tag:blogger.com,1999:blog-7385040697915914272024-02-08T07:11:48.100-08:001971 Karmann Ghia Convertible RestorationKevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.comBlogger26125tag:blogger.com,1999:blog-738504069791591427.post-92020075983192998942024-01-30T03:55:00.000-08:002024-01-30T04:27:37.960-08:0026. Karmann Ghia Restoration - Dashboard and Hood Frame<p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU6f0wnL7okPpPVdgjMORTLXqLQxgICUVy4rTO-XjgiIjOZQjgCsH2oFFJuu9wBCIxT97vL1qaKhFjPm3X0Dt1wS9bBZaXnf1xlQh9rUo-fKbE0jFWL3GPAFhpLnjCxwEWX7kEuhhNrvGmfR9EcxGhBnf9RIeCZD4Vtw5an3A1icsPepSa5BlMSFiN3upb/s4032/IMG_5720.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU6f0wnL7okPpPVdgjMORTLXqLQxgICUVy4rTO-XjgiIjOZQjgCsH2oFFJuu9wBCIxT97vL1qaKhFjPm3X0Dt1wS9bBZaXnf1xlQh9rUo-fKbE0jFWL3GPAFhpLnjCxwEWX7kEuhhNrvGmfR9EcxGhBnf9RIeCZD4Vtw5an3A1icsPepSa5BlMSFiN3upb/w400-h300/IMG_5720.JPG" width="400" /></a></div><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNxj1pUfVN8hnTkAoHtTBvMusp8vHgMUIKF4D5zfvKStJWf3xFHeo0LWV03glkqtQ5Jmjot6ix5W-aNAd8ZMwBvcfg0W-1ri8_1QJ3duHqC5d8rL0cEPvawmmD4wZCG4KP74RKP9f2JMj5z_dXoWAA5PeOVYNDb5aMO69vXV8xyjbwE7o9bjXv7-0_ZgJ1/s1238/Cigarette%20Lighter.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1106" data-original-width="1238" height="286" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNxj1pUfVN8hnTkAoHtTBvMusp8vHgMUIKF4D5zfvKStJWf3xFHeo0LWV03glkqtQ5Jmjot6ix5W-aNAd8ZMwBvcfg0W-1ri8_1QJ3duHqC5d8rL0cEPvawmmD4wZCG4KP74RKP9f2JMj5z_dXoWAA5PeOVYNDb5aMO69vXV8xyjbwE7o9bjXv7-0_ZgJ1/w320-h286/Cigarette%20Lighter.jpg" width="320" /></a></div><span style="font-family: arial;">Well this is the point at which I make a bad decision and without studying the dashboard too closely, I decided to start building the dashboard. So after fitting and wiring the switches I decided to fit a new cigarette lighter. I managed to buy a suitable replacement for the original, that was missing, and offered it to the hole in the dash, only to find that the hole was too small. I was now faced with the problem, how to make the hole bigger? Now obviously I could try using a hand file, but the bezel was only 1mm wide and I would need to be very accurate. Plus I wanted the hole exactly central to the existing one. So I bought a 24mm Q-Max cutter and then set about making a spacer, </span><span style="font-family: arial;">to fit the hole in the dash, </span><span style="font-family: arial;">with a hole in the middle for the cutter bolt to pass through. This spacer then held the cutter exactly in the centre of the hole in the dash. Then with masking tape, to stop the cutter marking the dashboard paint, I cut the hole and it was perfect.<br /></span><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYNsbCQ7ImPp3vhyalr5tuNtctvU0VS44ZH0hFH0_g9mQq9A5UqS3samJaVkK0zGvPbcvKGyjnk2jejCywTniAxdUis2-SntsPPHKgEvIQC9Pr-5qJE1RBOhy4tqL6MfrH25foRuY_tkv2N2qtnF0ShpclziUgseFtbOxPNlVcG349JJU_Cha3N1zhRaMr/s4032/IMG_5626.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYNsbCQ7ImPp3vhyalr5tuNtctvU0VS44ZH0hFH0_g9mQq9A5UqS3samJaVkK0zGvPbcvKGyjnk2jejCywTniAxdUis2-SntsPPHKgEvIQC9Pr-5qJE1RBOhy4tqL6MfrH25foRuY_tkv2N2qtnF0ShpclziUgseFtbOxPNlVcG349JJU_Cha3N1zhRaMr/s320/IMG_5626.jpg" width="320" /></a></div><span style="font-family: arial;">The next job was to renovate the clocks and as soon as I put them on the bench I noticed that I had two clocks with grey faces and one with a black face. The time clock was definitely an odd one out. Well I searched the web for a "grey" clock but could not find one anywhere. But eventually I found a grey faced Rev Counter of the correct size and purchased that. The next job was to strip and clean the speedo and fuel gauge. Removing the bezels and glass was a slow and delicate operation </span><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDPyyFjlByqdIJo8xPfCCZ0wk6cP6nHmW8ujtb_OttAp-TzHhqueSNuXJBxnTUpee9w34gzDIYeEzUqhXMtrmzWoGXvEwxHRif3xlHOaMVEshXhgExEGo2aenpL4sdOiIKfNwByVCkjPPSL9W3-2oomf1dUd1FZOsoOk7wdh_g85JfYpc9HDddD1RRtIKy/s2924/Clocks.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1906" data-original-width="2924" height="209" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDPyyFjlByqdIJo8xPfCCZ0wk6cP6nHmW8ujtb_OttAp-TzHhqueSNuXJBxnTUpee9w34gzDIYeEzUqhXMtrmzWoGXvEwxHRif3xlHOaMVEshXhgExEGo2aenpL4sdOiIKfNwByVCkjPPSL9W3-2oomf1dUd1FZOsoOk7wdh_g85JfYpc9HDddD1RRtIKy/s320/Clocks.jpg" width="320" /></a></div><span style="font-family: arial;">without breaking the glass but the result was excellent and they now look beautiful. </span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">At this point I still hadn't realised the mistakes I was making, but it is visible in this picture. So Now I decided to buy the upper and lower dash pads. I had to wait some time for the top pad to arrive from the USA and the bottom pad came from Germany.</span></div><div><span style="font-family: arial;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiN7V8m0DDHyaUC23aUI-Fs7iWyX_RxDzcTnVSmFpEne8YkCy5STPL76ovpRHPeQsNxX8bgpDV9KI9EG67xZTfcpbScixRVoOSIkfcAmi7Pm5mU7uWP88DkY_1_Hq2Vu7HUECWvlFpcTF9RxtH6WTk_hPwxKDT8DCQ0lHvQwBKrElgAJZWK5H92m_B8ZmHN/s757/Radio.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="292" data-original-width="757" height="123" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiN7V8m0DDHyaUC23aUI-Fs7iWyX_RxDzcTnVSmFpEne8YkCy5STPL76ovpRHPeQsNxX8bgpDV9KI9EG67xZTfcpbScixRVoOSIkfcAmi7Pm5mU7uWP88DkY_1_Hq2Vu7HUECWvlFpcTF9RxtH6WTk_hPwxKDT8DCQ0lHvQwBKrElgAJZWK5H92m_B8ZmHN/s320/Radio.jpg" width="320" /></a></div><span style="font-family: arial;">In the mean time I could fit the radio. This is a replica vintage look radio with DAB, USB and Bluetooth with four speaker outputs and a separate feed for a sub speaker.<br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh0JU_nZ4rjwwv5Qk1cA0ZCDkn1ujUUdVzpGNGvq9K4VcsK0u__a1evvSq9wIuGMsdswpiRnc6kVILjgGoxHkYDw0NfXNlD8ZXl1W7MQw77aOeo1hxkqgMXBAB5LV1zfkQp_iQMfiFw2bcEWagh2FmRS7rsHwiW0ACbTDEBlzFzUKcxhrYrSp_wMYo4SpJ/s4032/IMG-5846.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh0JU_nZ4rjwwv5Qk1cA0ZCDkn1ujUUdVzpGNGvq9K4VcsK0u__a1evvSq9wIuGMsdswpiRnc6kVILjgGoxHkYDw0NfXNlD8ZXl1W7MQw77aOeo1hxkqgMXBAB5LV1zfkQp_iQMfiFw2bcEWagh2FmRS7rsHwiW0ACbTDEBlzFzUKcxhrYrSp_wMYo4SpJ/s320/IMG-5846.jpg" width="320" /></a></div><span style="font-family: arial;">Well my dashboard pads arrived and as soon as I offered them up to the dashboard my mistake was obvious. The holes at the top left and right on the dashboard were still visible below the pads. Plus more slots on the far right and left. I had mistakenly thought that the pads would cover these holes and I was wrong. I had really wanted to keep the blue painted dash. But now I had no choice. The whole dashboard had to be stripped again and I had to order the wood laminate facia. <br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCHxnBb4aW0RfYiAzpEGMtzKMXRV1FSSmXqeBjmWTLqHt7zmTME6DL92D8kWEJtOmyh4_bFmhV89MpevkBvxnNJgS04DCtLZ92Jd91uHtSnEjNk2VAkbzVMfMyk_jYN-li_1uWx5fOxTk7JDcD5OdAKsm9ppO7Pym-dK4trre77f-7LU5C4pe3gKhnRMhd/s4032/IMG-5835.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCHxnBb4aW0RfYiAzpEGMtzKMXRV1FSSmXqeBjmWTLqHt7zmTME6DL92D8kWEJtOmyh4_bFmhV89MpevkBvxnNJgS04DCtLZ92Jd91uHtSnEjNk2VAkbzVMfMyk_jYN-li_1uWx5fOxTk7JDcD5OdAKsm9ppO7Pym-dK4trre77f-7LU5C4pe3gKhnRMhd/s320/IMG-5835.jpg" width="320" /></a></div><span style="font-family: arial;">So while I waited for the dash facia to arrive, I decided it was time to fit the windscreen. You will have read that I broke the original screen getting it out. So I now had a new screen, new rubber and new chrome trims. Now I have a very good friend who used to work for Autoglass as a fitter. So I asked him if he would help and he came along to the workshop. <br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLDA_HGlkbfzp70wbCVXxU1DgrwF9LL5X8LJefavRf-pzVIGxYs-TTtenm60-jVl6Xvzi4YKiKgTaBOSydQruSKZuOHI2Qc7QtvspAJ_YPdLu6vbRtM1wkjry9kZNERY3gYt8Ab6ZGEraTXe_vJURmIeKsiLFBCZfsJg9JI6Qgd0-lBbNCpC-gnXb9ndPM/s4032/IMG_5968.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLDA_HGlkbfzp70wbCVXxU1DgrwF9LL5X8LJefavRf-pzVIGxYs-TTtenm60-jVl6Xvzi4YKiKgTaBOSydQruSKZuOHI2Qc7QtvspAJ_YPdLu6vbRtM1wkjry9kZNERY3gYt8Ab6ZGEraTXe_vJURmIeKsiLFBCZfsJg9JI6Qgd0-lBbNCpC-gnXb9ndPM/s320/IMG_5968.jpg" width="320" /></a></div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">As usual, nothing is easy, we managed to get the new rubber around the glass but could not get the chrome trim to fit and after a whole night of trying, we gave up and went home. I spent the next few days reshaping the chrome trims (which come flat) to fit the shape of the screen and my friend returned for another attempt. Surprise surprise, it wouldn't fit on the car. The whole screen and rubber appeared bigger than the aperture. In a final desperate attempt, I found the old, 50 year old, screen rubber and spent a whole day cleaning it up. My friend returned for a third attempt and this time, with the original screen rubber, it fit!</span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><br /></div>The wood laminate arrived and it was time to start reassembling the dash. With<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizV7f4CMy67jCPrhMQmoeiZNfSmYpBihMsWf9uNkNJ5Wc0w1OiRMjbJ4VqfsbNQFxQBi93E42IqAz3SSqWU2kddF17d94RMOLRtrjx56k-_Dd8FsZV6HTIelQtf_-GbJ_j1tm1Y5n2AH-3tnqnHQWim47jg9EANjVqhWDdqEbGDUiOPX_ccIP3-jKyzMQn/s4032/IMG_5973.jpg" style="clear: right; float: right; font-family: arial; margin-bottom: 1em; margin-left: 1em; text-align: center;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizV7f4CMy67jCPrhMQmoeiZNfSmYpBihMsWf9uNkNJ5Wc0w1OiRMjbJ4VqfsbNQFxQBi93E42IqAz3SSqWU2kddF17d94RMOLRtrjx56k-_Dd8FsZV6HTIelQtf_-GbJ_j1tm1Y5n2AH-3tnqnHQWim47jg9EANjVqhWDdqEbGDUiOPX_ccIP3-jKyzMQn/s320/IMG_5973.jpg" width="320" /></a></span><span style="font-family: arial;"> the laminate stuck in place with contact adhesive, I now had the job of cutting out all of the holes. The larger holes were not too difficult, using a sharp Stanley Knife to carefully cut around the hole. But the switch holes posed a small problem as some of them were not indented on the laminate. I ended up using a small drill from the other side of the dash to find the centre of the holes and then drilling from the front by hand with the correct size drill. </span></div><div><span style="font-family: arial;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhBa0fRX9EulO1v1LgdYkIVlTy1jb-h7fmWPhdIg0PUgpwbjJE2HgZ3RvYVSGaiXlhmSg23lnKAZge2XmeEvaykzOznk5l5-EGfhEKBGlqE5KR1v6lByFrnmxDBe4xvRzg6NuWG7OyBYdZM3sEPpDPRlTqn87DqYW0jorHpZ98amWbv3TE46nwewkrsZrc/s4032/IMG_6055.