The resurrection of my 1960 karmann ghia

[Antoine_P]

Thanks Tobias

Thanks Charlie, you're right, really satisfying when you come back home knowing that you fixed a part of the project

So, next update. As I am just keeping up with the work done in the past, I can update fast.. it will be way slower as soon as I am up to date..

Once again, I know that you can buy it but..love to build as much as I can so I started on the airboxes.. seems like simple parts but they proves me wring, having a lot of small indents, curves,...well I spent quite a few hours there..

First cut my metal sheet:


Found a tube with the good radius and folded it:








Then it was again time to use my bead roller for the folding on the side:




On the first attempt I made it wrong and it did not follow the original curves where it will be welded so I made some hammerform and started again:




And it fits:


Cut the middle part:




Same method for the bottom part, also used a hammerform as the shape isn't that easy..












And adjusted:


Final adjusting will take place after I changed the front part of the wheel well

Oh.. and I also made the second side:




Stay tuned

Antoine

[Jaroslav]

You're going well. If you can put another plate between the clamps and the plate. You will have a more precise bend and you will not transfer the wave to the free surface of the sheet.

[Antoine_P]

Thanks a lot Jaroslav, you are right, I first tried as pictured and then clamped it between 2 wood forms, just forgot the pictures. But it was way better!

Please, if you see anything I can improve or should do differently, I am really happy to hear every feedback or criticism!

Antoine

[Jaroslav]

Ok. I think you're doing well. It's interesting to watch your process. To achieve a good result in a simple way. It is pleasure.

[Antoine_P]

Thanks

So, next small update..
One of the worst part of my ghia is the dashboard. Have a look:





I did not started the rebuild of it yet but it rusted so much that even the glove box door was rusted. I decided to rebuild it as a small side project.
Here the rusty start:






Opened it and realised it never had any primer or paint from the factory..of course it rusted..




So I cleaned everything, welded where needed and put some rust protection:




And closed it back:




Antoine

[Jaroslav]

You're detailed. At the beginning it looked pretty bad. Did you use the brush mechanically?
Larger areas we clean with water pressure of 2500 Ba.
Parts are undamaged.
It is immediately visible what needs to be repaired.
After washing, the sheet is painted with a rust remover and looks new.
If you have a chance, let it wash komplet No sand, sand will destroy it.

[Antoine_P]

Nice!

Yes, mechanically cleaned. For the small parts I bought a small blasting cabinet with glass pearl that I need to put in use. For the body, I am first finishing a bit of the front part to ensure the rigidity and then it will get media blasted. A well known local VW restoration shop use him since 15 years without any issue so I can trust him.

Antoine

[Jaroslav]

Sand can only be used with little pressure. Here it happened that parts from car returned puffy. I saw a bloated whole car. Just what the man without the brain was sandblasting was destroyed. Large areas inflate. If bad use sand.
Water is very clean procedure. This procedure use for prototypes and new cars for control.
Just information that this path exists.

[norson]

Originally Posted by Jaroslav

Sand can only be used with little pressure. Here it happened that parts from car returned puffy. I saw a bloated whole car. Just what the man without the brain was sandblasting was destroyed. Large areas inflate. If bad use sand.
Water is very clean procedure. This procedure use for prototypes and new cars for control.
Just information that this path exists.

I agree totally on not blasting sheet metal. I use molasses or citric acid, neutralizing with baking soda and preserving with metal prep-n-etch.

[Antoine_P]

Now I am again doubting.. I however saw a lot of cars having had this media/soda blasting and they were done right with no deformation or wavy metal.. I will think about it again, thanks a lot for your feedbacks!
Small update for tonight
As a lot of these old VWs, my ghia had in the past several holes made through the panel between tank and dash. They also did "update" the wiring loom by cutting some space for a big fuse box :cry:




So I made a patch panel:




And welded it and all the other holes:




And with rust protection primer:

(Of course as you may notice the patch was not yet welded on this picture..)



Antoine