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Old 12-08-2011, 01:58 PM   #51
Dale Moser
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Originally Posted by Joey~AP View Post
Dude! Buy a vice! Those grinders will eat elk hide welding gloves for breakfast!
Yes they will! The good news is the wound doesn't bleed much because the grinding wheel melts the skin, rather than cutting it, and cauterizes it shut! Hurts a little though.
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Old 12-08-2011, 02:44 PM   #52
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And after ya drop the grinder....its usually still motorvatin and will climb up yer leg!

Ive seen mine do it!
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Old 12-08-2011, 03:08 PM   #53
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Yup, the fight's only half over when you let go of it! Reminds me of belt sander races we used to have in shop class.
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Old 12-08-2011, 08:53 PM   #54
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Joey and Dale...is this what you call foreshadowing?
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Old 12-08-2011, 08:55 PM   #55
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The good thing is, once the bracing is in place, the only welding I have to do is on the body itself. I bought several pair of different size C-clamps and the c-clamp-vise-grip thingies too.
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Old 12-10-2011, 08:11 PM   #56
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Looking pretty cool Kevin, I am a fan of the Ghia. Following along!
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Old 12-12-2011, 10:26 PM   #57
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I had a Ghia in 67 while in high school ,then bought a 74 super beetle that went well with My 73 BMW R75/5 motorcycle
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Old 12-22-2011, 09:51 AM   #58
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Kevin,

Watched a show called Wheeler Dealers last night (british) were they bought a karmann ghia in Idaho and shipped it to the UK and refurbished it. They visited a shop in Cali that specialized in parts for the KG's. http://www.karmannghia.com/home.asp

Thought of you as I was watching it.
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Old 12-22-2011, 01:11 PM   #59
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Nice find, nice old car to restore, and the engine does look very good as you noted!

Good luck and keep the pics coming!
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Old 12-22-2011, 03:17 PM   #60
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heres a pic of the ghia I built for my girlfriend (now wife), this was twenty plus years ago. I used to be a vw freak. I built the same engine your doing for my super beetle. 1641 with lightened 8 dowel flywheel, port and polished heads, 3/4 race cam, dual 36mm delloto carbs, cima 87mm jugs, counter weighted crank ect ect....man I miss those days. I always wanted to built a "hot" 1776. never did
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Old 12-31-2011, 06:54 PM   #61
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Kevin,

Watched a show called Wheeler Dealers last night (british) were they bought a karmann ghia in Idaho and shipped it to the UK and refurbished it. They visited a shop in Cali that specialized in parts for the KG's. http://www.karmannghia.com/home.asp

Thought of you as I was watching it.
Humper - thanks for the link - that site is a source for a lot of my parts! GREAT STUFF.
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Old 12-31-2011, 06:55 PM   #62
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Originally Posted by expressfish View Post
heres a pic of the ghia I built for my girlfriend (now wife), this was twenty plus years ago. I used to be a vw freak. I built the same engine your doing for my super beetle. 1641 with lightened 8 dowel flywheel, port and polished heads, 3/4 race cam, dual 36mm delloto carbs, cima 87mm jugs, counter weighted crank ect ect....man I miss those days. I always wanted to built a "hot" 1776. never did
Expressfish - NICE Ghia...Cali look with the EMPI wheels is always a hit. I can't bite the bullet on a 1776...maybe some day.
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Old 12-31-2011, 07:07 PM   #63
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I have been on vacation for several days but it wasn't until yesterday when I was able to give Sue some much needed attention. If you look back a bit, you will see that I mentioned having fits with my welder…come to find out, the inner sleeve / sheath has a kink in it which was / is preventing the wire from feeding at a constant rate. My dad let me borrow his new wire feed and I was able to put the final touches on the support braces – while the welds are ugly and definitely won’t past a dye penetrant test, I think they will hold for what I need them for.
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I also succeeded in removing all the bolts that hold the frame / pans to the body. I removed the gear shifter and the steering wheel and column as well. The fiberglass job that the previous owner did made for some choice words. Removing some the fiberglass also revealed what I had already assumed, the pans will have to be cut out and replaced.
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Mason and I were able to lift each corner of the body with minimal effort and tomorrow I will enlist the help of a couple of neighbors to completely remove the body from the frame. This is the rolling jig that I made to hold the body. The dimensions are such that I can roll this jig with the body on it over the frame; thus taking up the same amount of garage space during the rebuild…
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Stay tuned...
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Old 01-01-2012, 04:53 PM   #64
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After Sunday mass and a nice lunch, it was time to get back to Sue. I enlisted a couple of neighbors along with Mason. We positioned the jig right next to the car…
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And after tugging and tugging and more tugging, we discovered “someone” left one of the bolts that connects the pan to the body in?! After this lone bolt was removed, the body lifted off with little effort. Even though the 4x4s were a bit warped, the jig worked like a champ.
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The frame is now exposed and will require some work – mainly the pans. I will also be able to easily replace the shocks, master cylinder, perform some transmission work and anything else that strikes my fancy.
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And here Sue sits – stacked in two pieces…three if you count the engine.
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Tomorrow I may take on some welding on the frame – I have quite a few holes that need filling and I foresee the grinder getting a bit of a workout as well. Until next time…
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Old 01-02-2012, 09:37 AM   #65
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This is fun to follow along. One of these days I want to restore something, but I don't think I could get a bicycle in my garage right now. Keep up the good work.
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Old 01-02-2012, 12:08 PM   #66
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Nice rack!
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Old 01-02-2012, 01:21 PM   #67
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This is great....waiting for the next installment
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Old 01-02-2012, 01:24 PM   #68
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Nice rack!
LOL... Stamp of approval, eh?
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Old 01-02-2012, 02:19 PM   #69
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Quote:
Originally Posted by Joey~AP View Post
And after ya drop the grinder....its usually still motorvatin and will climb up yer leg!