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhBa0fRX9EulO1v1LgdYkIVlTy1jb-h7fmWPhdIg0PUgpwbjJE2HgZ3RvYVSGaiXlhmSg23lnKAZge2XmeEvaykzOznk5l5-EGfhEKBGlqE5KR1v6lByFrnmxDBe4xvRzg6NuWG7OyBYdZM3sEPpDPRlTqn87DqYW0jorHpZ98amWbv3TE46nwewkrsZrc/s320/IMG_6055.jpg" width="320" /></a></div><span style="font-family: arial;">After refitting all of the clocks and switches I could now fit the two new top and bottom pads. I had previously only laid them in place. It was now time to fit them properly. Well the first thing that I discovered was that the captive bolts on the bottom (German) pad were 6mm. No problem. However the bolts on the top (American) pad were imperial and after a lot of searching I discovered that they were 3/16" Whitworth, which of course, I didn't have! This meant a trip to a local Nut and bolt company who fortunately found some and gave them to me (Thank you). Getting the nuts onto these pads is extremely awkward and takes ages to do, but there it is, fitted!</span></div><div><span style="font-family: arial;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVpa7X6MPoXgx_Vo5fqueZ0HEQAqtpDuuYUPH8uMdud6GJDCLIVZG8kl2iU7ajMyyWcYE74SgEwLK_EgTrvx1HWGCkhaV_96RFoCkItxRkK7BcacEEaxcqYpy0PBsIbtjJ4iiaMmWbJJt0d-OXN4H2FfJhQaLfo8Y5zzViqKnXY_kEY6Z944qYo0Z3As3Z/s4032/IMG_5773.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVpa7X6MPoXgx_Vo5fqueZ0HEQAqtpDuuYUPH8uMdud6GJDCLIVZG8kl2iU7ajMyyWcYE74SgEwLK_EgTrvx1HWGCkhaV_96RFoCkItxRkK7BcacEEaxcqYpy0PBsIbtjJ4iiaMmWbJJt0d-OXN4H2FfJhQaLfo8Y5zzViqKnXY_kEY6Z944qYo0Z3As3Z/s320/IMG_5773.JPG" width="320" /></a></div><span style="font-family: arial;">So now a change of direction, as I was looking at how to fit the four loudspeakers for the radio. Now the rear speakers had to go into the rear plastic quarter panel interior trims and these trims were in really bad condition. They had become brittle and had much of the edges broken off and one trim was actually broken in half. I searched for new ones on the web and found that they were really expensive. So I decided to try and repair them. I backed each one with thin aluminium, held in place with epoxy resin and pop rivets. Hopefully, once they are trimmed with vinyl, they will look fine.</span></div><div><span style="font-family: arial;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiODBEnVLSu4LSlDMCNYKntDV1ZIPS555gbWVn91Mb0ymHmS6ObCp_bl4XIgffCMinekbA85EWtyu5TnBakKmD_lHbi5CynJVJ5tqCEk6naKk-TpsIXv1DTJZfxVnn7PdGCSJRCp1LLuCjD9Z5lzjJ_eZyooNAlMLh1kVWqgRsb9Rpdn5nhTCnOdbV-I2pe/s4032/IMG-5733.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiODBEnVLSu4LSlDMCNYKntDV1ZIPS555gbWVn91Mb0ymHmS6ObCp_bl4XIgffCMinekbA85EWtyu5TnBakKmD_lHbi5CynJVJ5tqCEk6naKk-TpsIXv1DTJZfxVnn7PdGCSJRCp1LLuCjD9Z5lzjJ_eZyooNAlMLh1kVWqgRsb9Rpdn5nhTCnOdbV-I2pe/s320/IMG-5733.jpg" width="320" /></a></div><span style="font-family: arial;">Now in order to fit these panels, the hood frame had to be in place first. So it was time to fetch the frame down from the loft and have a go at fitting it. I had previously stripped the frame and had it powder coated. So now was the time to fit it. Well it's really nice to have something go well for a change and the frame fitted easily and even the rear window catch worked correctly.<br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">So next time I'll be reassembling the doors and fitting the engine.</span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">Copyright 30.01.24 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html" style="background-color: white; color: #2288bb; font-family: arial;">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #2288bb; font-family: arial;">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #2288bb; font-family: arial;">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #2288bb; font-family: arial;">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><br /><span style="font-family: arial;"><br /><div class="separator" style="clear: both; text-align: center;"><br /></div></span></div><div><span style="font-family: arial;"><br /></span><br /><p></p></div>Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-5938134173448047242023-12-10T03:23:00.000-08:002023-12-10T03:40:15.046-08:0025. Karmann Ghia Restoration - Lights, Horn & Screen Washer<p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtRKyDg5-z5a7aUl6dYpsXL9GlNgKhTOBc3Jgskupqf3mVFBG3Bv-LBUcJLHgUshB2Zzm6-3i0UYUXghyphenhyphenbt-BHfpcqz8RVUjG69DI7l0O2Uuath0HC-AXPX5nu9PbZVLfXqPSUMKi9zEOBxsbGi09bZQiLtcglx4DDfB99TrKUace-L0yeMeDxLuW42hS1/s4032/IMG_5612.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtRKyDg5-z5a7aUl6dYpsXL9GlNgKhTOBc3Jgskupqf3mVFBG3Bv-LBUcJLHgUshB2Zzm6-3i0UYUXghyphenhyphenbt-BHfpcqz8RVUjG69DI7l0O2Uuath0HC-AXPX5nu9PbZVLfXqPSUMKi9zEOBxsbGi09bZQiLtcglx4DDfB99TrKUace-L0yeMeDxLuW42hS1/w640-h480/IMG_5612.JPG" width="640" /></a></div><br /><p></p><p><span style="font-family: arial; font-size: medium;">Well wiring the headlight's was straight forward. I managed to renovate the original rubber tubes from the headlight bowls to the body and thread through the new wiring loom. Wiring them back to the fuse box and the switch wasn't too difficult but the headlight relay would flash the lights but not dip them. So in the end I had to buy a new relay. </span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrcb9XToNC44orBHn3kc_3SOKWP7Sm5VsJJIfpjYp4g9RdwgRAaGZRRO8LY2xuBYok5dH1u9q_QJQysQTsm1i06zX13QJYHpUQiUYh_FVI7a0DU8h-xLTxNoNW_xV0zGyZ4usbhe7pERUx-uPS9NzKgf6oBNRcNvp4f7sw-DsbGYkuprAKaop6Y3hdWEUM/s4032/IMG_5547.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrcb9XToNC44orBHn3kc_3SOKWP7Sm5VsJJIfpjYp4g9RdwgRAaGZRRO8LY2xuBYok5dH1u9q_QJQysQTsm1i06zX13QJYHpUQiUYh_FVI7a0DU8h-xLTxNoNW_xV0zGyZ4usbhe7pERUx-uPS9NzKgf6oBNRcNvp4f7sw-DsbGYkuprAKaop6Y3hdWEUM/s320/IMG_5547.JPG" width="240" /></a></div><br /><span style="font-family: arial; font-size: medium;">Now I had decided not to mount the Battery in the engine compartment. Instead I wanted to fit it under the back seat (Like in a Beetle). However the space under the back seat of a Karmann Ghia is not as deep as a Beetle and so I had to search for a suitable battery to fit the available space. Eventually I found that the battery for a Mercedes SL fit the space perfectly and here it is mounted in place.</span><p></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYC2T9qURkwcdMz5F4VVyj-zzqnTtdvfl13oN8DNcDPy0Bs3S69ItKcZBNwJHWMELOfJvVBrIxTb4q_Jl8vVFOZSKbDifBwQRny02ZUXhNnRvRcPDvPXpkNsUCoUzyZtrGV2_CmiQbqGrZWCjDoLIcAhQHgYzYAt7yFqMpLzSaOwRPgWaZw3PxkHwJ2it3/s4032/IMG_5607.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-size: medium;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYC2T9qURkwcdMz5F4VVyj-zzqnTtdvfl13oN8DNcDPy0Bs3S69ItKcZBNwJHWMELOfJvVBrIxTb4q_Jl8vVFOZSKbDifBwQRny02ZUXhNnRvRcPDvPXpkNsUCoUzyZtrGV2_CmiQbqGrZWCjDoLIcAhQHgYzYAt7yFqMpLzSaOwRPgWaZw3PxkHwJ2it3/s320/IMG_5607.JPG" width="320" /></span></a></div><span style="font-family: arial; font-size: medium;">The next job was to fit fit the horns. Now the original horns were long gone and the one I removed, when stripping the car, was just a single cheap plastic horn. I wanted to fit some "air horns" but this posed another problem. Without the original horns and rubber boot, how was I going to stop water coming in through the hole in the wheel well. So I experimented with very fine stainless steel wire mesh and found that if the mesh was fine enough, then the water would run off it rather than pass through it and the sound could still pass through it easily. So that's what I fitted, held in place with black body sealant. New air horns were fitted along with the compressor and a relay and wired back to the steering column. Oh boy! they sound loud and great.</span><p></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiD9DVHeVn2IPqVv0VDqlXRoXnomzCeNRtQg0tOtChQXx85lgFjghGA5whc-ucOlS3A71Ri4BZ969SZBzsY2Vovxs4oGhX5Siel_Shn6Aajy0UKqVR4H5otO-2mFQC_ht3TWNhLtbXUNab_CjN8wePMA3fHSCAceBUwCtBn6Z1K2-F8EB_sq7QDN2mrf93O/s4032/IMG_5582.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-size: medium;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiD9DVHeVn2IPqVv0VDqlXRoXnomzCeNRtQg0tOtChQXx85lgFjghGA5whc-ucOlS3A71Ri4BZ969SZBzsY2Vovxs4oGhX5Siel_Shn6Aajy0UKqVR4H5otO-2mFQC_ht3TWNhLtbXUNab_CjN8wePMA3fHSCAceBUwCtBn6Z1K2-F8EB_sq7QDN2mrf93O/s320/IMG_5582.JPG" width="240" /></span></a></div><span style="font-family: arial; font-size: medium;">The next task is to convert the washers to electric operation. This involved removing the air switch from the back of the wiper switch and devising a mounting for a micro-switch to trigger the electric pump. I studied lots of different micro switches before settling on a "lever type" as this requires the least pressure to make it work and is activated easily by the slim plastic rod on the back of the washer button. So I made adjustable aluminium mounting brackets and mounted the switch and it works perfectly.<br /><br /></span><p></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3YCAI74DCe05hoO94LqziRMyd13aQf9LuuFgiKf7HqP669s13aWGZp1ETZZQE9uXEr6WBHxOnHpkLptf_BiKh7_EpoMiP_sFO2zfpaPsBsMWCFzRpJH8JDwX27ExWDGC7Ul732NOjndGsX1lTwyhctB8W5y8Plng0GsAtCE8PKJlds_LFovkGrK_EmXRn/s4032/IMG_5609.