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Marcdeb 
Samba Member
Joined: May 22, 2019
Posts: 2713
Location: Vermont
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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 Posted: Fri Mar 19, 2021 12:45 pm Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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| Marcdeb wrote: |
Nice work. I like the tool you made. I might think you've done this before!  |
Thanks much for the compliment.
First time working on a Karmann Ghia but have some experience restoring other cars as a hobby. |
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 3779
Location: Near Rectilinear Halo Orbit
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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| Posted: Sat Mar 20, 2021 4:21 am Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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Thanks for pointing out that discussion. I should have referenced it in my original writeup as an alternative to my simple tool.
I had seen that thread and downloaded the book in the past. I considered making the tool per the drawing but decided to just make a much simpler version that would basically accomplish the same purpose. |
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Redlabel6
Samba Member
Joined: October 17, 2016
Posts: 367
Location: Minnesota
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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| Posted: Thu Aug 26, 2021 2:51 pm Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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Been a long time since my last post. Kinda got diverted from working on the car by other things like boat maintenance and repair, fishing, house maintenance, etc. etc. Plus I’ve been lax in keeping my posting timely as repairs were completed.
Have spent some time over the past month or so on the nose of the car cutting out all the rusted areas and either making patch panels or purchasing repair panels and welding them in place. Repairs have been completed to the horn opening, fresh air vents, headlight surround sheet metal and top sections on both fenders. Below I’ve posted pictures showing the progress for each of these repair areas. Let me apologize in advance for the number of pictures posted. In each posting I’m trying to show the progression of the repair, and that takes more than just a few pictures.
Pictures of the horn opening repair:
Pictures of the repair to the right fresh air vent:
Pictures of the repair to the left fresh air vent:
Pictures of left headlight surround area repair:
Pictures of right headlight surround area repair:
Next repairs will be to the lower sections of the nose and fender. Need to replace the lower apron / tire well sheet metal area and the bottom section of each fender below the headlight. |
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 2713
Location: Vermont
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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| Posted: Thu Aug 26, 2021 3:54 pm Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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| Marcdeb wrote: |
| You make it look easy, but I'm sure you have many hours invested. The work looks great. |
Thanks for the kind words but as my wife has heard me say numerous times "nothing is easy when it comes to restoring her car". |
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Zack1978
Samba Member
Joined: June 07, 2006
Posts: 538
Location: NJ
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| Posted: Thu Aug 26, 2021 6:48 pm Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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Amazing work!! You should be very impressed with all that you have done.
_________________
1972 Coupe |
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 3779
Location: Near Rectilinear Halo Orbit
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kingkarmann
Samba Member
Joined: November 05, 2003
Posts: 4062
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| Posted: Fri Aug 27, 2021 7:14 am Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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There are few real metalsmiths around. You are part of a rare breed.
Very nice 
_________________
"Who died and made you king of anything?"
Sara Bareilles
"Ego is the anesthesia that deadens the pain of Stupidity."
Rick Rigsby
Life is what we pay attention to...
Samba retirement is near, how does your story end? |
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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| Posted: Wed Sep 22, 2021 5:30 am Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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Started working on the lower section of the nose. The lower apron was toast so everything (what was left of the original metal and thick bondo) were removed and replaced with a front apron aftermarket repair panel. Needed to do some adjusting to the repair panel but finally got it to fit fairly well.
Took some time positioning the repair panel to ensure it was properly aligned with the nose ridge of the car and the apron indent was centered in the spare tire wheel well.
Plug welded the back edge of the apron lip to the lower lip of the spare tire well inner panel to match the original installation. Applied seam sealer where the two panels are welded together. I butt welded the front edge of the repair panel to good nose metal.
Here are some pictures of the repair:
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kingkarmann
Samba Member
Joined: November 05, 2003
Posts: 4062
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| Posted: Thu Sep 23, 2021 8:25 am Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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I can lose myself in photo's like this.
Very daunting but oh so impressive!
_________________
"Who died and made you king of anything?"
Sara Bareilles
"Ego is the anesthesia that deadens the pain of Stupidity."
Rick Rigsby
Life is what we pay attention to...
Samba retirement is near, how does your story end? |
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obus
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Joined: March 08, 2001
Posts: 10732
Location: just off Garden State Parkway Exit 81
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 2713
Location: Vermont
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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| Posted: Thu Sep 23, 2021 12:47 pm Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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| kingkarmann wrote: |
I can lose myself in photo's like this.
Very daunting but oh so impressive! |
| obus wrote: |
| Great work! That lower nose on mine is a hot mess as well with bondo and who knows what else. |
| Marcdeb wrote: |
I'm impressed. Do it right and do it once!  |
Thanks to all for the kind words. Hoping to get to the repair of the lower front left fender over the next few days. Will post more pictures when that section of the front of the car is done. |
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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| Posted: Sun Sep 26, 2021 2:08 pm Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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Was able to spend time repairing the lower left front fender. Using a left below headlight aftermarket repair panel and a home-made repair panel was able to finish work on the left front fender. I’m happy to say the aftermarket repair panel fit pretty good, only needing trimming and minor tweaking.
Below are some pictures showing the repair.
Next job will be to attack the repair of the lower right front fender. That is the last section of the car that needs to have rusted sections / bondo removed and repair panels installed. |
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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| Posted: Thu Sep 30, 2021 3:13 pm Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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Spent time completing the repair of the lower right front fender. Basically followed the same procedure I used to repair the lower left front fender. Similar need to do some trimming and tweaking to the aftermarket right below headlight repair panel.
Not sure why, but there was a gap between the lower headlight repair panel and lower apron repair panel when I did a test fit of the headlight repair panel. I spent a lot of time making sure the apron repair panel was centered so it wasn’t that the panel was mispositioned. In any case, I just welded in a strip of 18 gauge steel sheet to fill the gap. Also had to make a repair panel for the cut out rusted area just above the apron repair panel.
Pictures follow:
Next will be to weld in the headlight buckets. That should be the last welding of repair/replacement panels. |
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Marcdeb
Samba Member
Joined: May 22, 2019
Posts: 2713
Location: Vermont
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Legacy
Samba Member
Joined: October 26, 2008
Posts: 203
Location: Charlotte Hall, MD
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| Posted: Sun Oct 03, 2021 3:03 pm Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration |
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Welded in the headlight buckets and primed the front repaired sections. See pictures below.
I’ve reached a milestone today. I have now repaired all the rust on the front/sides/back of the car. Next, I plan to remove the rattle can primer and take car back to bare metal and spray the car in epoxy primer. Don’t think I’ll be able to put color on the car until the spring due to the weather changing here in Maryland and other projects that need attention. |
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