Ive seen mine do it!
Quote:
Originally Posted by Dale Moser View Post
Yup, the fight's only half over when you let go of it! Reminds me of belt sander races we used to have in shop class.
Wimps!


Keep it up KHo!
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Old 03-31-2012, 04:14 AM   #70
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This is Greatness, keep the updates coming.
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Old 03-31-2012, 03:16 PM   #71
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Thank Higee - progress is VERY slow but progress is progress.
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Old 03-31-2012, 03:27 PM   #72
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today it the 1 year anniversary of this project...guna be sweet!
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Old 04-09-2012, 10:19 AM   #73
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Chop, chop!
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Old 04-09-2012, 06:23 PM   #74
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Quote:
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Chop, chop!
I know...I know.
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Old 04-11-2012, 09:54 PM   #75
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Nice Ghia, hard to find a convertible. Got me a 62 Ragtop w/1776cc.
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Old 04-14-2012, 04:20 PM   #76
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Nice Ghia, hard to find a convertible. Got me a 62 Ragtop w/1776cc.
Sue will have a 1776 when all is said and done. A new inner shield / sleeve is due to arrive on Monday. I will be able to get back on the body work once I have that installed.
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Old 04-26-2012, 02:59 PM   #77
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sue will have a 1776 when all is said and done. A new inner shield / sleeve is due to arrive on monday. I will be able to get back on the body work once i have that installed.
mistake...1671 not 1776
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Old 04-26-2012, 03:03 PM   #78
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It has been way too long since Sue was last fondled. I rolled her out this morning and had a few things I wanted to knock out.
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Sue – like most Ghias – had a factory dash (which is an overstatement) and a knee pad. You can see both here on Sue when I picked her up in Alabama.
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Upon completion, Shannon and I do not want to reinstall either, rather, we are going for a painted dash – similar to what is shown here.
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In order to get this look, many dash mounting holes have to be filled. I need to locate some steel “blanks” or something similar to put underneath the holes prior to filling them in. Some of these holes approach 3/8” diameter. You can see some of them marked and prepped for welding here.
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I also removed these “skirts” that are suspended from the center member. The prior owner’s fiberglass job encroached on these pieces and essentially ruined them.
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I found more stuff that needed to be removed / busted out…
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Finally, I wanted to start locating the trim mounting holes. For whatever reason, the previous owner Bondo’ed the holes in that support the side chrome trim. This made quite a mess.
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Here is the front passenger side quarter panel where the Karmann “bat” emblem will go along with the final trim pieces.
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Ever so slowly…but surely…
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Old 04-26-2012, 07:59 PM   #79
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Wow Cool thread Kevin, sorry I missed it till now.
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Old 04-26-2012, 08:54 PM   #80
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TTT for Joey.
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Old 04-27-2012, 06:40 AM   #81
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Quote:
Originally Posted by KHo View Post
TTT for Joey.

Get er done!

6" over beam and 3x3's?
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We're paratroopers, Lieutenant. We're supposed to be surrounded......

/l _ ,[____],
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Old 04-27-2012, 07:18 AM   #82
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very cool
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Old 04-27-2012, 02:37 PM   #83
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Quote:
Originally Posted by Joey~AP View Post
Get er done!

6" over beam and 3x3's?
Easy now...easy. Question for you. The holes in question...do they make / sell a stamping / round blank or something similar that I could put on the underside, tack and fill? Essentially a round piece of steel (a disk so to speak) such that its o.d. is slightly larger than the hole's i.d. If so, does said creature have a technical name? Thanks in advance.
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Old 04-27-2012, 02:40 PM   #84
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check some machine shops..these are usually just toss outs/drops...other wise a flat bar of copper can be used on the back side to weld fill the holes...the weld wout stick to the copper
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Old 04-27-2012, 04:40 PM   #85
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I have some flat bar copper
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Old 04-27-2012, 04:43 PM   #86
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Great job
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Old 04-27-2012, 08:21 PM   #87
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I was thinkin about that. Maybe get some knockouts from a 4 square box for backing and then do a rosette weld.