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3YCAI74DCe05hoO94LqziRMyd13aQf9LuuFgiKf7HqP669s13aWGZp1ETZZQE9uXEr6WBHxOnHpkLptf_BiKh7_EpoMiP_sFO2zfpaPsBsMWCFzRpJH8JDwX27ExWDGC7Ul732NOjndGsX1lTwyhctB8W5y8Plng0GsAtCE8PKJlds_LFovkGrK_EmXRn/s320/IMG_5609.JPG" width="320" /></span></a></div><span style="font-family: arial; font-size: medium;">Now to mount the Light switch and wiper switch in the dashboard. I had to make a tool to tighten the switch bezels, as they only have two small chamfered slots in them. This I made with a small tube, filed to leave just two small protruding pegs on the end that fit the slots and a long machine screw through the other end of the tube to form a "T" handle. </span><p></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCK5nEErxtFP7RD_x4pKKkoDPnkMQ9pTEF4xZXL7nj2B2CDMI6mEkJmb_N-PCsbfWmiGhGxOip69hPtPe_cUP9TVklu7w68fIFndJFyakxaJxCqacTEWsq7WTohcK5-crL1rluNnCh0VSVWmsyDfPqIVc-QfaxYRhwiCvBqa_AaYxTE7G7NMnmyPdqLb_X/s4032/IMG_5611.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCK5nEErxtFP7RD_x4pKKkoDPnkMQ9pTEF4xZXL7nj2B2CDMI6mEkJmb_N-PCsbfWmiGhGxOip69hPtPe_cUP9TVklu7w68fIFndJFyakxaJxCqacTEWsq7WTohcK5-crL1rluNnCh0VSVWmsyDfPqIVc-QfaxYRhwiCvBqa_AaYxTE7G7NMnmyPdqLb_X/s320/IMG_5611.JPG" width="240" /></span></a></div><span style="font-family: arial; font-size: medium;"><br />Now it's time to mount the washer bottle and true to form the old one leaked. So I had to buy a replacement and then drill it, through where the original pressure valve fitted, to allow the water pipe to enter it. It could then be piped to the pump and up to the new jet at the windscreen. Time for a test. I connected the battery and pushed the button. The pump whirled and water shot out of the jets, straight into my face, as I still haven't fitted the windscreen!!! </span><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaS2s7i2EdAWVbTF71mUaoVTA2LW5q70qpOpBDmHy0mPoLY4SBmMmoWvtxIzqYkHH1Eg3IwbLeUyL9bk_6MMx_fPsp3NWn7eBlZ5ZUfawexMiA-R-ziR9H_ZUx96W6zwp_VUgIxD7Wia-qzwFijnimD6_3IVLC68FyIs6coUIcJYRXtKmmFESM6xif3vem/s4032/IMG_5613.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaS2s7i2EdAWVbTF71mUaoVTA2LW5q70qpOpBDmHy0mPoLY4SBmMmoWvtxIzqYkHH1Eg3IwbLeUyL9bk_6MMx_fPsp3NWn7eBlZ5ZUfawexMiA-R-ziR9H_ZUx96W6zwp_VUgIxD7Wia-qzwFijnimD6_3IVLC68FyIs6coUIcJYRXtKmmFESM6xif3vem/s320/IMG_5613.JPG" width="320" /></a></div>The final test was to fit the spare wheel and check that both the horns and the washer bottle all clear the wheel and that there was still room for the jack. As you can see, everything fits great.</span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /> <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw8Ujd275GBGdho2uQ2kUyxC7IIisBzOXYefy1HT4Lamx9nBZq-eJ6Yi64cYOCNvF8r0kUbvjtqNfDdp2csN-T7kdgmVXAC2iJv7qJMkqJOe3UMKey91zhfr8qhyphenhyphenhLrq4LF9o_AV2Fx3lRnSMQzvKtf0fjvkDK1KbDpUWwADLY-8Na-FfZ6xbVv5GklfS_/s4032/IMG_E5692.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw8Ujd275GBGdho2uQ2kUyxC7IIisBzOXYefy1HT4Lamx9nBZq-eJ6Yi64cYOCNvF8r0kUbvjtqNfDdp2csN-T7kdgmVXAC2iJv7qJMkqJOe3UMKey91zhfr8qhyphenhyphenhLrq4LF9o_AV2Fx3lRnSMQzvKtf0fjvkDK1KbDpUWwADLY-8Na-FfZ6xbVv5GklfS_/s320/IMG_E5692.JPG" width="320" /></a></div>It was at this point that I was thinking about the original wiring and it occurred to me that the main positive cable, which is connected to the starter motor and travels the full length of the car to feed the fuse box, carries all the current for the car's electrics but is not fused in any way. If that wire should ever short to earth then the cable could catch fire. My original idea was to fit an in-line fuse but after investigating I came up with a much better solution. By wiring the cable back to the battery area, I could fit a 60A breaker that would protect the car and be easily reset once the fault was found. So here it is:-</span><p></p></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinkkG3JCYL1hFkPBdD9PpjUDDEx4okO6SyZlGDRXlZJO0m9UUtpyQqS-FtLo18Wy2m3qK87dkORLECsB6NverKm-bAvqHe-LPWPEEFjLU6vBHW4sjnaB6Oy2MhJFR11dpmfgfmDqUn6ZqUL4lBTwvquVMZefUdyFb3sAnSVC5iiImGUpELFv_8DxB_3OLH/s4032/IMG_5661.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-size: medium;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinkkG3JCYL1hFkPBdD9PpjUDDEx4okO6SyZlGDRXlZJO0m9UUtpyQqS-FtLo18Wy2m3qK87dkORLECsB6NverKm-bAvqHe-LPWPEEFjLU6vBHW4sjnaB6Oy2MhJFR11dpmfgfmDqUn6ZqUL4lBTwvquVMZefUdyFb3sAnSVC5iiImGUpELFv_8DxB_3OLH/s320/IMG_5661.JPG" width="320" /></span></a></div><span style="font-size: medium;"><span style="font-family: arial;">I now decided that it was time to fit the rear window. Now this has been stored safely in the loft since the car was stripped. It was in really bad condition with 50 years of mould and dirt ingrained on the glass. I tried widow cleaning fluid and it didn't touch it. So I went for paint thinners and that didn't touch it either. So I finally used Nitromores paint stripper, which finally did the job. I felt that I was lucky as all of the dirt was on the outside of the glass so I did not have to damage the heated elements on the inside. The next job was to look at the mountings. <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8GrMG_OcxTW65zWIJMjCLWqUFJi3UhbF9eeFUjp7fqWGIcdsM0WISYOh34oFosYYK2ab14RYSf5B1g0vIrud9rI4pUh2mMf95XQ1-qIVsUpUQc8ZD4MkKfYS-yROx_UTzOMQR8CeKReTQFRWVWV2Y234RIjIN_QAhO7toj2A0LCruP7uKE4am31XNdRIo/s4032/IMG_5670.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8GrMG_OcxTW65zWIJMjCLWqUFJi3UhbF9eeFUjp7fqWGIcdsM0WISYOh34oFosYYK2ab14RYSf5B1g0vIrud9rI4pUh2mMf95XQ1-qIVsUpUQc8ZD4MkKfYS-yROx_UTzOMQR8CeKReTQFRWVWV2Y234RIjIN_QAhO7toj2A0LCruP7uKE4am31XNdRIo/s320/IMG_5670.JPG" width="240" /></a></div><br /></span><span style="font-family: arial;">The hinges</span><span style="font-family: arial;"> were great and just needed cleaning and painting, but the mountings that bolt the hinges to the glass were missing and had been replaced by rusty nuts and bolts. I decided to make new ones and set about the task on the lathe. So with two new aluminium mushrooms, new rubbers and stainless screws on the inside, the hinges could be mounted on the glass. </span></span><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6y-H8536m_1ilzMcmrLb7byfGYe2BIpY8AGHLZPvXDN32ToB9Wb8gYRn5IEULAh5Kom2Lqy3Jj3dzBOB4PaXIl4lYFLcXGWRI-vmLbOyQ_ws8XcjWlba7atmRdC6annkgGuy6q7EclcOonNhd9vK9fag9emZrg-qfGSolZUTom0qd15N1_alwfE7AXAMw/s4032/IMG_5671.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6y-H8536m_1ilzMcmrLb7byfGYe2BIpY8AGHLZPvXDN32ToB9Wb8gYRn5IEULAh5Kom2Lqy3Jj3dzBOB4PaXIl4lYFLcXGWRI-vmLbOyQ_ws8XcjWlba7atmRdC6annkgGuy6q7EclcOonNhd9vK9fag9emZrg-qfGSolZUTom0qd15N1_alwfE7AXAMw/s320/IMG_5671.JPG" width="240" /></span></a></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><span style="font-family: arial; font-size: medium;">The next task was to look at the catch for the rear window and it had a problem.. One of the pivoting legs was broken in half. Being cast, this could not be repaired and so it was either buy a new, very expensive, catch or try to fix it. <br /></span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaxehk5qCu-JxQQ_qL6nKFC7RQx_O7820oLf8K_TlJR45Pv-S1uK9Wh7c85jh_X-W8mAbEq3k8LXjdkMuu2GGa63-0g5sLMfTU_1AzrpnDe8zvULHoND71gvMgRnYyl2qD06RtAmckWGjZmrmvW79a6SDCmZNpGogxK7SmByHwUthDtYZfaYmOrCriUN1f/s4032/IMG_5681.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaxehk5qCu-JxQQ_qL6nKFC7RQx_O7820oLf8K_TlJR45Pv-S1uK9Wh7c85jh_X-W8mAbEq3k8LXjdkMuu2GGa63-0g5sLMfTU_1AzrpnDe8zvULHoND71gvMgRnYyl2qD06RtAmckWGjZmrmvW79a6SDCmZNpGogxK7SmByHwUthDtYZfaYmOrCriUN1f/s320/IMG_5681.JPG" width="240" /></span></a></div><span style="font-family: arial; font-size: medium;"><br /><br /></span><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;">I went for the second option and made a new pivot leg from thick aluminium and the drilled and tapped the body and used cap screws to fix it back together. </span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA6GECmVJxaW2CTBJEWO2Sy7zxA439-XhOm0yzxWpu2tHPtFglPVw14YTU1memgD_d3ZAEYwCPVYR7qyiri5HgKv4sEo1AjvAiGNqzagWiK9OtGEeiMlvJD5NC635WCBURWOspj21vfyLvyzv0cqOT5WPG_HtebZWTQoJOW1A4lLXlsDh7UvSC_Kh_G6e7/s4032/IMG_5684.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-size: medium;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA6GECmVJxaW2CTBJEWO2Sy7zxA439-XhOm0yzxWpu2tHPtFglPVw14YTU1memgD_d3ZAEYwCPVYR7qyiri5HgKv4sEo1AjvAiGNqzagWiK9OtGEeiMlvJD5NC635WCBURWOspj21vfyLvyzv0cqOT5WPG_HtebZWTQoJOW1A4lLXlsDh7UvSC_Kh_G6e7/s320/IMG_5684.JPG" width="320" /></span></a></div><span style="font-size: medium;"><br /><span style="font-family: arial;">Well, at last, the rear window could be fitted and wired and guess what? The heated screen didn't work. So I had to remove it again and investigate the element. It turned out to have 14 breaks in it. I went on the internet and searched for a repair kit, which involves conductive paint. I bought 2 kits and set about the repair. Each break was located and painted and then left 24 hours to dry and then re-tested. I had to do this three times before finally having all elements working and being able to re-fit the window.</span></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;">Well at this point I just wanted to add a bit of trim. Now I had the original Karmann Ghia badge, but it had a really deep groove scored into it in the black area. So I set about filling the groove with black gloss paint. Day after day I added more paint and left it to dry until it was finally filled. I then rubbed it down until smooth and then polished it. And here is the finished result.</span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQPQqrwiT_XGVbxL8dTA8sM4wMaIkDqOC0dSncRtN11hx-62QOTV2jS6uoKgzVTErEcJLD7W5Ttfo4UP9IYCmoIn99LLPEjp9lFN64apTn4GPeD69GnNCGjKFnLHUTGYQYc-wRXloK88lIUG6clFwclFA7TCvPrlMH2cEnk_KCK06BAj2aLaLrE70FezmH/s4032/IMG_5696.JPG" style="margin-left: 1em; margin-right: 1em;"><span style="font-size: medium;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQPQqrwiT_XGVbxL8dTA8sM4wMaIkDqOC0dSncRtN11hx-62QOTV2jS6uoKgzVTErEcJLD7W5Ttfo4UP9IYCmoIn99LLPEjp9lFN64apTn4GPeD69GnNCGjKFnLHUTGYQYc-wRXloK88lIUG6clFwclFA7TCvPrlMH2cEnk_KCK06BAj2aLaLrE70FezmH/w400-h300/IMG_5696.JPG" width="400" /></span></a></div><div><span style="font-size: medium;"><br /></span></div><span style="font-family: arial; font-size: medium;">On the next episode the hood frame is fitted and the dashboard assembled</span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial;"><span style="font-size: medium;"><span style="background-color: white; color: #222222; line-height: 18.48px;">Copyright 15.10.23 all rights reserved.