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1969 Karmann Ghia Auto Stick Restoration
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Marcdeb Premium Member
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PostPosted: Fri Mar 19, 2021 12:34 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

Nice work. I like the tool you made. I might think you've done this before! Think
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68 Karmann Ghia Cabrio Autostick
71 Karmann Ghia Cabrio

Previously Owned:
2011 VW EOS Hard Top Conv
2008 Saab 9-3 2.0T Conv
2003 Saab 9-3 SE Conv
2001 Saab 9-3 Conv
1998 BMW 3 Series Conv
1997 Saab 900 Conv
1997 Mazda Miata

68 Ghia Vert Survivor with 22,350 miles: https://www.thesamba.com/vw/forum/viewtopic.php?t=768107&highlight=
71 Ghia Vert Restoration: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc
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Legacy
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PostPosted: Fri Mar 19, 2021 12:45 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

Marcdeb wrote:
Nice work. I like the tool you made. I might think you've done this before! Think


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
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PostPosted: Fri Mar 19, 2021 8:25 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

There is this discussion from while back on the tool
https://www.thesamba.com/vw/forum/viewtopic.php?t=361094
Two thirds of the way down is a drawing with the dimensions for the nose ridge tool sourced from the VW Local manufacture workshop tool book. Tool#734

You can find the book here... https://www.thesamba.com/vw/archives/info/local_manufacture.php

Nicholas
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Legacy
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PostPosted: Sat Mar 20, 2021 4:21 am    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

sputnick60 wrote:
There is this discussion from while back on the tool
https://www.thesamba.com/vw/forum/viewtopic.php?t=361094
Two thirds of the way down is a drawing with the dimensions for the nose ridge tool sourced from the VW Local manufacture workshop tool book. Tool#734

You can find the book here... https://www.thesamba.com/vw/archives/info/local_manufacture.php

Nicholas


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
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PostPosted: Sun Mar 21, 2021 6:22 am    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

A buddy made a nose tool for me when I worked on my '73.
Worked great!
Image may have been reduced in size. Click image to view fullscreen.

d
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Legacy
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PostPosted: Thu Aug 26, 2021 2:51 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

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 Iíve 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 Iíve 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 Iím trying to show the progression of the repair, and that takes more than just a few pictures.

Pictures of the horn opening repair:
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Pictures of the repair to the right fresh air vent:
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Pictures of the repair to the left fresh air vent:
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Pictures of left headlight surround area repair:
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Pictures of right headlight surround area repair:
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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 Premium Member
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PostPosted: Thu Aug 26, 2021 3:50 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

You make it look easy, but I'm sure you have many hours invested. The work looks great.
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Marc
68 Karmann Ghia Cabrio Autostick
71 Karmann Ghia Cabrio

Previously Owned:
2011 VW EOS Hard Top Conv
2008 Saab 9-3 2.0T Conv
2003 Saab 9-3 SE Conv
2001 Saab 9-3 Conv
1998 BMW 3 Series Conv
1997 Saab 900 Conv
1997 Mazda Miata

68 Ghia Vert Survivor with 22,350 miles: https://www.thesamba.com/vw/forum/viewtopic.php?t=768107&highlight=
71 Ghia Vert Restoration: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc
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Legacy
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PostPosted: Thu Aug 26, 2021 3:54 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

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
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PostPosted: Thu Aug 26, 2021 6:48 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

Amazing work!! You should be very impressed with all that you have done.
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PostPosted: Fri Aug 27, 2021 2:10 am    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

My Karmann built 356C was just like yours.... rust in all the wrong places
You're doing a fine job with yours
Nicholas
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Last edited by sputnick60 on Fri Aug 27, 2021 4:25 pm; edited 1 time in total
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kingkarmann Premium Member
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PostPosted: Fri Aug 27, 2021 7:14 am    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

There are few real metalsmiths around. You are part of a rare breed.
Very nice Cool
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PostPosted: Wed Sep 22, 2021 5:30 am    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

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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PostPosted: Thu Sep 23, 2021 8:25 am    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

I can lose myself in photo's like this.
Very daunting but oh so impressive! Cool
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PostPosted: Thu Sep 23, 2021 9:21 am    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

Great work! That lower nose on mine is a hot mess as well with bondo and who knows what else.
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June 1973 Pumpkin Orange Thing aka Othing L30H
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PostPosted: Thu Sep 23, 2021 9:26 am    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

I'm impressed. Do it right and do it once! Smile
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68 Karmann Ghia Cabrio Autostick
71 Karmann Ghia Cabrio

Previously Owned:
2011 VW EOS Hard Top Conv
2008 Saab 9-3 2.0T Conv
2003 Saab 9-3 SE Conv
2001 Saab 9-3 Conv
1998 BMW 3 Series Conv
1997 Saab 900 Conv
1997 Mazda Miata

68 Ghia Vert Survivor with 22,350 miles: https://www.thesamba.com/vw/forum/viewtopic.php?t=768107&highlight=
71 Ghia Vert Restoration: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc
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Legacy
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PostPosted: Thu Sep 23, 2021 12:47 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

kingkarmann wrote:
I can lose myself in photo's like this.
Very daunting but oh so impressive! Cool


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! Smile


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
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PostPosted: Sun Sep 26, 2021 2:08 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

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. Iím happy to say the aftermarket repair panel fit pretty good, only needing trimming and minor tweaking.

Below are some pictures showing the repair.
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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
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PostPosted: Thu Sep 30, 2021 3:13 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

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 wasnít 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:
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Next will be to weld in the headlight buckets. That should be the last welding of repair/replacement panels.
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Marcdeb Premium Member
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PostPosted: Thu Sep 30, 2021 4:34 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

Wow! Amazing.
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68 Karmann Ghia Cabrio Autostick
71 Karmann Ghia Cabrio

Previously Owned:
2011 VW EOS Hard Top Conv
2008 Saab 9-3 2.0T Conv
2003 Saab 9-3 SE Conv
2001 Saab 9-3 Conv
1998 BMW 3 Series Conv
1997 Saab 900 Conv
1997 Mazda Miata

68 Ghia Vert Survivor with 22,350 miles: https://www.thesamba.com/vw/forum/viewtopic.php?t=768107&highlight=
71 Ghia Vert Restoration: https://www.thesamba.com/vw/forum/viewtopic.php?t=726710&postorder=asc
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Legacy
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PostPosted: Sun Oct 03, 2021 3:03 pm    Post subject: Re: 1969 Karmann Ghia Auto Stick Restoration Reply with quote

Welded in the headlight buckets and primed the front repaired sections. See pictures below.

Image may have been reduced in size. Click image to view fullscreen.

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Iíve 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. Donít think Iíll 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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