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-   -   The resurrection of my 1960 karmann ghia (https://allmetalshaping.com/showthread.php?t=18852)

Antoine_P 03-10-2019 03:55 PM

The resurrection of my 1960 karmann ghia
 
Hello all,

As I always loved reading build thread, I decided to take the time and document my journey here too.

A bit of background: I am a 30 years old french mechanical engineer living in Germany that felt in love with metal shaping. I always wanted a ghia and was already part of the local club as much as collecting everything I can about this car before getting one.

My first aircooled is a 62 ragtop bug I bought 4 years ago as a barn find and it is now enjoyed every day when there is no salt on the roads.

But back to this topic: I bought in September 2017 a 60 (sept 59) strato blue ghia here on the samba. Originally from Portland, Oregon but I bought it already imported. As the pictures were showing, it was in poor condition (and still is..) but I decided to save it. It will end up as a vintage/oldspeed restored ghia.

Here is a picture from the ad:

https://www.thesamba.com/vw/gallery/pix/1870699.jpg

And when it came home:

https://www.thesamba.com/vw/gallery/pix/1870698.jpg

https://www.thesamba.com/vw/gallery/pix/1870697.jpg

https://www.thesamba.com/vw/gallery/pix/1870696.jpg

https://www.thesamba.com/vw/gallery/pix/1870695.jpg

https://www.thesamba.com/vw/gallery/pix/1870694.jpg

https://www.thesamba.com/vw/gallery/pix/1870692.jpg

I am of course already much further, and doings as much as I can (I’m a father of a young boy) to finish it for a meeting in june 2021.

I will bring the thread up to the actual stand in the next days, should I detail all the restauration here or just the metalwork?

Antoine

rewdco 03-10-2019 04:35 PM

Bonjour Antoine,

If it's up to me to decide, yes please, show us the whole restoration proces! Always interesting!

Mechanical engineer, working in Stuttgart...? You're not working at Trumpf in Ditzingen are you?

Keep up the good work!

Fasteddie 03-10-2019 10:09 PM

I would like to see it all, if you have time. Love the old VW's.
I think you are allowed to post the whole build. Looks like a big project.

Antoine_P 03-10-2019 11:22 PM

Thanks a lot guys for your positive reactions! I will then post everything I have but please, if it's too much and you want the focus on metal only, keep me in touch!

@Jan: "sadly" no..working for the automotive industry ;) but my shop is quite close to Ditzingen;)

So, after its arrival, I did a bit of disassembly and created some reinforcement to "replace" the doors:
https://www.thesamba.com/vw/gallery/pix/1870709.jpg

https://www.thesamba.com/vw/gallery/pix/1870710.jpg

https://www.thesamba.com/vw/gallery/pix/1870704.jpg

https://www.thesamba.com/vw/gallery/pix/1870702.jpg

https://www.thesamba.com/vw/gallery/pix/1870705.jpg

https://www.thesamba.com/vw/gallery/pix/1870706.jpg

And then it was time to build a dolly and take off the body:

https://www.thesamba.com/vw/gallery/pix/1870720.jpg

https://www.thesamba.com/vw/gallery/pix/1870719.jpg

https://www.thesamba.com/vw/gallery/pix/1870718.jpg

Now you can enjoy the view on the terrible fiberglass pan riveted by the previous owner :shock: :evil:

https://www.thesamba.com/vw/gallery/pix/1870717.jpg

https://www.thesamba.com/vw/gallery/pix/1870716.jpg

Stay tuned! :wink:

Antoine

Antoine_P 03-11-2019 01:18 AM

As I am firstly just bringing it up to the current status, it might give the feeling that this moves fast but in fact I started on september 2017 and I am not that far. Also bought and moved in my new shop during this time which didn't help with progress.. Normally I am working 4h on it every wednesday and sometimes a couple hours on the weekend.