</span><br style="background-color: white; color: #222222; line-height: 18.48px;" /><br style="background-color: white; color: #222222; line-height: 18.48px;" /><span style="background-color: white; color: #222222; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; line-height: 18.48px;" /><b style="background-color: white; color: #222222; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html" style="background-color: white; color: #2288bb; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; line-height: 18.48px;" /><br style="background-color: white; color: #222222; line-height: 18.48px;" /><b style="background-color: white; color: #222222; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #2288bb; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; line-height: 18.48px;" /><br style="background-color: white; color: #222222; line-height: 18.48px;" /><b style="background-color: white; color: #222222; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #2288bb; text-decoration-line: none;">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; line-height: 18.48px;" /><br style="background-color: white; color: #222222; line-height: 18.48px;" /><b style="background-color: white; color: #222222; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #2288bb; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a><br /></span><br /></span></div>Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-66189552527913706122023-10-15T05:08:00.004-07:002023-10-15T05:08:29.612-07:0024. Karmann Ghia Restoration - Lights & Bumpers<p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpA3NqSbPTX13J0Di7EBS7ESA3iPcyYNsUlFDxJzGvIaj0LZryivATvkLQgzbGlFiJY8XkUJMXXfsQE9jZoXiXR8te2-ItE_HhLrmSYFDzRJjkH07WhFNWq8_XXdPkPC748liKnRqdEEmlr5kU-tiPqohAZf0A0MW8fJv95EInQ0EeOtufYH5_0uNDaxvw/s4032/IMG_5542.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpA3NqSbPTX13J0Di7EBS7ESA3iPcyYNsUlFDxJzGvIaj0LZryivATvkLQgzbGlFiJY8XkUJMXXfsQE9jZoXiXR8te2-ItE_HhLrmSYFDzRJjkH07WhFNWq8_XXdPkPC748liKnRqdEEmlr5kU-tiPqohAZf0A0MW8fJv95EInQ0EeOtufYH5_0uNDaxvw/w400-h300/IMG_5542.JPG" width="400" /></a></div><br /><p></p><p></p><div class="separator" style="clear: both; text-align: right;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzSePWs0IO4zRlnSLOGBa45cqexCCDQhzuIIRZIbSGhbvDU_BotImeO6GHGFje_Q7UwSoAQFncljgtd1cvTbxLdsIwk9p7qTJQLggUNg5WaRmhZnPP8veC3Af4qKLx9rTZ37qnj6NCBxwQOGdV0cms1X8-1gt6oZOZCJzelhRnmxrcJ8GJj62lVjyW1JTb/s4032/IMG_5390.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzSePWs0IO4zRlnSLOGBa45cqexCCDQhzuIIRZIbSGhbvDU_BotImeO6GHGFje_Q7UwSoAQFncljgtd1cvTbxLdsIwk9p7qTJQLggUNg5WaRmhZnPP8veC3Af4qKLx9rTZ37qnj6NCBxwQOGdV0cms1X8-1gt6oZOZCJzelhRnmxrcJ8GJj62lVjyW1JTb/s320/IMG_5390.JPG" width="240" /></a></div><span style="font-family: arial;">Well while the car was away at the painters, I decided to order a new wiring loom and to my surprise I found that they were made just around the corner from my workshop. So now is the time to fit the new loom threading it from the engine compartment, over the inside left wheel arch into the back of the car and then along the sill and up under the dash board to the fuse box area. That done I could now start fitting the lights and I decided to start at the back, with the number plate light. Inspection of the reflectors revealed that they were in tact but the silvering had gone from them. I had heard of a chrome paint and felt that it may be worth having a go with it to restore the reflectors. So I bought some (which is quite expensive for a small pot) and to my surprise it worked well enough to make the reflectors usable.<br /></span><p></p><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: left;"><span style="text-align: left;">So now I could fit and wire the number <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZRT18-FPzAK0eCy96cS9cBsA9Y0fobl7N75TCB_58J4l7TM1EBwKlpbQZtRImPOOhs0AFzG0iGhTRnV2feaQuGxIqDjhYOhUnkUodMnMNz7DpCj6RB6sQHflXhsS68jrfo3n8dWm6ZdDdCiieEkLs-JlnOnxWvZxuVfUgpzKc3ole44_1o8WUmU0uYDOp/s4032/IMG-5453.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZRT18-FPzAK0eCy96cS9cBsA9Y0fobl7N75TCB_58J4l7TM1EBwKlpbQZtRImPOOhs0AFzG0iGhTRnV2feaQuGxIqDjhYOhUnkUodMnMNz7DpCj6RB6sQHflXhsS68jrfo3n8dWm6ZdDdCiieEkLs-JlnOnxWvZxuVfUgpzKc3ole44_1o8WUmU0uYDOp/s320/IMG-5453.jpg" width="320" /></a></div>plate light with </span>two new lenses and lamps and I couldn't resist fitting the Karmann Ghia badge on the engine compartment lid and it does look nice. So on to the rear lights. Both of the original lenses were cracked, so I had no choice but to buy new ones. The reflectors, again cleaned up nicely with the new paint-on chrome. However, when it came to fitting the lenses to the reflectors, I found that the lenses did not seat properly on the seals. They bottomed in the centre near the screws leaving an air gap at the top and bottom, which would let in the rain. So I had to set about the new lenses with a Dremel reshaping them until they fit correctly. </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">I this point I decided to fit the steering column to allow the wiring from the indicator arm to be connected. I had to dismantle the collapsible section of the column in order to pass the top <div class="separator" style="clear: both; text-align: right;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxJ77KACq2JdeeJZGdLn9jzj2UB6KwxAKv6IR6vZXWTCoD3i4wsK1TL5m63COklRBJEmnfAb7BweQqoaALgZXIzkN2l39SUWbDHot1ovd5dqSe6tu3jlU41nHckHoI4hIpnFgojH4e9x6gVAfW353K-vRiatFi728Tx8wxmXzR1IWiVp0Ccm6LcWgcfbaU/s4032/IMG_5484.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxJ77KACq2JdeeJZGdLn9jzj2UB6KwxAKv6IR6vZXWTCoD3i4wsK1TL5m63COklRBJEmnfAb7BweQqoaALgZXIzkN2l39SUWbDHot1ovd5dqSe6tu3jlU41nHckHoI4hIpnFgojH4e9x6gVAfW353K-vRiatFi728Tx8wxmXzR1IWiVp0Ccm6LcWgcfbaU/s320/IMG_5484.JPG" width="240" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXX2ldcPDjFtADDGDUFSMvO_t8mQ5LsuHiP1qjvFNaKeHGfkriSyw4Ju-yiX7_qfGuIaC7QKO3cIYkwqoZOPswaBb5KjlVjP2cBiQEziGK0MU6UzmzNn5uLoSHdGU4MRvfQckAhwN6h3rNZPSdLD6V4isxe-n6c_uiIDCqqwhRe7xWRPgI53WJQ0K3cFN_/s4032/IMG_5485.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXX2ldcPDjFtADDGDUFSMvO_t8mQ5LsuHiP1qjvFNaKeHGfkriSyw4Ju-yiX7_qfGuIaC7QKO3cIYkwqoZOPswaBb5KjlVjP2cBiQEziGK0MU6UzmzNn5uLoSHdGU4MRvfQckAhwN6h3rNZPSdLD6V4isxe-n6c_uiIDCqqwhRe7xWRPgI53WJQ0K3cFN_/s320/IMG_5485.JPG" width="240" /></a></div><br />section of the column up the tube, as it is too long once assembled to get up the tube without hitting the bodywork. However, once I figured out how it went together it wasn't too difficult and, once in place, the indicator switch module could be fitted. </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Now on to the front indicators. I managed to <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieEFrfTS1H-2Vy7pggKaP2iFFHQMaMylITAhv7mtgPunf-0tIGkRIgeU7V8JRnqfewDc_2pzzgaK5wYvC_I4TmbczDh0k9RBGoN2xsa70Q4HZsz5Np09ghWyYpBjvuVDYxoM20k9aUs8r8iuGAP4dovxv5k9UOAjB5TuCv37RJx9wDQoEH9zbZ4rQJOrxX/s4032/IMG-5449.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieEFrfTS1H-2Vy7pggKaP2iFFHQMaMylITAhv7mtgPunf-0tIGkRIgeU7V8JRnqfewDc_2pzzgaK5wYvC_I4TmbczDh0k9RBGoN2xsa70Q4HZsz5Np09ghWyYpBjvuVDYxoM20k9aUs8r8iuGAP4dovxv5k9UOAjB5TuCv37RJx9wDQoEH9zbZ4rQJOrxX/s320/IMG-5449.jpg" width="320" /></a></div>pick up new lenses, rubbers and the right hand reflector. But no one had a left hand reflector. So I had to revert to renovating the old reflector including new mounting studs and again chrome painting the reflectors. Fitting the right indicator was easy and it went on with no trouble. But the left hand one was a different story. Having had replacement metalwork in that area the reflector in it's rubber just would not go in the hole and in the end I had to cut away metalwork until it would fit. That lens and reflector was on and off 8 times but eventually it fit.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Now for the bumpers. As you read earlier, <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3CKkvQhGCMF2OM6TA_qAispbpH4IPC-RLrJ4ORqtMkByfkbgzCFqNTEfuk_DxXQiUl2ci-2yZJ0EnKXLSNEmVi2YFRiAgU9VvgB3Sr-_6jiY1rZcp-gbAN6agYJ2LqJfSjs3Kljmdg9GcE4C4vFQwW0Z0Mo6jLTprx96QIREhRQsoFtbY0kfFQGrD8jlf/s4032/IMG_5543.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3CKkvQhGCMF2OM6TA_qAispbpH4IPC-RLrJ4ORqtMkByfkbgzCFqNTEfuk_DxXQiUl2ci-2yZJ0EnKXLSNEmVi2YFRiAgU9VvgB3Sr-_6jiY1rZcp-gbAN6agYJ2LqJfSjs3Kljmdg9GcE4C4vFQwW0Z0Mo6jLTprx96QIREhRQsoFtbY0kfFQGrD8jlf/s320/IMG_5543.JPG" width="320" /></a></div>I had already assembled and fitted them, before the car was painted. So now the trick was to fit them again without scratching the nice new paintwork. I first covered the corners of the wings with duct tape. I then loosened all the the bolts holding the sections of the bumpers together and then passed the two bumper irons through new rubbers and into the mountings in the wheel well and bolted them into place. Now for the difficult bit, I had to fit the new aluminium spacers on the ends of the bumper blades along with rubber washers between them and the bodywork. Once they were all in place, I could then tighten all of the fixing bolts and then remove the protective tape.<div class="separator" style="clear: both; text-align: center;"><br /></div></div><div class="separator" style="clear: both; text-align: left;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNLQjFMKV-Pg4t8AfCD9iaQtJHgWiOWC7Gzk3Z494oF4pQf8epbP5m6r2TEwVrPXtOwxTby6oc4-k41xuvoCkOpLvUFak7UeIjraF3ir__BN1RLlUvgWpAuCVyDeJk5P-NvpagaRpTDFRZcXbCOVZk0GgrGOd5jd1XgensGxlUcDc114zObrTZ3hbRvLQ7/s4032/IMG_5545.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNLQjFMKV-Pg4t8AfCD9iaQtJHgWiOWC7Gzk3Z494oF4pQf8epbP5m6r2TEwVrPXtOwxTby6oc4-k41xuvoCkOpLvUFak7UeIjraF3ir__BN1RLlUvgWpAuCVyDeJk5P-NvpagaRpTDFRZcXbCOVZk0GgrGOd5jd1XgensGxlUcDc114zObrTZ3hbRvLQ7/s320/IMG_5545.JPG" width="240" /></a></div>Now to repeat the procedure with the rear bumper. Not quite so difficult this time, having worked out how to do it at the front. Along with the bumper I could now fit the rear reflectors. Again I had to replace the fixing studs, which had broken off during removal. Unfortunately one of the side red reflectors was broken and so I had to order a new one and then figure out how to fit it. But they are on and look great.