Restoration thread: my 60 strato blue coupe

[TRS63]

Hi all,

@Inchpincher61: I will list what I still need for metalwork and keep you in touch

@Viktor Cz: wow, really great work man, well done!

@Ghia: Cyril, tu as mal vu! J'ai encore la tôle, qui est tordu mais que je vais réparer, et dans tous les cas en conformité avec l'origine! Tu me connais, je suis un "vintageux"!

I will update more this week but can't load the pics from my phone so I need to find some time for the computer..

Antoine

[GHIA]

Tu as raison, j'ai cru que les deux dernières photo étaient de toi

[TRS63]

So, finally found some time to upload more picture..means it’s time for an update!

Let’s make the last post on the pan until end of march as I am now waiting for the last seat rail..

So, except one, I have all seat rails but not the central part between the rails.. So I had to build it

Let’s first trace it:

And it’s time for the build:

Bent:

Let’s not forget the end that needs to go on the rails:

Checking:

Ready to be welded:

Stay tuned, several updates will come in a short time to bring you to the actual status!

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

[KGCoupe]

Sort of like metal origami.

Beautiful work - you make it look very simple, which is surely a sign of your skill level and experience.

[art_lessing]

can you show how you put that little fold into the ends? I need to make patches for the battery trays and other places..This little crimp would be good for putting in patches where unseen butt welds are not neccessary, ie engine compartment, pans etc.....

[TRS63]

Hi Guys,

really happy you like it!

@KGCoupe: I am not that experienced and only learn by doing but I spent quite a lot of time studying the art of metalshaping and try to put now all into practice. I hope I can help other members here and I am open to any criticism or advice on how to do better

@art_lessing: sure, please feel free to ask any question!
I used my vice and 2 piece of steel, here are two pictures:

I hope it's clear, otherwise please ask!

Well, I see that you like to see some metalshaping so here comes the next update

I know you can buy the splash guards but: I want to learn more and I try to keep this project on a reasonable budget so I built mine..
As usual, first is the drawing:

Then I build myself a hammerform out of wood:

Ready to cut:

cut and I started to bend the sides using my bead roller:

and then it's time for the hammerform:

and after some hammering, some shrinker/stretcher action,... I have it:

Fitment check:

and it's time for the second side:

check:

and after making the holes, all in primer:

Just to give you an idea of the condition of my ghia..this felt down just by moving the body:

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

[Evil_Fiz]

Thanks for sharing your tips and progress. I created a template/drawing from my mangled seat rail crossmeember. Can you confirm or correct my measurements. I too want to get functional at metal shaping. I did not see a seat return spring clip on your crossmember. Is that a later model feature?

I have another favor to ask which may benefit others as well. Could you create a 1:1 tracing/scan, in PDF format, of the wooden form you built for the splash guards and share it? How wide is the lip on the guards. My car did not include them and I would like to fab those myself as well.

...we're all in this together,
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

[TRS63]

Hi Emil,

For your measurements, I will check them next time I am in the shop and will confirm them to you. But there is a difference in the width between the seats before/after 68, I can only confirm you for my 60.
Good point concerning the spring, to be honest I did not think about it. If anybody can tell me if my 60 need and if yes how does it looks like (picture?)
For the splash guard: I don't know how to scan it 1:1. If you're ok, I can draw it on a paper and send it to you in a letter. Would be happy to help you and if you can scan it with the good scale for everybody, that would be awesome!

So, next update. Once again, I know that you can buy it but..love to build as much as I can so I started on the airboxes..
First cut my metal sheet:

Found a tube with the good radius and folded it:

Then it was again time to use my bead roller for the folding on the side:

On the first attempt I made it wrong and it did not follow the original curves where it will be welded so I made some hammerform and started again:

And it fits:

Cut the middle part:

Same method for the bottom part, also used a hammerform as the shape isn't that easy..

