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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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 Posted: Tue Jan 10, 2023 7:42 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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Decided to test mount the dome light, mirror and visors.
I drilled out the four pins that held on the shafts so that I could get them chromed. The mirror and shafts are original. I do have the original Ghia visor pivots, but I am using some reproduction visors to start. I was hoping my Argentina connection would make new visors, but he’s busy right now.
The dome light is original too. I just thought it important to test fit everything in case I had a problem with the headliner.
The Golf under the cover is my sons launch edition Golf race car. He has it up to 350 hp but is on his 7th stock transmission. He gets them for $700 so it beats and race transmission for now.
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JeffL
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Joined: September 04, 2004
Posts: 1370
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Sat Jan 14, 2023 7:52 am Post subject: Re: 56 Ghia build with Webasto and Judson |
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Has anyone remade these cardboard gaskets I think the number is 111201621B and maybe earlier versions. Listed as Anti Squeak in my 62 parts manuals
Update: I see Wolfsburg west sells these. Anyone used one. I just put in that part number on their site.
It’s 4 separate pieces held together with staples.
Maybe I could soak it and then reform it to reuse it. Pretty thin and narrow to cut out a new one without a stamping press.
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obus 
Samba Member
Joined: March 08, 2001
Posts: 11065
Location: just off Garden State Parkway Exit 81
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| Posted: Sat Jan 14, 2023 11:48 am Post subject: Re: 56 Ghia build with Webasto and Judson |
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| JeffL wrote: |
Decided to test mount the dome light, mirror and visors.
I drilled out the four pins that held on the shafts so that I could get them chromed. The mirror and shafts are original. I do have the original Ghia visor pivots, but I am using some reproduction visors to start. I was hoping my Argentina connection would make new visors, but he’s busy right now.
The dome light is original too. I just thought it important to test fit everything in case I had a problem with the headliner.
The Golf under the cover is my sons launch edition Golf race car. He has it up to 350 hp but is on his 7th stock transmission. He gets them for $700 so it beats and race transmission for now.
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May i ask where you got those repro visors from?
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July 1959 Mango Standard Bus aka Obus L346 L347 https://www.thesamba.com/vw/forum/viewtopic.php?t=256592&highlight=
June 1973 Pumpkin Orange Thing aka Othing L30H
https://www.thesamba.com/vw/forum/viewtopic.php?t=711775&highlight=
1960 Paprika Red Karmann Ghia Convertible aka Schatze L452 built 5/20/60
https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=
66 21 window bus built 8/31/65 https://www.thesamba.com/vw/forum/viewtopic.php?t=777273 |
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John Moxon
Samba Moderator
Joined: March 07, 2004
Posts: 13952
Location: Southampton U.K.
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| Posted: Sat Jan 14, 2023 12:28 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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| obus wrote: |
| JeffL wrote: |
Decided to test mount the dome light, mirror and visors.
I drilled out the four pins that held on the shafts so that I could get them chromed. The mirror and shafts are original. I do have the original Ghia visor pivots, but I am using some reproduction visors to start. I was hoping my Argentina connection would make new visors, but he’s busy right now.
The dome light is original too. I just thought it important to test fit everything in case I had a problem with the headliner.
The Golf under the cover is my sons launch edition Golf race car. He has it up to 350 hp but is on his 7th stock transmission. He gets them for $700 so it beats and race transmission for now.
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May i ask where you got those repro visors from? |
I'm pretty sure Jeff will confirm, they're from Ricardo: https://splitpartsunlimited.com/product-category/convertible-hebmueller/
He doesn't advertise the early KG visors but he will make whatever you like... if you ask nicely. 
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John.
Judson Supercharger Information on The Samba
My 1958 Shorrock Supercharged Karmann Ghia
Stop dead photo links! Post your photos to The Samba Gallery! |
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Sat Jan 14, 2023 1:36 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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| John Moxon wrote: |
| obus wrote: |
| JeffL wrote: |
Decided to test mount the dome light, mirror and visors.
I drilled out the four pins that held on the shafts so that I could get them chromed. The mirror and shafts are original. I do have the original Ghia visor pivots, but I am using some reproduction visors to start. I was hoping my Argentina connection would make new visors, but he’s busy right now.
The dome light is original too. I just thought it important to test fit everything in case I had a problem with the headliner.
The Golf under the cover is my sons launch edition Golf race car. He has it up to 350 hp but is on his 7th stock transmission. He gets them for $700 so it beats and race transmission for now.
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May i ask where you got those repro visors from? |
I'm pretty sure Jeff will confirm, they're from Ricardo: https://splitpartsunlimited.com/product-category/convertible-hebmueller/
He doesn't advertise the early KG visors but he will make whatever you like... if you ask nicely. |
Correct at the time I didn’t think about the Ghia/Bus hardware. He is swamped after Covid so I will wait for the Ghia ones. I’d like to send him my hardware.