</div><div class="separator" style="clear: both; text-align: left;">Finally it's time to fit the <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNDDYVhN0aBrcg4mXi-YITDmGzwXWNtbeBfLMo1ZIXQ_cXS05yN-i-NnYQMxiuPiWw9KotWplEnOb-gKf99so79vWqs0uGqdNL5JrXT7H5n7nZeMGNAqJFfHVt1-mKixBOt_ysfHu74Ez_1qHDZsv0iEmFvwuh5r0u7cvq-ygzzP80O1HkNePkSCAd8wSt/s4032/IMG_5590.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNDDYVhN0aBrcg4mXi-YITDmGzwXWNtbeBfLMo1ZIXQ_cXS05yN-i-NnYQMxiuPiWw9KotWplEnOb-gKf99so79vWqs0uGqdNL5JrXT7H5n7nZeMGNAqJFfHVt1-mKixBOt_ysfHu74Ez_1qHDZsv0iEmFvwuh5r0u7cvq-ygzzP80O1HkNePkSCAd8wSt/s320/IMG_5590.JPG" width="320" /></a></div>new headlights. It took a long time to renovate the baskets that hold the sealed beam units. Each had to be disassembled and resprayed and fitted with new springs, so that the headlights could be adjusted correctly. Then with all new rubber seals and the rims re-polished, the headlights could be fitted. All of these lights could now be wired back to the fuse box. When fitting the fuse box I found that the plastic fixing tabs were broken and it would not hold in place and so I spent a couple of hours making new secure mountings. It's going to be a long slow process wiring the car. I've downloaded several wiring diagrams but as I've decided not to include the diagnostic socket, (Which does virtually nothing), none of the diagrams exactly match the wiring. But I'll get there.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">On the next blog I start wiring the dash board.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><span style="background-color: white; color: #222222; line-height: 18.48px;">Copyright 15.10.23 all rights reserved.</span><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html" style="background-color: white; color: #2288bb; font-size: 13.2px; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #2288bb; font-size: 13.2px; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #2288bb; font-size: 13.2px; text-decoration-line: none;">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-size: 13.2px; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #2288bb; font-size: 13.2px; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div></span><p><span style="font-family: arial;"></span></p>Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com1tag:blogger.com,1999:blog-738504069791591427.post-39824661876313039572023-06-18T03:53:00.002-07:002023-06-27T02:15:43.061-07:0023. Kermann Ghia Restoration - The Rebuild Begins<div class="separator" style="clear: both;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo6lHBWgklZ8kcJxX0bZaUvXskjBVwpQqSSoHYLm5z86YmRAyEdgjMy5o9c6LQ_A2OeTU0RmuuK5vayzB08QPJP5O4CRE66gOFbVgQoH46vDJoRrR--pLlbq3BNK7pXW1CVo21CLxEg7PsHYGc3dz1Cfv_kSpFNYYHtLI1wiBuctlX_0aYniceCjZd1Q/s4032/IMG_5283.JPG" style="display: block; padding: 1em 0px; text-align: center;"><img alt="" border="0" data-original-height="4032" data-original-width="3024" height="600" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo6lHBWgklZ8kcJxX0bZaUvXskjBVwpQqSSoHYLm5z86YmRAyEdgjMy5o9c6LQ_A2OeTU0RmuuK5vayzB08QPJP5O4CRE66gOFbVgQoH46vDJoRrR--pLlbq3BNK7pXW1CVo21CLxEg7PsHYGc3dz1Cfv_kSpFNYYHtLI1wiBuctlX_0aYniceCjZd1Q/s600/IMG_5283.JPG" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo6lHBWgklZ8kcJxX0bZaUvXskjBVwpQqSSoHYLm5z86YmRAyEdgjMy5o9c6LQ_A2OeTU0RmuuK5vayzB08QPJP5O4CRE66gOFbVgQoH46vDJoRrR--pLlbq3BNK7pXW1CVo21CLxEg7PsHYGc3dz1Cfv_kSpFNYYHtLI1wiBuctlX_0aYniceCjZd1Q/s4032/IMG_5283.JPG" style="display: block; padding: 1em 0px; text-align: center;"><br /></a><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo6lHBWgklZ8kcJxX0bZaUvXskjBVwpQqSSoHYLm5z86YmRAyEdgjMy5o9c6LQ_A2OeTU0RmuuK5vayzB08QPJP5O4CRE66gOFbVgQoH46vDJoRrR--pLlbq3BNK7pXW1CVo21CLxEg7PsHYGc3dz1Cfv_kSpFNYYHtLI1wiBuctlX_0aYniceCjZd1Q/s4032/IMG_5283.JPG" style="display: block; padding: 1em 0px; text-align: center;"></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjN5AUVLWX7B_iXRr6Dj3UL76VSiiaElMAwdfB7CJsbxd7nO8gzn_8R5r9I4m0OuvlBzX3HSBm1mph_wyunFcxF_vrS6uR4bkKUpAN7hMKOH7noTtQ0nK5aKbxMpIiPan9XoDn2i6hu-Kx9FuPS0sThkRpdJSjjct794imxs5Q7UNeBVP1gcb5oroy-pA/s4032/IMG_5298.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjN5AUVLWX7B_iXRr6Dj3UL76VSiiaElMAwdfB7CJsbxd7nO8gzn_8R5r9I4m0OuvlBzX3HSBm1mph_wyunFcxF_vrS6uR4bkKUpAN7hMKOH7noTtQ0nK5aKbxMpIiPan9XoDn2i6hu-Kx9FuPS0sThkRpdJSjjct794imxs5Q7UNeBVP1gcb5oroy-pA/s320/IMG_5298.JPG" width="240" /></a></div><span style="font-family: arial; font-size: medium;">So with the body back in my workshop and at last with it's paint in place, it's time to start the slow rebuild. Well there were a couple of jobs to do before mating the body back with the chassis. The first job was to wrap the heater tubes under the back seat. It is much easier to reach these tubes before the body is mounted on the chassis. These tubes are perforated to act as noise reduction and need to be wrapped with insulating material. I had saved the old wrapping, but now they are nowhere to be found. So I decided to find some suitable pipe lagging material to do the job. Two different diameter of lagging were used combined with adhesive aluminium tape and cable ties. As you can see this was successful.</span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9NY-UX93jvCHX32uc0iX7xyf4k0hsVebvwmqnRdJvIQ8Fuy85rTgI9svXjs6rCcM0g2Q9zvKJbEQyGhEujA9wurPETstZ7DiClbhQs2YbwC8b7xhM3N4GcZ7UDXaJTEuXk8Y6QWf3tG51m6EDwS1Uj5FUrA0SoivUimAFFdeJhSLWgTAZKnCIm8kVuQ/s4032/IMG_5300.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9NY-UX93jvCHX32uc0iX7xyf4k0hsVebvwmqnRdJvIQ8Fuy85rTgI9svXjs6rCcM0g2Q9zvKJbEQyGhEujA9wurPETstZ7DiClbhQs2YbwC8b7xhM3N4GcZ7UDXaJTEuXk8Y6QWf3tG51m6EDwS1Uj5FUrA0SoivUimAFFdeJhSLWgTAZKnCIm8kVuQ/s320/IMG_5300.JPG" width="240" /></a></div><span style="font-family: arial; font-size: medium;">The next job was to connect the bonnet springs to the hinges, as the painter had removed the bonnet to paint it and then could not get the springs back on. These springs are very strong, and after trying several ways of levering the springs with no success, I finally decided to pass a loop of wire through the speedo hole in the dash board, through the loop in the spring and fit a large wooden handle through the loop in the wire inside the car. I could then pull on the handle and pull the spring back towards the dashboard until it snapped into place.<br /></span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHBreSD9Qt1mqWpviw790i04lC4UBdR1jYkmD6Cx3rNHSa2eMsw_q7OGxOCeXyXpTPe2B5VtGKutwI66O90lPgDfuQJPLAMJfoirDDTrgovxQC9L3R_gHkKBmJ_nGmBNiVnfc6RURcrnrw7VUfCoYUch1Tk2HG7wlLlCH-kSQ6s3MB-RcrLRsNptZF6A/s4032/IMG_5303.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHBreSD9Qt1mqWpviw790i04lC4UBdR1jYkmD6Cx3rNHSa2eMsw_q7OGxOCeXyXpTPe2B5VtGKutwI66O90lPgDfuQJPLAMJfoirDDTrgovxQC9L3R_gHkKBmJ_nGmBNiVnfc6RURcrnrw7VUfCoYUch1Tk2HG7wlLlCH-kSQ6s3MB-RcrLRsNptZF6A/s320/IMG_5303.JPG" width="320" /></a></div><span style="font-family: arial; font-size: medium;">The next job was easy and that required the fitting of the two heater tube extensions. These tubes just required cleaning up and then mounting through the bulkhead to the, now insulated, heater tubes.<br /></span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg710NOSWQqcUogbsbja7OM2k6721iTlHoh6tt2e82ScgHRE-tsDcJL_uEi9iv3Br1fg75AcnYmkPX3hbLEVyOZCikccEBlvthvtolr79bSJnTdvbgoRMkuWUv3TY01JCbG6SDba1z7cMhA8gSYXNVvbi6MEMwg3n-OSvdhZWWxTLeALwcm36LQhvQc3w/s4032/IMG_5305.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg710NOSWQqcUogbsbja7OM2k6721iTlHoh6tt2e82ScgHRE-tsDcJL_uEi9iv3Br1fg75AcnYmkPX3hbLEVyOZCikccEBlvthvtolr79bSJnTdvbgoRMkuWUv3TY01JCbG6SDba1z7cMhA8gSYXNVvbi6MEMwg3n-OSvdhZWWxTLeALwcm36LQhvQc3w/s320/IMG_5305.JPG" width="240" /></a></div><span style="font-family: arial; font-size: medium;">It was now time to prepare the chassis and body to be reunited. I first removed the wheels from the chassis and put the chassis on castors, so that I could position it correctly under the body. I then put a bead of sealant all around the rubber seal on the chassis and then, using two bars under the wheel arches, I slowly lowered the body down on the lift, adjusting the position of the chassis as I went, until the two came together. The next job was to bolt the two together and this required every bolt hole being re-tapped with a 8mm tap. I didn't count them, but I guess there were about 40 of them. I then cleaned all of the clamping plates and used new stainless steel bolts. </span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ9U9b8tepwcP7INuVzFX3uRHqOsYHczV5dZ0s_iGCAMPd6s0RZoq8Lr62Y1sz1BSDMfSnkEguxsEdC-xWB1NVQgoF3VNVk6SIuny-xgF9mkOCtPE9ZrsTHPaKCr_DSaosvLAUo03KGQxJ9afYRM4M_Nbjj27GD540ydaEkapZ5Nq5OwMSOYZnl64A3Q/s4032/IMG_5311.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ9U9b8tepwcP7INuVzFX3uRHqOsYHczV5dZ0s_iGCAMPd6s0RZoq8Lr62Y1sz1BSDMfSnkEguxsEdC-xWB1NVQgoF3VNVk6SIuny-xgF9mkOCtPE9ZrsTHPaKCr_DSaosvLAUo03KGQxJ9afYRM4M_Nbjj27GD540ydaEkapZ5Nq5OwMSOYZnl64A3Q/s320/IMG_5311.JPG" width="240" /></a></div><span style="font-family: arial; font-size: medium;">The body mated down well onto the chassis and was bolted into place including the extra fixings to </span><span style="font-family: arial; font-size: medium;">the front</span><span style="font-family: arial; font-size: large;"> </span><span style="font-family: arial; font-size: medium;">axel. I noticed that the door gaps had widened and, after investigating, found that the reason was that I had tightened down the rear body fixings into the rear shock absorber cast mounting brackets and that these needed spacers. So I then had to make some thick spacers to fit between the body and the chassis brackets where the body bolts to the top of the rear shock absorber brackets and the door gaps closed to the correct spacing again.<br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuAUZvB1x5gH52TfCXzbv_shqzTA9Fe08pPxr64CCNi74kH6NJgBkOLEkdV9i0tAgVPyUXDJnrcGd7OvKWymSkgjhoZteDAJCqdfvKKbvb7UE-GxcnO8-d-J0FznsTP8Cl-67bzaZd5ns3QU3WfeB-Di5qulFgIwOB1OD4HtF1ooLjS-rEhG_rZBF9rw/s4032/IMG_5346.