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davidmeigs
Samba Member
Joined: July 07, 2019
Posts: 16
Location: Virginia
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 Posted: Tue Mar 23, 2021 11:07 am Post subject: 74 Karmann Ghia Convertible Metal Rework |
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This is a body-off restoration of a 74 Convertible. Sandblasting revealed the repairs from body work by a Houston VW dealer in 1983. Made an attempt at reshaping the passenger fender but it seems frozen in place by the original welds to the nose panel. The driver side fender was replaced but the passenger side was roughly beaten into place with some sharp hammer blows that left sharp dents. I’ve smoothed the dents but it seems like there is too much steel there to lift the top of the fender back into place. Further up the fender is too high but it seems like forcing it down will push even more steel toward the front of the fender. As a side note, I removed the front part of fresh air intake by drilling out welds so I could get to the under side of the passenger side fender. I’m tempted to grind out the seam attaching the fender to the nose, reshape the fender, then flush cut the metal and Tig weld the new flush seam. Any thoughts welcome.
Last edited by davidmeigs on Sun Mar 28, 2021 4:28 pm; edited 1 time in total |
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kingkarmann
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Joined: November 05, 2003
Posts: 4497
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| Posted: Fri Mar 26, 2021 7:44 am Post subject: Re: 74 Karmann Ghia Convertible Metal Rework |
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Congrats!
You have the second rarest KG production. Only 1558 verts made so it's well worth the effort you are putting in.
Not being a body expert by any means I would suggest if you have those skills to remove the fenders at the factory seams, get every thing back into alignment and re-attach.
Maybe pose this question to the "Body & Paint" forum too!
Please keep us updated. We love build threads  |
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Braukuche
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Joined: September 03, 2004
Posts: 11198
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| Posted: Fri Mar 26, 2021 8:57 am Post subject: Re: 74 Karmann Ghia Convertible Metal Rework |
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Typical lapped repairs. I’d cut the panel out. Grind off the overlap and butt weld it back in. You could then work out any damaged areas, butt it would be easy. Otherwise to level it off you’ll have to use a lot of filler.
If you chose to stick with the existing repair then I’d shrink the excess metal and use kitty hair to cover over the overlap and then bondo to level it off.
Both repairs if done properly will hold up fine.
_________________
Go Reds! Smash state!
Retirement is here!
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
1989 Westfalia |
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Marcdeb
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Joined: May 22, 2019
Posts: 3245
Location: Vermont
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c21darrel
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Joined: January 22, 2009
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Location: San Dimas
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davidmeigs
Samba Member
Joined: July 07, 2019
Posts: 16
Location: Virginia
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| Posted: Fri Mar 26, 2021 2:03 pm Post subject: Re: 74 Karmann Ghia Convertible Metal Rework |
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| Thanks for the replies. Yes the nose was replaced. It has since been backed into but I have been able to reshape the deepest dents. The fresh air duct on the driver’s side is in good shape. I removed the passenger side air duct and it is off the car and pretty rough. I will probably buy a replacement. The nose meets the inner fender on the driver side but there’s a 3/4” gap on the passenger side. I am trying to figure out why. I’ve ordered the Eastwood mini metal saw to make the cuts. I plan to start on the driver’s side and repair the seam there first, then move to the driver side of the nose where it attaches to that fender and finally to the roughest seam on the passenger’s side where the nose is overlapped to the original fender. |
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davidmeigs
Samba Member
Joined: July 07, 2019
Posts: 16
Location: Virginia
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| Posted: Wed Apr 07, 2021 1:59 pm Post subject: Re: 74 Karmann Ghia Convertible Metal Rework |
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Ok, I cut through the fender and the good news is the layer of expected rust signaled when to stop cutting. So I have the top layer separated and now need to cut the under layer so it’s flush with the top. There’s still some of the top layer to peel away.
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The repairs look like they just laid replacement panels over existing panel, as Dan said. I think to do it right, cut, grind and clean then butt weld. Its a lot of work. How are the air ducts looking underneath?
