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dc
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Joined: April 03, 2004
Posts: 1426
Location: Kitsap Peninsula
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 Posted: Mon May 25, 2020 7:45 pm Post subject: Re: '63 Ghia - Second Chance |
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| LVGhia72 wrote: |
Looks Good  |
Thanks!
A few hours of very careful trial and error - it really has to be adjusted perfectly to fit right  - and the rack is on!
Chrome plated M8 x 1.25 x 40mm with chrome washer on top of stainless lock washer seems about right... Little clear rubber protectors at all the touch points plus black liquid tape for the underside of the clamps.
The paint is in really thin/poor shape and most of the purple paint loss is simply from peeling the marking tape off after it was all fitted  Just a couple of bad scratches from all the on-again off-again trial fits.
BUT - now that it fits really well in the clamped postion - I'm reasonably confident when it comes off and then back on again when the roof is painted it should not be quite as tricky....honestly though, any time I've run a rack on any VWs over the years, they inevitably cause some scratches here and there 
Next up - need to do some "real" work - gotta get the gas tank installed so I am closer to more than just short test drives!
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dc
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Location: Kitsap Peninsula
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| Posted: Tue May 26, 2020 5:22 pm Post subject: Re: '63 Ghia - Second Chance |
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Got the gas tank installed 
A bit of splurge for this "cheap and nasty" resto - but I went for the Wolfsburg West - made in USA - tank. Very nice! Powder coated, 70mm filler neck, fit perfect, as did the install kit.
The fuel gauge is the cheap plastic white one - but I modified it very slightly to accept the cleaned-up original metal cap. Seems to work just fine BUT I have not put gas in yet to make sure it doesn't interfere with the lever. Otherwise, I can just go back to the plastic cap.
Here's my former gas tank
Oh! and here's a replacement hood that is MUCH better than the one on the car 
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dc
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Location: Kitsap Peninsula
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| Posted: Wed May 27, 2020 7:00 pm Post subject: Re: '63 Ghia - Second Chance |
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The beat goes on-
Got the rear bumper installed today-
Not easy! Lots of adjustments but got every bolt in nice and snug in the end!
Left off some of the rubber bits - not too concerned. The bumper is strong and straight- some pits and rust and minor dings BUT matches the rest of the car well!
Never seen any photos stretching back to the 70's with bumpers on this car...
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dc
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Joined: April 03, 2004
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Location: Kitsap Peninsula
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| Posted: Fri May 29, 2020 11:02 pm Post subject: Re: '63 Ghia - Second Chance |
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Another big milestone day
After pouring in 4 gallons out of can into the new tank (gauge works fine now), removing and cleaning and reinstalling the carb., installing the stock oil bath air cleaner, installing the freshly restored and painted breast plate tin, attaching some temp. heat tubes... it was time for a REAL drive
Drove around the neighborhood - 1st 2nd and 3rd gear- up to 35mph no issues with the motor, trans. or brakes!
LOTS of issues to address but NONE of them are major mechanical issues
Pretty exciting stuff!!! Even the damn horns work now!
Made a couple of videos but no pictures today 
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Rome
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Joined: June 02, 2004
Posts: 9653
Location: Pearl River, NY
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| Posted: Sat May 30, 2020 6:21 am Post subject: Re: '63 Ghia - Second Chance |
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| That's a very big accomplishment and milestone! Hope your ongoing, longer and faster drives continue to be problem-free. |
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Trylon
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Joined: August 16, 2019
Posts: 4853
Location: Connecticut
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| Posted: Sat May 30, 2020 7:23 am Post subject: Re: '63 Ghia - Second Chance |
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Ha!
Eye-opening as to just how basic these cars are.
Besides no fuel gauge, and a limited capacity, is there any other down side to this ‘tank’?
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1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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dc
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Joined: April 03, 2004
Posts: 1426
Location: Kitsap Peninsula
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| Posted: Sat May 30, 2020 8:30 am Post subject: Re: '63 Ghia - Second Chance |
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| Trylon wrote: |
Ha!
Eye-opening as to just how basic these cars are.
Besides no fuel gauge, and a limited capacity, is there any other down side to this ‘tank’? |
It worked great! The little can was placed in the spare tire wheel - hooked up to the main fuel line.... this set-up belongs to my mechanic and he wants it back
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dc
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| Posted: Mon Jun 08, 2020 5:51 pm Post subject: Re: '63 Ghia - Second Chance |
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Uhgg  Starting to investigate the wiring situation now that the engine is pretty well set...
What a mess!
Look at the fuse panel -
TWO Missing and number 8 is broken
Frayed wires - but hey "REBUILT" speedo
Made in USA 6V flasher (doesn't work)
Dorman USA - extra ignition bypass switch - when flipped it makes the car keep running after you turn off the ignition BUT it doesn't prevent the car from starting when it is switched - so backwards if it was supposed to be a secret starter switch
No wonder I only have one right rear running light and only one left rear brake light and zero signals or front indicators.