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuAUZvB1x5gH52TfCXzbv_shqzTA9Fe08pPxr64CCNi74kH6NJgBkOLEkdV9i0tAgVPyUXDJnrcGd7OvKWymSkgjhoZteDAJCqdfvKKbvb7UE-GxcnO8-d-J0FznsTP8Cl-67bzaZd5ns3QU3WfeB-Di5qulFgIwOB1OD4HtF1ooLjS-rEhG_rZBF9rw/s320/IMG_5346.JPG" width="320" /></a></div><span style="font-family: arial; font-size: medium;">I could now fit the wheels and the car is now sitting on it's own wheels for the first time in years. You will notice that I have fitted the old wheels while I work on it, keeping the new ones safe and clean until they are needed.;</span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4q_oEAAE1c-eXnpxgPkU2w2V2RwBCm5xmMHu0yZLR_AmerLep0hMGXUZnxRsxwMYcgrVC1fq-i2WjSo-NX5GYaehamjc2GRRbWmMFQu1-biirV-6rSdyk-mUJ4a2-u0S-wbVRem2P3haWRyGP05vztRQgv8ASHcqdRrAb8rJe3b99sCX07425AveXig/s4032/IMG_5378.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4q_oEAAE1c-eXnpxgPkU2w2V2RwBCm5xmMHu0yZLR_AmerLep0hMGXUZnxRsxwMYcgrVC1fq-i2WjSo-NX5GYaehamjc2GRRbWmMFQu1-biirV-6rSdyk-mUJ4a2-u0S-wbVRem2P3haWRyGP05vztRQgv8ASHcqdRrAb8rJe3b99sCX07425AveXig/s320/IMG_5378.JPG" width="240" /></a></div>It's time to fit the new glove box and the bonnet release cable. This is a relatively easy job, with just a central strap pulling the glove box into place. The pull cable could then be ran to the front of the car and connected to the bonnet catch. So I can now lock and open the bonnet by pulling the lever in the glove box. </span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUzVywVKgv-f5kU59SBJYuay0CJYycOQ6aLf8DpPHcqgI1dznSgxnWrH9SdLXvjL-_4u7ogqKtaqojj4QKSRiSIuijSeVGBlJqQGa3bWkO6SQnWhh7CvCvMaCI7sl7Gp9vOaWn_7IWnHkLZ33uQHzdzgBXhYVnY2IpRkcnGwCGimQaWQI49QLTSjbMLw/s4032/IMG_5380.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUzVywVKgv-f5kU59SBJYuay0CJYycOQ6aLf8DpPHcqgI1dznSgxnWrH9SdLXvjL-_4u7ogqKtaqojj4QKSRiSIuijSeVGBlJqQGa3bWkO6SQnWhh7CvCvMaCI7sl7Gp9vOaWn_7IWnHkLZ33uQHzdzgBXhYVnY2IpRkcnGwCGimQaWQI49QLTSjbMLw/s320/IMG_5380.JPG" width="240" /></span></a></div><span style="font-family: arial; font-size: medium;">Two more jobs, the hinges could be re-fitted, along with the glovebox lid and a new knob and catch.. It's great to be putting things back on at last!</span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyjYYNoYmsIZEErpxL8INEgJ0PLHFl2WvJ_Xy0aMmo9PxVnOsJMu6StwogeLPaPiU9Ia2PY7E5muaslK7cSJ-ulMfI9oJJW7HkvgpNhlrtS-MdQyAfqlvuDrk-XEJ5HsHY6uN52-yRNHz4_akiGyvYQb-x0PM9KaE9EImekdMuBIezUda9WYN7J7nO1Q/s4032/IMG_5382.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyjYYNoYmsIZEErpxL8INEgJ0PLHFl2WvJ_Xy0aMmo9PxVnOsJMu6StwogeLPaPiU9Ia2PY7E5muaslK7cSJ-ulMfI9oJJW7HkvgpNhlrtS-MdQyAfqlvuDrk-XEJ5HsHY6uN52-yRNHz4_akiGyvYQb-x0PM9KaE9EImekdMuBIezUda9WYN7J7nO1Q/s320/IMG_5382.JPG" width="320" /></span></a></div><span style="font-family: arial; font-size: medium;">The next job that I decided to do was to fit the nostril air intake grills at the front of the car. This involved finding the plastic baskets, that fit behind them. After cleaning and painting the baskets they fitted easily with self tapping screws. I then polished the grills and fitted new rubber seals around them and offered them into the holes. I then discovered that the fixing tags on the grills were broken and could not be used to fix the grills into place. So I had to carefully drill the sides of the grills and fix them by screwing self tapping screws through the sides and directly into the bodywork. However the result was excellent, you can't see the fixing screws and the grills fit perfectly.<br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs_e3Y-c2lfPbyHSK1jBaZNWPNMHR7Uq_A4sBcpD6eYPqzFk1hMOd0ktYJBCPFfZwwwczSwlrhKu9bNu4l1GHddpfE7zAcpTjC1MxiL1yWH3F8zGtxC9SGD2msLwWNfBGqztVTJLTABCVKJUQ4BtJpYC2tSSIkTy-3gkBCcdAGZsa5rPdLTk3NlORv0w/s4032/IMG_5389.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs_e3Y-c2lfPbyHSK1jBaZNWPNMHR7Uq_A4sBcpD6eYPqzFk1hMOd0ktYJBCPFfZwwwczSwlrhKu9bNu4l1GHddpfE7zAcpTjC1MxiL1yWH3F8zGtxC9SGD2msLwWNfBGqztVTJLTABCVKJUQ4BtJpYC2tSSIkTy-3gkBCcdAGZsa5rPdLTk3NlORv0w/s320/IMG_5389.JPG" width="320" /></span></a></div><span style="font-family: arial; font-size: medium;"><br />The next job was one that I had not been looking forward to. Fitting the engine compartment engine sealing rubbers. It would have been great to simply slide the rubbers into their grooves, but nothing is that easy. Even with lots of lubrication the rubbers simply would not slide. So In the end it was the very slow process of levering the rubber into it's groove with a screwdriver centimetre by centimetre. Total time three and a half hours! but they are in and no damage.</span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_jmMInP6JzYM3AXySggXA927gO1YrUXoTrx5qpVnwMMvGvwShOKFjrcrhW7F4ecI55s3IAQ3naFjmBdZhb5oRXnRfxAdiWYe9_k2GUaRJggl0N59J5Hy4HFukR-lU9kT7uG7I5tfNtaHQIWzzbV3SHyGxXEN-pqWuAy0ECGg33mBULe5twQv049HICg/s4032/IMG_5403.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_jmMInP6JzYM3AXySggXA927gO1YrUXoTrx5qpVnwMMvGvwShOKFjrcrhW7F4ecI55s3IAQ3naFjmBdZhb5oRXnRfxAdiWYe9_k2GUaRJggl0N59J5Hy4HFukR-lU9kT7uG7I5tfNtaHQIWzzbV3SHyGxXEN-pqWuAy0ECGg33mBULe5twQv049HICg/s320/IMG_5403.JPG" width="240" /></span></a></div><span style="font-family: arial; font-size: medium;">I now decided to fit the petrol filler flap release mechanism. I had bought the new complete cable and catch from VW Heritage two year earlier, when the old one had disintegrated during it's removal. Well now was the time to fit it. So I fitted it and pulled the handle to release the flap and it broke! I spoke to VW Heritage and they said, despite the item being new, I had bought it too long ago for it to be under warranty and that I would have to buy another one. I was determined not to buy another one and so set about making replacement parts on my lathe, which took most of the day, but eventually I managed to repair it.</span></div><div class="separator" style="clear: both;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWCtUcAC0BmjDlfKh9zBQpiYDLrfRq_Ro0V5rOe0Bv_UjumPGrgl6coL8zdfXcrmGYrUZ-I25whUfyrdQ1chbyjVhpRJE0fuj53VY5OXPu11YXRLU41dltdiakFbBctPQnEhORaiM2fmjrWT_-4wRtKHmqEIVNhksO34q-l9_Jz-ZHwXwcaNuHFGMC0w/s1706/IMG_5393a.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: arial; font-size: medium;"><img border="0" data-original-height="1706" data-original-width="1657" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWCtUcAC0BmjDlfKh9zBQpiYDLrfRq_Ro0V5rOe0Bv_UjumPGrgl6coL8zdfXcrmGYrUZ-I25whUfyrdQ1chbyjVhpRJE0fuj53VY5OXPu11YXRLU41dltdiakFbBctPQnEhORaiM2fmjrWT_-4wRtKHmqEIVNhksO34q-l9_Jz-ZHwXwcaNuHFGMC0w/s320/IMG_5393a.jpg" width="311" /></span></a></div><span style="font-family: arial; font-size: medium;">Here you can see the cable fitted under the wing and the petrol filler flap now flips up at the pull of the handle under the dash board.</span></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial;">Lot's more to come, as the car slowly comes together.</span></div><div class="separator" style="clear: both;"><span style="background-color: white; color: #222222; font-family: arial; font-size: medium; line-height: 18.48px;">Copyright 18.06.23 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: arial; font-size: medium; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html" style="background-color: white; color: #2288bb; font-family: arial; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #2288bb; font-family: arial; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #2288bb; font-family: arial; text-decoration-line: none;">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: arial; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #2288bb; font-family: arial; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span></div><div class="separator" style="clear: both;"></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial;"><br /></span><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div><div class="separator" style="clear: both;"><span style="font-family: arial; font-size: medium;"><br /></span></div>Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-16207730592544572712022-11-16T06:06:00.001-08:002022-11-16T06:15:34.481-08:0022. Karmann Ghia Restoration - Paint<p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsku29iJAXAZtJ9p9kEo3e3BzjHGPysIwAaFXnD8ZTJXe7ZmsW8Rd7lgZIofpCgdc9JVpRmtrN-qUHlXNip-_ourtD3iwa45ES0_eTJw2rhkbaMhbQ_koKt_mbRCW8UH1_mmxO02Be9zWVap-LZnd6VBuonPJ6c0LPrNK4JpMQZ_jA2nLbVx84MBS3yg/s4032/IMG_5079.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsku29iJAXAZtJ9p9kEo3e3BzjHGPysIwAaFXnD8ZTJXe7ZmsW8Rd7lgZIofpCgdc9JVpRmtrN-qUHlXNip-_ourtD3iwa45ES0_eTJw2rhkbaMhbQ_koKt_mbRCW8UH1_mmxO02Be9zWVap-LZnd6VBuonPJ6c0LPrNK4JpMQZ_jA2nLbVx84MBS3yg/w640-h480/IMG_5079.JPG" width="640" /></a></div><br /><span style="font-family: arial; font-size: medium;"><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZyZT0KCzIFK89omfIH-IZd0cf-3L-VN_Tlzxlys5K4OeGZi5GwPadMMrjrU1OQsZ4_ZTCX66ZvMJ8xSyq_0BXGjuc7s3zRhES4cs7Shg1mkUwNk1vMMaydyu-y5HEXjQfBZ9ulOEQTWG6E-un5VUUPgmnS-IXW7od7iHGn9z2xtff9FcnJHSW6fE6nw/s4032/IMG_4868.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><br /><br /></a><span style="font-family: arial; font-size: medium;">Following my last blog, I decided that I had to put the body back on the chassis to ensure that the new wheels would fit under the wings, before I sent it off for painting. So I had to devise a way of lifting the body onto the chassis on my own. </span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaqlXpfhqf60jdabc4nwZpePfF0b59BJ6HhE3kFT2i7vu0nt9qgtSgkZ7a5MbKa84aLtHo7Brot8qjSSYdDcAGsDEAddzUPgTpLqAr9xJuBw3VSUfAQbgnHO9D6Oj51TuyP4c_IKD_SYHMT5Bnvzb9odUTwbLID2DzAOpv2bRvLnH5Ofg2LH3zW9bbjA/s4032/IMG_4868.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaqlXpfhqf60jdabc4nwZpePfF0b59BJ6HhE3kFT2i7vu0nt9qgtSgkZ7a5MbKa84aLtHo7Brot8qjSSYdDcAGsDEAddzUPgTpLqAr9xJuBw3VSUfAQbgnHO9D6Oj51TuyP4c_IKD_SYHMT5Bnvzb9odUTwbLID2DzAOpv2bRvLnH5Ofg2LH3zW9bbjA/s320/IMG_4868.JPG" width="320" /></a></div>The answer was to lift the body with my car lift, using poles across under the body and then position the chassis under the lift, put the chassis on castors and remove the wheels.