And adjusted:

Final adjusting will take place after I changed the front part of the wheel well

Oh.. and I also made the second side:

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

[rbsurfguy]

Fantastic work Antoine, I am sure many here, like me, had the ability you posses with metal work! Awesome!
Jeff
_________________
1971 Ghia convertible (Body off rebuild)
2019 VW Atlas 4Motion
2012 Passat-Sold


See my build on The Samba at:
Jeff's 71 Vert Restoration/Reassembly http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=

[TRS63]

Hi Jeff,

Thanks a lot for your kind words!

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

[Mrfun2fly]

Hey bud, I'm restoring a 60 also but don't nearly have the skills you do.

I was pretty fortunate w my ghia, it was pretty complete so havent had to find many parts.

If you can find the time, think you could post a list of what is different with the 60 compared to other ghias?

Thank you sir:)

Lee

[Mellow Yellow 74]

Interesting to see your use of the hammer forms. I made my own hinge pillar cover plates and fresh air ducts too. I turned the edges using a swaging tool then used a hammer and dolly and the kick shrinker/stretcher. The hinge pillar cover plates weren’t too bad but I spent many hours on the ducts.

Don’t forget the drain slots and the wiring holes in the ducts. I formed the recess drain slot using a bolster between the jaws of a vice but haven’t done the wiring holes yet because these are like a formed fishmouth. I am thinking of just doing a hole in front of the duct and using a trimmer like newer models use instead of having the wiring going into the duct.
_________________
1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon)

[TRS63]

Thanks guys for your support

@Lee: I will make a list with everything I know and maybe some more experts here can complete/correct it!
@Mellow Yellow 74: thanks a lot. Never used hammerform before and wanted to try it, I think it turned out ok. But I also had to use a shrinker/stretcher concerning the holes: thanks for the reminder, I noted they are still needed before welding but I want to try an idea on how to make the wiring hole.. if it works I will share it here!

So, next small update..
One of the worst part of my ghia is the dashboard. Have a look:

I did not started the rebuild of it yet but it rusted so much that even the glove box door was rusted. I decided to rebuild it as a small side project.
Here the rusty start:

Opened it and realised it never had any primer or paint from the factory..of course it rusted..

So I cleaned everything, welded where needed and put some rust protection:

And closed it back:

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]

So, let's make another update
As a lot of these old VWs, my ghia had in the past several holes made through the panel between tank and dash. They also did "update" the wiring loom by cutting some space for a big fuse box

So I made a patch panel:

And welded it and all the other holes:

And with rust protection primer:

(Of course as you may notice the patch was not yet welded on this picture..)

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

[Mellow Yellow 74]

I can appreciate this, mine had various random holes in and under the dash and on the inner wheelhouse panels that I had to weld up - holes for an aftermarket wiper bottle bracket, holes for a relocated brake fluid bottle bracket and hoses, holes for a rheostat to use the 6V wipers with 12V power, a hole for a separate wiper wash button and holes for speaker wires etc.
_________________
1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon)

[TRS63]

Thanks a lot, yes that's true, these cars all have scars from their past..

So, small update on the right rear quarter panel..
When I did receive it, it was clear that it was full of bondo like the door:

So I started to remove it, with the fear of what is underneath:

But in fact it's better than I thought, only one dent some waves in the front where you can access from behind so I can save it:

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

[TRS63]

And while I was already working on this side, I also put a part of the front inner fender wheel back into shape
You can see here a dent in the middle:

After a bit of hammerwork:

And same here with the collision damage:

After a bit of planishing:

The rusted through front part will of course be replaced..

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]

Last update here and we are more or less up to date

This part on the right of the rear seat had been cut and poorly "welded" together by a previous owner:

The bottom could be saved but the top was never gonna be nice enough so I decided to rebuild it from scratch

First the removal:

And here we go:

Let's draw it:

A few tests for the beads:

And it was time to start:

Taking shape:

Fitting test:

Of course I repaired also the front part:

And it was time to weld all back together:

And in primer:

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

[Evil_Fiz]

_________________
“…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

[TRS63]