???
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Old 04-28-2012, 03:40 PM   #88
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Quote:
Originally Posted by DaveJr View Post
I have some flat bar copper
I may have to borrow some of that from you Dad and give it a whirl.

Quote:
Originally Posted by Joey~AP View Post
I was thinkin about that. Maybe get some knockouts from a 4 square box for backing and then do a rosette weld.

???
Any worries welding with the galvanization if I go this route?
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Old 04-29-2012, 08:42 AM   #89
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No. Just dont breath the fumes. It winr hut ewe ef u dew, do.
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We're paratroopers, Lieutenant. We're supposed to be surrounded......

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Old 04-29-2012, 09:26 AM   #90
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You can use aluminum for a back up plate too. The weld won't stick to it either.
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Old 04-29-2012, 04:46 PM   #91
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drink milk after you weld the Galvanized stuff
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Old 04-29-2012, 07:06 PM   #92
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Quote:
Originally Posted by Joey~AP View Post
No. Just dont breath the fumes. It winr hut ewe ef u dew, do.
I think I have located a source for some 1/8" flat bar that I can trim to the correct sizes, clamp up and weld away. Stay tuned.
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Old 05-05-2012, 05:53 PM   #93
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After Caleb and I toured the Vintage Park “Coffee and Cars” Show on Saturday morning (http://discussions.texasbowhunter.co...60#post5236160), I was a bit motivated to do some work on Sue.

My dad cut me some 1/8” flat bar into 1” squares. These were ideal for going on the underside of the dash holes for ‘filling’. While I am no professional welder, the holes are ‘full’ enough now where the paint and body dude / dudette can smooth them over with bondo / filler.
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In preparation for the paint and body shop, I finished removing the remaining portions of the electrical harness and various pieces of tubing.
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Onto the rear apron… I ordered two (2) separate pieces to take the place of the damaged apron. I apologize for the poor lighting…I had to turn Sue around 180 degrees in anticipation for using the welder.
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Now I know I said I was not professional welder, but I would have at least ground this down to look a bit more purty…
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Several minutes with my grinder, a ball peen hammer and chisel and it was out.
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Here is the new center third section…
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…but we have a problem. This gap is, undoubtedly, due to an impact at some point in time. This is when I put things up. I will have the paint and body shop figure this one out…
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And note to self…pick up a long sleeved denim shirt before doing any more welding…OUCH
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Until next time…
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Old 05-06-2012, 10:49 AM   #94
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Quote:
Originally Posted by KHo View Post
After Caleb and I toured the Vintage Park “Coffee and Cars” Show on Saturday morning (http://discussions.texasbowhunter.co...60#post5236160), I was a bit motivated to do some work on Sue.

My dad cut me some 1/8” flat bar into 1” squares. These were ideal for going on the underside of the dash holes for ‘filling’. While I am no professional welder, the holes are ‘full’ enough now where the paint and body dude / dudette can smooth them over with bondo / filler.
Attachment 335555

Attachment 335556

In preparation for the paint and body shop, I finished removing the remaining portions of the electrical harness and various pieces of tubing.
Attachment 335557

Onto the rear apron… I ordered two (2) separate pieces to take the place of the damaged apron. I apologize for the poor lighting…I had to turn Sue around 180 degrees in anticipation for using the welder.
Attachment 335558

Now I know I said I was not professional welder, but I would have at least ground this down to look a bit more purty…
Attachment 335559

Several minutes with my grinder, a ball peen hammer and chisel and it was out.
Attachment 335560

Here is the new center third section…
Attachment 335561

…but we have a problem. This gap is, undoubtedly, due to an impact at some point in time. This is when I put things up. I will have the paint and body shop figure this one out…
Attachment 335562

And note to self…pick up a long sleeved denim shirt before doing any more welding…OUCH
Attachment 335563

Until next time…
and heavy starch the sleeves...
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Old 05-06-2012, 07:21 PM   #95
KHo
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and heavy starch the sleeves...
10-4
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Old 05-07-2012, 05:47 PM   #96
expressfish
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mig will do it everytime
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Old 05-21-2012, 09:36 PM   #97
KHo
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Ttt for Joey...thinking I may have paint and remaining body work quoted this week.
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Old 05-22-2012, 10:46 AM   #98
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Just let me know when you want me to come haul it off for you!
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We're paratroopers, Lieutenant. We're supposed to be surrounded......

/l _ ,[____],
l---- L-- -OlllllllO-
()_)--()_)---o-)_)
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Old 05-22-2012, 12:19 PM   #99
KHo
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Just let me know when you want me to come haul it off for you!
LOL...I won't let my wife see that comment as I know what her answer would be..."...you available this evenin'?"
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Old 05-22-2012, 09:25 PM   #100
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I will call her.
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We're paratroopers, Lieutenant. We're supposed to be surrounded......

/l _ ,[____],
l---- L-- -OlllllllO-
()_)--()_)---o-)_)
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