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifngva_EhAQXb4EarICoJHoWns769XWYu2QLIe9hWXDTpPVpT2d8dGV3RHu6RH8JbNwUBxzqnrDkFv-NRpfa_ll-8ENXk-x9XHffCOhQwFvzOCBertIDPjQ0YK_rgZP6dgU1u86ndxEmPYHX5EnfuRcSW4W3m8IKlTZdyyVsGa-RxTsOlyfkNLBQ5aTA/s4032/IMG_4872.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifngva_EhAQXb4EarICoJHoWns769XWYu2QLIe9hWXDTpPVpT2d8dGV3RHu6RH8JbNwUBxzqnrDkFv-NRpfa_ll-8ENXk-x9XHffCOhQwFvzOCBertIDPjQ0YK_rgZP6dgU1u86ndxEmPYHX5EnfuRcSW4W3m8IKlTZdyyVsGa-RxTsOlyfkNLBQ5aTA/s320/IMG_4872.JPG" width="320" /></a></div><p></p><p><span style="font-family: arial; font-size: medium;">Now the chassis could be positioned in exactly the right place, using the stands on castors, and the body slowly lowered into position. </span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcfcXyvJY8xHsIbGRVa64iIP8sdoJ8oXcv0MI2Luz8C5Xs6nuC9zhkhDoeOSaVNPA9Ha5V7sLq2xgnM_oaU5dPnVgY2o7_cKbDxHqiBd7yrqaF_pv4iTZOXh4eSL14lezfWx-01eSlQku8B0V8CQnMcLlBTbE7XfaPM9vswSzeeDL93gSR6ZuWUaU_dA/s4032/IMG_4876.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcfcXyvJY8xHsIbGRVa64iIP8sdoJ8oXcv0MI2Luz8C5Xs6nuC9zhkhDoeOSaVNPA9Ha5V7sLq2xgnM_oaU5dPnVgY2o7_cKbDxHqiBd7yrqaF_pv4iTZOXh4eSL14lezfWx-01eSlQku8B0V8CQnMcLlBTbE7XfaPM9vswSzeeDL93gSR6ZuWUaU_dA/s320/IMG_4876.JPG" width="320" /></a></div><br /><span style="font-family: arial; font-size: medium;">Now with the body on the chassis, I could try fitting the new wheels and tyres and, at last, some good news. The wheels fit!! Brilliant. So now I can take the body off again, put it back on the rotating spits and get it off for painting. </span><p></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKn45Q71diuqKpRQ_SWvjamjfouCVxRa_651eilqhI75ILoxau-TcfpLZutwRpu8p_Rae_isBtw9xaCev3D8HefPiGoEEGvY5L05U9DkBeaWvYDYj4fQBRWeUl4g220Cif_uH8hT03cNF-LIpQpJWxsPpMu7EqVY6yPTxIN1ahwlA16p_ys5s0fPfHhQ/s4032/IMG_5066.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKn45Q71diuqKpRQ_SWvjamjfouCVxRa_651eilqhI75ILoxau-TcfpLZutwRpu8p_Rae_isBtw9xaCev3D8HefPiGoEEGvY5L05U9DkBeaWvYDYj4fQBRWeUl4g220Cif_uH8hT03cNF-LIpQpJWxsPpMu7EqVY6yPTxIN1ahwlA16p_ys5s0fPfHhQ/s320/IMG_5066.JPG" width="320" /></a></div>I decided to fit the bonnet and boot catches before sending the car away as they tend to fall open and hit the stands when the body is turned upside down. This posed two problems; The boot (engine cover) lid catch requires a pull wire to operate the catch and this was missing (The previous owner just had a bit of wire under the rear bumper to open the catch). I managed to buy a pull cable and knob but could not get any kind of mounting boss for it so I decided to make one. This worked and the engine cover lid can now be released by pulling the knob inside the car.<br /><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiaj1T3Bclkt0T1aoIiSCReV8hx3Al9s10R-eeyivsIytt43_P1BfLGOJFe_DPxFh1FLFeigq2tCX4wOVfjINIamf1hKKCfHcxxaGuIXRFllzzIAd8cHpvwXAk0_NCaWwke48t_KjBT2BqKhgEfUBYaRf8p0Q70sWQfnrTADnDXLN5InmQmYNz0hy5yQ/s4032/IMG_5161.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiaj1T3Bclkt0T1aoIiSCReV8hx3Al9s10R-eeyivsIytt43_P1BfLGOJFe_DPxFh1FLFeigq2tCX4wOVfjINIamf1hKKCfHcxxaGuIXRFllzzIAd8cHpvwXAk0_NCaWwke48t_KjBT2BqKhgEfUBYaRf8p0Q70sWQfnrTADnDXLN5InmQmYNz0hy5yQ/s320/IMG_5161.JPG" width="320" /></a></div>The front bonnet release posed another problem, as the bonnet release lever is mounted on the glove box and, as you can see, the glove box was beyond help. <p></p><p><br /></p><p><br /></p><p><br /></p><p><br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkNAfo_MsK1_MUasXhs3-Q1g1qnDeIQQOMJMqjdpDKlYiKezbqEpOmoZIkYckg1gQEEnnrRKZ1xjeL5jrBoW1IaWmIkQJoCvkrI9xkWNj5X0DauOWi8nZu6pxOLBpKhmpORWaADEMQdy0ZjHC-QNMMNEhfUL0rHLqC9iSA0S6eWeyMDNSNTlWJHD4SaA/s4032/IMG_5154.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkNAfo_MsK1_MUasXhs3-Q1g1qnDeIQQOMJMqjdpDKlYiKezbqEpOmoZIkYckg1gQEEnnrRKZ1xjeL5jrBoW1IaWmIkQJoCvkrI9xkWNj5X0DauOWi8nZu6pxOLBpKhmpORWaADEMQdy0ZjHC-QNMMNEhfUL0rHLqC9iSA0S6eWeyMDNSNTlWJHD4SaA/s320/IMG_5154.JPG" width="240" /></a></div>The answer was to buy a new plastic glove box and mount the original lever and cable onto it. As you can see, this was successful, but posed another problem. As the new glove box won't be fitted until after the body is painted, how can I provide a bonnet release to open the bonnet with no glove box fitted? The answer came to use the old wire from the engine cover release and mount it through a hole in the inner wing with a pull under the wheel arch. <br /><p></p><br /><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgC1ayJBPF-BnMN354vywJbtIYPj1V2K5Mp7h3_5HnQ4aUmQr2a9hoCSydCUQxUn7Bnexwtqp7s0g5Ge3NlzOjhT2B9zafgSscxT5j1uStIjCu7fECslq9FMYAjB1BxFFCqZ1a0c4WRE7fGIvVNp5SZT8rJkW-uhYW-aaA8mOqi3s-g8Jq7kn6vDrjOmA/s4032/IMG_4917.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgC1ayJBPF-BnMN354vywJbtIYPj1V2K5Mp7h3_5HnQ4aUmQr2a9hoCSydCUQxUn7Bnexwtqp7s0g5Ge3NlzOjhT2B9zafgSscxT5j1uStIjCu7fECslq9FMYAjB1BxFFCqZ1a0c4WRE7fGIvVNp5SZT8rJkW-uhYW-aaA8mOqi3s-g8Jq7kn6vDrjOmA/s320/IMG_4917.JPG" width="240" /></a></div><p></p><p>So the Karmann Ghia body finally went off for paint in February 2022 and that gave me the opportunity to do some other small jobs ready for when it returns. </p><p>The first was the seats. I wanted to fit them to the rails on the chassis and make sure that they slide and adjust correctly. Well this was great and they slid on quite easily and adjusted fine. However I then noticed that the two black plastic kick guards on the bottom of the seats were both broken. <br /></p><p><br /></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5gVfNNUxO8NC5kBllgSPNlIJ7karX0QDxM-CVENxc1jmlz-vjY7YKJ2I6HkW39ECnBFP2Sxk5B9ggCaFR0f23xEi2NcNhfyz9-V_8hHhYfkuizLPngGp7DFgk6GJM_h6bmBvB6faADFeefG9hwZrNJ_Ayu5z2YWYDgcLeh8FDN3wiQOOLT3eknEM4_A/s4032/IMG_4923.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5gVfNNUxO8NC5kBllgSPNlIJ7karX0QDxM-CVENxc1jmlz-vjY7YKJ2I6HkW39ECnBFP2Sxk5B9ggCaFR0f23xEi2NcNhfyz9-V_8hHhYfkuizLPngGp7DFgk6GJM_h6bmBvB6faADFeefG9hwZrNJ_Ayu5z2YWYDgcLeh8FDN3wiQOOLT3eknEM4_A/s320/IMG_4923.JPG" width="320" /></a></div><br /><p>So I tried to buy some new ones with no success, I looked on all the web sites world wide, but no one had any. So I decided to make some out of aluminium.</p><p><br /></p><p><br /></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpPIw5nfwJZE4-K-XIwZxBUgQdSk8hoRjzdxAwVyK5fRsPiAENkALSHGPZ-Xj3ul44DKA9-fuyNNGOZGBFpQd-4GOu99Qd74ziEJ6H8gEY5lNwcJF_Cvn4xF2GUoHC9A8drqZGB_f2TIVhZF3laTPLKLrCbsUH95cNQXgFlS7pwUjOW68BiGiwliX65g/s4032/IMG_4961.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpPIw5nfwJZE4-K-XIwZxBUgQdSk8hoRjzdxAwVyK5fRsPiAENkALSHGPZ-Xj3ul44DKA9-fuyNNGOZGBFpQd-4GOu99Qd74ziEJ6H8gEY5lNwcJF_Cvn4xF2GUoHC9A8drqZGB_f2TIVhZF3laTPLKLrCbsUH95cNQXgFlS7pwUjOW68BiGiwliX65g/s320/IMG_4961.JPG" width="320" /></a></div><br /><p>What do you think?</p><p><br /></p><p><br /></p><p><br /></p><p><br /></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4cJrk7KW2TDWNxTZPzw-sIOLZqW64u25vElUO8f3PB46MoJ0m88L7BtAQOXYp3xMI74UnbfbJWnJef-XgtZXMBdia0_Dzx5Em1_pftB9D7mbPVCx1OXwxQwX39KZOWBNpWUhsXGE3rajMrYWnY4IwemXIYmuEDXkZVY9lPWRnzS40v_5JLQPhrxlR2w/s4032/IMG_5027.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4cJrk7KW2TDWNxTZPzw-sIOLZqW64u25vElUO8f3PB46MoJ0m88L7BtAQOXYp3xMI74UnbfbJWnJef-XgtZXMBdia0_Dzx5Em1_pftB9D7mbPVCx1OXwxQwX39KZOWBNpWUhsXGE3rajMrYWnY4IwemXIYmuEDXkZVY9lPWRnzS40v_5JLQPhrxlR2w/s320/IMG_5027.JPG" width="240" /></a></div><p></p><p>The next job was the Tow Bar. It is my intention tow my box trailer with the Karmann, when it is done, to allow me to take my bikes and the car to vintage shows and show them all. Well getting a tow bar was difficult, but I finally manged to buy one for a beetle. Now once the body is back on the chassis, I will probably have to cut the ball off the bar and extend it to reach the back of the Karmann. However, in the mean time I needed to manufacture the fixings for the tow bar which did not come with it. So I made two new "U" bolts to fit over the torsion tubes and two heavy right-angle brackets for the gearbox mounts. <br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuj0VcobhgWbVJxOPoJN4SOl0oPT0T2uXnMTuuUiaBYg5uVSyfj_moXz7LSDTbzpZSthR1jqbitEUUkZiZ9Giz3IlUExud4yS8k0LOfubbCWQCAOUIAN_hs0zANBK6dc_tFbg2Ydvb4dwVauCKTKlzQ0Lon26XfGhBUlXDiDiv37yS8rfkQyK5TpqPkQ/s4032/IMG_5079.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuj0VcobhgWbVJxOPoJN4SOl0oPT0T2uXnMTuuUiaBYg5uVSyfj_moXz7LSDTbzpZSthR1jqbitEUUkZiZ9Giz3IlUExud4yS8k0LOfubbCWQCAOUIAN_hs0zANBK6dc_tFbg2Ydvb4dwVauCKTKlzQ0Lon26XfGhBUlXDiDiv37yS8rfkQyK5TpqPkQ/s320/IMG_5079.JPG" width="320" /></a></div>Whilst doing these preparation jobs, the body has now been at the paint shop for 6 months (They said it would take two months) and I got a call to say that they had decided that they had "Bit off more than they could chew" and would I please take it away! They had managed to get it into "filler coat" but that was it. Furious, I had to organise the relay truck to take it away again and bring it back to my workshop.<br /><p></p><p>So I had to track down another man who could finish the car and arrange to deliver it to him. So on 17th September 2022 the Karmann body went, on the relay truck again, to the second painter, called <span style="color: #2b00fe;"><a href="https://www.coolblucustoms.co.uk/cool-blu-customs-derby.php" target="_blank">"Coolblu"</a> </span>in Swadlingcote. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfY63B8nKaMmONgpcFIiu_Yp9ulQ2sqCcnuk-ncDXoUFIPsUqLhGyHT-fPWs9C3jFTL8rFog7MjZXp4bbkFosj8Nt5NEQ40Ksk08QO_3iuJNSZxm9HbvtFvMz-HMHGi0brYLeJlCVlSE7G6Y-Zpl0DW_tuE4d1aHwashS2diFfXWGkumlRRALTnv6-mA/s4032/IMG_5160.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfY63B8nKaMmONgpcFIiu_Yp9ulQ2sqCcnuk-ncDXoUFIPsUqLhGyHT-fPWs9C3jFTL8rFog7MjZXp4bbkFosj8Nt5NEQ40Ksk08QO_3iuJNSZxm9HbvtFvMz-HMHGi0brYLeJlCVlSE7G6Y-Zpl0DW_tuE4d1aHwashS2diFfXWGkumlRRALTnv6-mA/s320/IMG_5160.JPG" width="320" /></a></div><p></p><p>In the mean time, I decided that it would be a good idea to change the generator, on the engine, for an alternator. So I bought the kit and set about fitting it. As you can see, this went well, and apart from having to cut a small boss off the oil filler stand, it fitted perfectly.