Oil Pressure light worked once and then never again (and that was way before the rebuilt engine was installed)
Headlights work - hi and lo
Horns work
Radio will work when I hook up power and ground
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dc
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| Posted: Mon Jun 08, 2020 5:58 pm Post subject: Re: '63 Ghia - Second Chance |
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BEFORE
AFTER
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TRS63
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Location: Stuttgart - Germany
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dc
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Joined: April 03, 2004
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Location: Kitsap Peninsula
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| Posted: Tue Jun 09, 2020 9:10 pm Post subject: Re: '63 Ghia - Second Chance |
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Makin' progress
Fixed the two broken fuse holders - so we have 8 now!
Pulled the weird kill switch thingie - with no ill affect on starting and running
Replaced a bulb - brake right rear and checked connections.
Now I have both brakelights working and both rear running lights working.
Oil light works again- just a loose connection
Front signal wires both are fried - gotta replace those and still no turn signals-
Will the rears work without the fronts hooked up or could it be the flasher?
Anyone?
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dc
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| Posted: Wed Jun 10, 2020 7:45 pm Post subject: Re: '63 Ghia - Second Chance |
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Ordered a new flasher relay- and some more bulbs and fuses...
Drove 5 miles around the neighborhood today
No issues - maybe a tad slow to start when hot but sort of a typical VW thing.
Ride is pretty smooth - perhaps the right rear shock is a little worn out but no wandering or instability - nice!
Got it in 4th gear all the way up to 45-50mph and was still smooth and nice.
Some painted engine components are still curing/slight odor...
LOVE this car so FAR
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TRS63
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dc
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Location: Kitsap Peninsula
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| Posted: Tue Jun 16, 2020 5:38 pm Post subject: Re: '63 Ghia - Second Chance |
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Turn signals are working now (at least in the rear) - so that's good!
Needed a new flasher, two bulbs, and some exercise in the stalk/column to make good contact again.
Back to body work
It's been bugging me that the passenger side rear fender arch was improperly repaired years ago - a late panel was used. Not really noticeable until the correct early bumper was installed!
I didn't do a great job fixing it - the arch is not 100% perfect and the seam is not finished under the bumper - but it works for now and I can clean it up and refine it a bit when the bumper is off again in the future.
Here's the before, during and after shots:
And now...for the main event!
Ever since I bought the car in November I've been itching to fix the nose. It's finally time - it runs and drives, it stops, it has seat belts, etc. NOW FOR THE NOSE
I'm going to be very slow and careful and try to do a nice job here...stay tuned-
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dc
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| Posted: Wed Jun 17, 2020 3:41 pm Post subject: Re: '63 Ghia - Second Chance |
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Phase I has begun!
First off, I hammered out some of the dents form the backside and scrapped and chiseled out some of the body filler to see how bad the nose was....
Pretty BAD - My skills are not good enough to rebuild all that damage from scratch - SO... transplant 
Marked and measured...
Cut CAREFULLY, leaving extra material on either side of the repair piece!
Rough fit - Looks GOOD!
Lots of work now to prep the seams, trim carefully, drill out spot weld at the bottom apron seam... etc.
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dc
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| Posted: Thu Jun 18, 2020 6:13 pm Post subject: Re: '63 Ghia - Second Chance |
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If Phase I was cut, trim and fit, then...
Phase II is Fit and Tack!
More today... slowly getting there.
Had to remake one of those little triangle braces at the bottom of the spare tire well - it was rotten 
Four or five tacks along the rubber seal channel at the top of the nose (not pictured) and then some careful tacks along the passenger side of the nose immediately above and below the intake "nostril"
Just two small tacks on the driver's side - more trimming required...
Bottom is just hanging loose for now
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dc
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| Posted: Fri Jun 19, 2020 2:33 pm Post subject: Re: '63 Ghia - Second Chance |
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More Phase II -
35 more tack welds this morning - all good just the very bottom edge needs tack welded.
All the way down the passenger side - more rotten metal to fix on the tire side of the repair but that's not TOO bad
Driver's side metal is better... had to zig-zag around the stamping under the horn:
I'm using the technique of overlapping the metal on my repair seams and then cutting a 45 degree angle under the edge for tight fit! Works good- thanks YouTube!
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dc
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| Posted: Tue Jun 23, 2020 8:06 am Post subject: Re: '63 Ghia - Second Chance |
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Phase II - tacking - is done
My back hurts and I have two welding scars from contorting myself on the ground for hours working on the bottom edge
I'm still not done down there - more welding and then grinding/finishing at the awkward angles BUT all the nose rust is gone. There are still spots with HEAVY pitting and dents and dings but it is way better
The bright spots in the photo are the FIVE new small pieces I had to fab to recreate the complex curve lower lip...
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NWGhiaGuy 
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Location: Bellingham, WA
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| Posted: Wed Jun 24, 2020 4:10 pm Post subject: Re: '63 Ghia - Second Chance |
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| Had to check out your progress. It's been a while since I looked! Just sent an email w/ photos regarding those front turn signals and the rain gutter trim. DS |
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dc
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| Posted: Wed Jun 24, 2020 5:57 pm Post subject: Re: '63 Ghia - Second Chance |
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| NWGhiaGuy wrote: |
| Had to check out your progress. It's been a while since I looked! Just sent an email w/ photos regarding those front turn signals and the rain gutter trim. DS |
thanks Dan-
Just replied a few minutes ago - no Ghia work today
Bathroom remodel fun...
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