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calexican
Samba Member
Joined: June 11, 2008
Posts: 730
Location: El Paso, TX
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| Posted: Sun Jan 15, 2023 11:28 am Post subject: Re: 56 Ghia build with Webasto and Judson |
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| Such a great build. Love the attention to detail with fabrics, vinyl, soundproofing, etc… |
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Braukuche
Samba Member
Joined: September 03, 2004
Posts: 10999
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| Posted: Sun Jan 15, 2023 1:56 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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Headliner looks sharp.
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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 |
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Sun Jan 15, 2023 2:35 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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Thank you for the compliments.
Today we did the first polish on the 4 aluminum trim/track pieces. I need to find some of the right chrome plated dome head screws.
For the headliner the opening, C pillars and rear window are glued now.
Nice look down on those original floor pans, car spent it’s life on Long Island!
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Sun Jan 15, 2023 2:54 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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For those raised head slotted screws, totally stainless has them on p.140 of their catalogue: https://shop.totallystainless.com/2010catalog/catalog46.pdf
The heads polish up really well and the look is very close to chrome and you can get the various sizes a Ghia needs.
Chromed steel screws are fairly rust prone as they are easily damaged as you fit them.
your car is looking fantastic, keep up the careful work |
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Wed Jan 18, 2023 4:39 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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Crazy photo
The upholstery shop wanted a stiff layout of the headers. I bought a 7 pack of backer boards. I cut one to set the sapcing of the outer headers so the cables would be straight to sew around.
The last thing I want to do is mount new cables. In the original install you would feed the new cable through the sewn hole.
I still kept the panel I cut out for the sunroof………
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TRS63
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Joined: December 17, 2017
Posts: 999
Location: Stuttgart - Germany
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Fri Jan 20, 2023 3:36 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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Step 12 - repeat steps 6 through 11
We picked up the sunroof cover and will do our best to have a lay flat stretched cover.
Sewing around the cables was a challenge as were the rear corners but I’m claiming progress! For the rear corners a split Rivet was used to hold the corner in place by each tension cable.
And yes I have time to clean off the counter before the dinner party
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JeffL
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TRS63
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Joined: December 17, 2017
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Braukuche
Samba Member
Joined: September 03, 2004
Posts: 10999
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| Posted: Sat Jan 21, 2023 8:26 am Post subject: Re: 56 Ghia build with Webasto and Judson |
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Never realized what a pain it is to fabricate a sunroof cover! The ones you buy for regular cars seem so simple.
_________________
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 |
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Sat Jan 21, 2023 11:24 am Post subject: Re: 56 Ghia build with Webasto and Judson |
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| Braukuche wrote: |
| Never realized what a pain it is to fabricate a sunroof cover! The ones you buy for regular cars seem so simple. |
Yes I agree. Without any templates I have to put things on and off multiple times. Today I will put all of the rails back on to close the outer cover and see where the front should be turned under to hold tension. Then I can take everything back off to cut and glue the corners. Hope to accomplish this today.
I glued the headliner to the front windshield this morning. I have had everything clamped under tension so it is stretching out, then glue it. Long process but seems to be working with a good output.
I need to make some gaskets for under the aluminum trim before I start the fitting. This is how they kept the water out.
As per the Golde manual, which looks the same as a Webasto
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Sat Jan 21, 2023 11:48 am Post subject: Re: 56 Ghia build with Webasto and Judson |
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This is a 3/16 foam that will crush well. I installed it already on the passenger frame. I needed it down with a putty knife so it was “pre crushed”
The rail is a pretty complex piece. In the front where the header moves down to lock you can see where they cut and weld it to add the depth.
Left side is shown in background not crushed yet
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Sat Jan 21, 2023 2:29 pm Post subject: Re: 56 Ghia build with Webasto and Judson |
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Not bad. The original markings still held from the front header test a month ago. Left side was a little loose and when I turned it over that side was not on the line so it we get a little more pull when square.
Now on to cutting in the corners and gluing to the main header.
You know those short Phillips screw drivers that you get with your set you never use, I could use a shorter one to get the screws in between the fabric to screw down the header.
Measure twice then come back in an hour and measure again …… and then cut.
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JeffL
Samba Member
Joined: September 04, 2004
Posts: 1370
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| Posted: Sun Jan 22, 2023 11:59 am Post subject: Re: 56 Ghia build with Webasto and Judson |
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While not perfect, pretty good will do.
The front header is high on the edges. It is up causing the one wrinkle at the front. Maybe I need to carve out a little Pennsylvania oak in the header to get the metal track to sit closer to the roof.
Remember my father in law with just the old header bow in hand guessed how to refabricate a new one. He didn’t even have the top frame.
There are likely some felt smoothing pieces I need to put over some of the hardware.
Maybe it needs to sit out in the sun, in about 4 months…., to relax. I sure do after this. At least now the top has more tension than I do. Really a snug pull over on the lever
I am very pleased with the convertible fabric and color choice.
On to finishing the sliding headliner.
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