car, here the latest arrival:
Guess what it is:

Yes the 60 only gearbox (thanks Mick!) that will be rebuilt:

Speaking of 60 only parts, also received (thanks Lee!) the water bottle and the horns with screw connectors:

Then I got this really rare 60 color chart:

Can’t wait to see those colors:

And I received the awesome decal from Jonas:

Stay tuned for the metal work on the parcel shelf J

Cheers

Antoine
_________________
Antoine
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

[Braukuche]

Nice find on the one year only water bottle. I never could find one when I did my 60 ages ago.
_________________
Go Reds! Smash state!

Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now

[Inchpincher61]

Antoine....

It is so exciting to see all those 60 only parts!

It took me hours, days, weeks of research to find out the most important changes through the years. I have no idea how many time you might have spent to find all those 60 details.

By the way I love to follow your thread because its amazing to see all your metal work.

Even if its not "perfect" you do everything by yourselfes. I have the greatest respect for it!

Its similar to Daves Ghia. Just awesome to see those fearless Ghia guys

[TRS63]

@ Braukuche: thanks a lot! yes, was very lucky that Lee accepted to sell it to me

@Inchpincher61: thanks a lot, really appreciated! I sure will continue to share my metal work here, happy to see it being followed And you're right, the amount of time spent searching all the 60 only details already is a lot but hey, passion drives us all here

So, next update was about fixing the parcel shelf. I replaced every rusted through or heavily pitted sections. I did not rebuilt it all as it is finally hidden under a carpet so no show car rebuilt here, just being sure this section is solid.

I first started in the middle:

Then a bit further:

Next steps were the corners. Really tricky with the beads, the different curves,.. took me several attempts to get them right, including a lot of test fit on the car, with the rear seat,.. Here in pictures:

Then the front part:

it was time:

adjusting:

welding:

welded:

the metal string welded on it also needed to be replaced. Made it in 2 parts due to material availability, and of course some welding primer where there are welded together:

next update coming soon

Antoine
_________________
Antoine
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

[TRS63]

When I was that far, I needed to put the heating system back:

and the small tab to attach the rear seat:

Next step was preparing the body to have it back. First by repairing this rust damage:

and then stripping it all under the parcel shelf:

Put some primer where it will then be harder to access:

As I am there, I can show you how is the all stripping ongoing:

then, it was time for the parcel shelf to be back:

and with some primer, feel so good to see some part of the body "ready"

cheers

Antoine
_________________
Antoine
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

[Braukuche]

Parcel shelf should be covered with a hardboard piece covered with vinyl matching the seats. Unless you are doing a custom interior. Repair is niecely done as usual.
_________________
Go Reds! Smash state!

Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now

[TRS63]

[TDCTDI]

Other than the need for a title, VIN #s, & all of the necessary pieces for patterns, I don't know why you bought this car in the first place.

Did you save all of the old pieces so you can make more cars from the patterns?

Great work! You are definitely bringing this one back from the dead.
_________________
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.

[rbsurfguy]

[KGCoupe]

Following along each small panel restoration/fabrication project is fascinating and educational, but I get the feeling that I'm way underestimating how much time one of those projects actually takes because of how easy Antoine makes everything look.

It would be great if you could add a total time spent - from initial paint removal when you begin, to primer application when the project is completed - just so we can get a better feel for how long something like that takes for someone who knows what the heck they're doing.

[Evil_Fiz]

[kiwighia68]

[TRS63]

Thanks so much guys for your feedbacks and compliments, really appreciated! The support here is amazing!

@TDCTDI: I did not trust myself starting only with the title but for sure I don’t know if that would have been much more work.. I still have everything I cut (except what felt down in rusty dust..) and all templates/hammer form I used.. As long as I have enough space, I keep it, who knows if it can help one day!

@Jeff: those are really kind words!! I actually would love to open my fabrication/restoration shop but the current private situation isn’t ready to take that risk..who knows what the future will say

@ KGCoupe: Sure is hard to estimate. I know that, because I am following my progress and estimating my work left (if all goes as planned, still 591h of work without including engine/gearbox). I can try to give it in my future updates, but to give an estimation: the total work on the parcel shelf (removing, patching, cleaning,welding back) was 20h of work. I have room to improve my efficiency as I am still learning on the way.
Another example was when I did that part:

The disassembly/built/welding back/primer took me 7 working hours.

@Emil: sorry for your internet connection.. you’re right about the huge time amount. I think that I am around 800-900h until now (sadly I did not start following my hours at the beginning, only doing it since nov 2018 and I bought the ghia in sept 2017).

@Kiwighia68: Thanks a lot. You’re right about it, it is not only about saving the ghia but also pushing myself through this challenge both on endurance and on ability side. I am learning a lot on it (remember, before that I only welded a rabbit pickup body without really forming metal..), having a lot of pleasures and also testing myself, if I can do that at the level I can be satisfied..

So, the latest update that will bring us to the current status. Total working time on that part will be added when it’s ready/in primer.

I worked on the front part.
The start:

Last check and putting it in position, then it was time to start the welder. First some points, taking my time to avoid too much heat and planishing as it goes:

And fully welded:

Then it was time to continue the cleaning, roof was next and brought two surprises:
Here this damage:

Planished back in shape:

And this damage:

In the bottom to see:

And back in shape:

Really flat:

Roof is ready for primer, but I had no more primer in the shop..

The view leaving the shop is just motivating me a lot:

But no worries, won’t be boring the next months.. After putting the air channel on the right front quarter, I will probably continue with that:

Or the dashboard, or the heater channel, or,…

Cheers

Antoine
_________________
Antoine
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

[iboughtrustandbondo]

Your posts are so inspiring.

Inspiring me to abandon the crap job I am doing and find another hobby.

Your work is so beautiful...those welds!

[halbug]

Amazing Work Throughout!

I am impressed - really! May bring my Ghia to Stuttgard when I ever get to the body

Thanks for sharing
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

[TRS63]

Thanks a lot for the support!

@iboughtrustandbondo: no, please, continue ! It’s all a question of training, and I Hope my thread motivates you to continue!

@halbug: as a huge fan of the quality of your work, really appreciate your compliments!! you might start the body before my ghia is far enough to free some space in my shed but if I can help, it would be my pleasure and keep me in touch if you ever come near Stuttgart, maybe we can manage to meet

So, today is a special day.. my ghia turns 60!!!

So I take the occasion to post a small update (I was on holidays the past weeks so no work in the shop..).
I rebuild one side of the metal part under the backseat. Here the very rusted original part to make a template :

Cut some metal:

First bends and it’s clear that some shrinkage will have to take place :

I know it can be made easier with some cuts but I wanted to challenge myself..

And here we are:

And check in position :

Second side to come

Cheers

Antoine
_________________
Antoine
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

[ELFRIED]

Hi Antoine,

Can you explain how exactly you do the shrinking?

Thanx

[TRS63]

Hi Elfried,

Sure! I forgot to take pictures but used the method called tuck shrinking. Here a link I found:
https://garage.eastwood.com/tech-articles/how-to-tuck-shrink/

Works well but of course, your material is getting thicker and thicker and so harder to work

Cheers

Antoine
_________________
Antoine
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

[Peter D.]

Amazing work! I love seeing your progress.
_________________
2019 Golf Alltrack, '65 Ghia Coupe Restoration in Progress

[TRS63]

Thanks Peter
So, same story for the other side except that I had no parts to start with so I just mirrored the first side.
Start:

First bend:

During the shrinking phase :

After shrinking:

And finished:

Well, just need to finish the upper meter of the body and I will be driving a Ghia:

Stay tuned

Antoine
_________________
Antoine
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