So, the next update :D
I first decided to start on the frame, removing the undercoat:
https://www.thesamba.com/vw/gallery/pix/1870729.jpg

https://www.thesamba.com/vw/gallery/pix/1870728.jpg

And then preparing to its opening as the fuel line was untight:
https://www.thesamba.com/vw/gallery/pix/1870727.jpg

https://www.thesamba.com/vw/gallery/pix/1870726.jpg

Opened!
https://www.thesamba.com/vw/gallery/pix/1870725.jpg

https://www.thesamba.com/vw/gallery/pix/1870724.jpg

Then it was time to change all the rusted lines and close it back..
https://www.thesamba.com/vw/gallery/pix/1870723.jpg

https://www.thesamba.com/vw/gallery/pix/1870722.jpg

Of course with rust protection!
https://www.thesamba.com/vw/gallery/pix/1870742.jpg

https://www.thesamba.com/vw/gallery/pix/1870741.jpg

Closed:
https://www.thesamba.com/vw/gallery/pix/1870740.jpg

https://www.thesamba.com/vw/gallery/pix/1870739.jpg

And protected:
https://www.thesamba.com/vw/gallery/pix/1870738.jpg

Stay tuned ;)

Antoine

Gojeep 03-11-2019 04:28 AM

Great that you are showing the whole project.
Were able to pressure test the fuel lines before closing it all back up?

Antoine_P 03-11-2019 04:33 AM

Thanks a lot Marcus!
I am trying to do my best on it, doesn't want to do a show car but a (really) nice driver ;)
To answer your question: I replaced the entire fuel line with a new one that I tested. All the tubes that I repaired as seen on the pic are only for cables like gas, clutch, heater,..

So, let's continue the topic :)

Now that the bottom was ready, time to turn the frame and do the same, clean and primed:
https://www.thesamba.com/vw/gallery/pix/1870737.jpg

https://www.thesamba.com/vw/gallery/pix/1870736.jpg

And then I started to adjust the half pan:
https://www.thesamba.com/vw/gallery/pix/1870734.jpg

https://www.thesamba.com/vw/gallery/pix/1870735.jpg

Used the future heater channel to adjust:
https://www.thesamba.com/vw/gallery/pix/1870768.jpg

And then after cleaning/primering the half pan, it was time to weld them:
https://www.thesamba.com/vw/gallery/pix/1870778.jpg

https://www.thesamba.com/vw/gallery/pix/1870777.jpg

I also finished to clean/put in primer the back end:
https://www.thesamba.com/vw/gallery/pix/1870787.jpg

https://www.thesamba.com/vw/gallery/pix/1870786.jpg

https://www.thesamba.com/vw/gallery/pix/1870785.jpg

To be continued :)

Antoine

Peter Tommasini 03-11-2019 05:05 AM

BIIIIGGG job. But so far ...well done ;)
Peter

Antoine_P 03-11-2019 03:32 PM

Thanks a lot Peter, it really means a lot to me! I will do my best to not disappoint you!
Well, as I am already here, I can also show you some of the parts I already found/bought :D
I got myself some NOS front fender panels:
https://www.thesamba.com/vw/gallery/pix/1870758.jpg

https://www.thesamba.com/vw/gallery/pix/1870757.jpg

https://www.thesamba.com/vw/gallery/pix/1870756.jpg

The 60 only rear light backplate:
https://www.thesamba.com/vw/gallery/pix/1870762.jpg

https://www.thesamba.com/vw/gallery/pix/1870761.jpg

https://www.thesamba.com/vw/gallery/pix/1870760.jpg

The 60 only nose grill with their 3 screws:
https://www.thesamba.com/vw/gallery/pix/1870731.jpg

https://www.thesamba.com/vw/gallery/pix/1870730.jpg

A NOS indicator switch:
https://www.thesamba.com/vw/gallery/pix/1870691.jpg

And 1 NOS and 1 good used chrom trim for the door, also a 60 only part:
https://www.thesamba.com/vw/gallery/pix/1870715.jpg

https://www.thesamba.com/vw/gallery/pix/1870714.jpg

https://www.thesamba.com/vw/gallery/pix/1870713.jpg

Antoine

Charlie Myres 03-11-2019 05:07 PM

Great work Antoine! :)


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