<br /></p><p><br /></p><p><br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw0bRQw30Ml7g6l4Wi6NuYFWi-zma5jMC_svyGx_IbSCQAu2oy1bAEblPix5Q_N7-g9wPPJTUqoW6nTjokCOy2XqLY-SElQizJ6Jva1mvLvRsw3ErzpmWMytryfJiQHt4S_N87rR7suxDK1AFKkK_ps1OWwp2lJf_QPmf5QNjW1mmV0jWafCj8PJq_kQ/s4032/IMG_5283.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw0bRQw30Ml7g6l4Wi6NuYFWi-zma5jMC_svyGx_IbSCQAu2oy1bAEblPix5Q_N7-g9wPPJTUqoW6nTjokCOy2XqLY-SElQizJ6Jva1mvLvRsw3ErzpmWMytryfJiQHt4S_N87rR7suxDK1AFKkK_ps1OWwp2lJf_QPmf5QNjW1mmV0jWafCj8PJq_kQ/s320/IMG_5283.JPG" width="240" /></a></div><p><br /></p><p><br /></p><p><br /></p>Finally, last night (15th November 2022) I went to pick up the painted body and it is beautiful. It's now back in my workshop and ready for the long reassembly.<br /><p></p><p><br /></p><p><br /></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuxf_bt5LGsjniUUnu17ChVBdkL1mYofmH6O0JEJ_INRrk6rYzR5XhYyJq9gHaygY6IJrYd4Nha8FIe2tTuWA-Fa53KAd712suC0ZsRdLaZYGcHpMJjnYF7wiZooKpBukptDUDcWyT6C0QI2zuf3kco7YNvFEBT8XWEd1IP9SMp8YAX2luvRQRApcG8w/s2370/IMG_5271-2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1922" data-original-width="2370" height="520" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuxf_bt5LGsjniUUnu17ChVBdkL1mYofmH6O0JEJ_INRrk6rYzR5XhYyJq9gHaygY6IJrYd4Nha8FIe2tTuWA-Fa53KAd712suC0ZsRdLaZYGcHpMJjnYF7wiZooKpBukptDUDcWyT6C0QI2zuf3kco7YNvFEBT8XWEd1IP9SMp8YAX2luvRQRApcG8w/w640-h520/IMG_5271-2.jpg" width="640" /></a></div><br /><p>On the next blog, I hope to have the body back on the chassis.</p><p><span face="Arial, Tahoma, Helvetica, FreeSans, sans-serif" style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;">Copyright 16.11.22 all rights reserved.</span><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><span face="Arial, Tahoma, Helvetica, FreeSans, sans-serif" style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html" style="background-color: white; color: #2288bb; font-size: medium; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #2288bb; font-size: medium; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #2288bb; font-size: medium; text-decoration-line: none;">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-size: medium; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #2288bb; font-size: medium; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a></p><p><br /></p><p><br /></p><p><br /></p></span><p></p>Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-17095133137832457512022-01-22T02:53:00.001-08:002022-01-22T02:53:50.719-08:0021. Karmann Ghia Restorations - The Doors<p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEj9TtV-8EYJU3UR2UeVXFk6APT4H345ibq9m5nhMcisPc1sXD-rOdAA6apuZ6JCHkUdjlZiOXM2asxwWpVPEHWN75IUk_HEjOimgkVT-C5RMpQOTQeSWtFcnnS6cY8IhrLRmU5fH5OpiZuxT2LiLJTdSm0ySChfXUTcwO-KGIy1zGamDCadz8_6qQnGrA=s4032" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/a/AVvXsEj9TtV-8EYJU3UR2UeVXFk6APT4H345ibq9m5nhMcisPc1sXD-rOdAA6apuZ6JCHkUdjlZiOXM2asxwWpVPEHWN75IUk_HEjOimgkVT-C5RMpQOTQeSWtFcnnS6cY8IhrLRmU5fH5OpiZuxT2LiLJTdSm0ySChfXUTcwO-KGIy1zGamDCadz8_6qQnGrA=w400-h300" width="400" /></a></div><span style="font-family: arial; font-size: medium;"><p><span style="font-family: arial; font-size: medium;">Well it's been a very long time since my last blog and progress has been very slow, mostly due to Covid lockdown. But I am finally making progress. As I mentioned on my last blog, my next job was to weld new pieces of metal onto the </span>kickboards under the rear seat. This was done and painted and looked OK. </p></span><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEi01-j3b2S0vnKcLGsYTBLar5zzs3ts5IRUmOwrm1-rqo_QoNPNaL_MR2HCDucDgbAMYcR1D9Tjzhf3krzMA__2gjy2iB7TiOkQhM1su3U34FfiWHm3WNTm_M6Nqkf6a_OcNQeuA92oTYmQP85IrMKGVvdG7CZWT-e7GLeL7eGMoifxCbZnOT3CsdhAgA=s3264" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEi01-j3b2S0vnKcLGsYTBLar5zzs3ts5IRUmOwrm1-rqo_QoNPNaL_MR2HCDucDgbAMYcR1D9Tjzhf3krzMA__2gjy2iB7TiOkQhM1su3U34FfiWHm3WNTm_M6Nqkf6a_OcNQeuA92oTYmQP85IrMKGVvdG7CZWT-e7GLeL7eGMoifxCbZnOT3CsdhAgA=s320" width="240" /></a></div><span style="font-family: arial; font-size: large;">I was then looking at my new wheels and the wheel well at the front of the car and decided to try one of the new wheels into the hole. Well surprise surprise, it didn't fit! The new wheel and tyre being bigger would not go down into the well and the horn support bracket and jack clamp all got it the way. Well there was nothing for it but to remove both brackets and then panel beat the inner wings on both sides to widen the wheel well. <br /></span><p></p><p><span style="font-family: arial; font-size: large;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEig_t19lN1y0psSQSyn2A6we2CKmGoyrm9Vznsm1OWCwTGfHlWuwTLAxNcL6IM7OAgu2Ij7XgzGyL0shWBjUQHB9CtS4QmtoKaqbgrMLQPKX4WJRm57ZDY_QyNH8IEQ6vJfb0icBOPdbQ0jDPQ0DYMdRQaqh-sXNdk8_CZ5nkY_SFP0noMq4nx2XnmcFw=s3264" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEig_t19lN1y0psSQSyn2A6we2CKmGoyrm9Vznsm1OWCwTGfHlWuwTLAxNcL6IM7OAgu2Ij7XgzGyL0shWBjUQHB9CtS4QmtoKaqbgrMLQPKX4WJRm57ZDY_QyNH8IEQ6vJfb0icBOPdbQ0jDPQ0DYMdRQaqh-sXNdk8_CZ5nkY_SFP0noMq4nx2XnmcFw=s320" width="240" /></a></div><span style="font-family: arial; font-size: large;">That done I could then try the new wheel in the well and find a new position for the jack clamp and weld it back into place. I then had to design and make a new horn bracket and try that in place with the horn attached to ensure that it would not foul the spare wheel. Designing the new horn bracket was more complicated than I had expected as I had to ensure that I could adjust it's position, with the horn on it, with the spare wheel in place. This involved drilling a hole in the bodywork and bolting the new bracket in place, then turning the bracket until everything cleared the wheel. Once in the right place, the bracket could be welded in place. The bolt could then be removed and the hole welded up again. But there it is, done.</span><p></p><p><span style="font-family: arial; font-size: large;"><br /></span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjSEuKHhm5asmBloNXm2fzjLj3SI7Hog7NXNCvhnzWyetXNjG17eNVTHujhISs-ARn6tMir1BYUKWzbQ-NwBC7XKWMpmNw5QDFikgoF9FGh8Ydtb1T6W70ym5Dg-VeC9mLbsaJox_YXDYoNLaWlK36djP5hSUcLe9kWaEkoldVBm7My2ati_WLvfbYRqA=s3264" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEjSEuKHhm5asmBloNXm2fzjLj3SI7Hog7NXNCvhnzWyetXNjG17eNVTHujhISs-ARn6tMir1BYUKWzbQ-NwBC7XKWMpmNw5QDFikgoF9FGh8Ydtb1T6W70ym5Dg-VeC9mLbsaJox_YXDYoNLaWlK36djP5hSUcLe9kWaEkoldVBm7My2ati_WLvfbYRqA=s320" width="240" /></a></div><p></p><p><span style="font-family: arial; font-size: medium;">Now the job I have not been looking forward to. The doors. Inspection of the doors showed rot at the bottom of each door, but this only required plating and welding. The main problem was down the slot on the top where the window passes through. Just inside this slot are two plates, one on each side. These plates carry 7 rubber buffers, that fit either side of the window to stop it rattling. The holes that carry these buffers had rotted away. I had no choice but to cut open the top of the doors and make new plates. Here you can see the door cut open and one of the new plates held in place ready for welding. I was lucky when making the plates that my small press was just wide enough to do the small bend along the top edge. The holes that you can see in the new plate for the buffers were drilled right through with the door. The other holes, only in the new plate, are for welding through to hold the plate in place.<br /></span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiozuRetMxHL08_Idq7xPGA-doTJME4DlD53NKtMfSdFVQQUbufGo3pMyW-ZE7tNBl5-KSkkYnTW0UDpr99CDZeSAploI-A3Fe0EcLJD4XEbiEdKRQpz3xZJN9i_-Av76RXdHgrm4uC4-SomVBGKec8YbmVnRDb8AzTkU9U8toDxwfinAinz8J7z46WWg=s3264" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEiozuRetMxHL08_Idq7xPGA-doTJME4DlD53NKtMfSdFVQQUbufGo3pMyW-ZE7tNBl5-KSkkYnTW0UDpr99CDZeSAploI-A3Fe0EcLJD4XEbiEdKRQpz3xZJN9i_-Av76RXdHgrm4uC4-SomVBGKec8YbmVnRDb8AzTkU9U8toDxwfinAinz8J7z46WWg=s320" width="240" /></a></div><p></p><p><span style="font-family: arial; font-size: medium;">The top of the door then had to be carefully welded back on again and refinished to a smooth condition. The whole process then had to be repeated for the other door. </span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgYZu6rxdFyBIFcsbRz7TtKSDx0jEU8FR4iJc9vDRl6K-tZreM5pzEBQ8Sjdhp9_576vhN_BCtzbE3WomrxmrHWGF8GQRq5cRys-X3pZzzgnaPXrybcK08N9ycvC51AeOGpJKBbgH-okWI-7F0xfd2rB4n8UYViagapJJlUqyZtL1VcUJjXd_sH0F4qlw=s3264" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/a/AVvXsEgYZu6rxdFyBIFcsbRz7TtKSDx0jEU8FR4iJc9vDRl6K-tZreM5pzEBQ8Sjdhp9_576vhN_BCtzbE3WomrxmrHWGF8GQRq5cRys-X3pZzzgnaPXrybcK08N9ycvC51AeOGpJKBbgH-okWI-7F0xfd2rB4n8UYViagapJJlUqyZtL1VcUJjXd_sH0F4qlw=s320" width="320" /></a></div><span style="font-family: arial; font-size: medium;">The whole process took days but in the end the doors were fit to spray and use.</span><p></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p><br /></p><p><span style="font-family: arial; font-size: medium;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjk0U3BCtCZo6wLBPWIdJ5vNuLt0pDw3m84-U8LfGELsYXY51J-HMkYQOd1fNtlWoXtf8nS1_FAvYayF17pkruB2X8Wum6vAvGGprSwt-VEkyzwJ75v5RKY3ecBep4GboyX5EGk5d3ZdWw53sJJkElY7V2t-Q8_p9iIDlgoZNWXF8U6GlBBW9jGyg8LCQ=s4032" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/a/AVvXsEjk0U3BCtCZo6wLBPWIdJ5vNuLt0pDw3m84-U8LfGELsYXY51J-HMkYQOd1fNtlWoXtf8nS1_FAvYayF17pkruB2X8Wum6vAvGGprSwt-VEkyzwJ75v5RKY3ecBep4GboyX5EGk5d3ZdWw53sJJkElY7V2t-Q8_p9iIDlgoZNWXF8U6GlBBW9jGyg8LCQ=s320" width="320" /></a></div><span style="font-family: arial; font-size: medium;">Finally the doors could be fitted to the body to see if they still fit and amazingly, they do!! I then had to look at the chrome trim fixing holes down the side of the body. Now the ones in the doors were still there but most of the ones on the replacement body panels were missing. So, to get them in the right places, I used a laser to project a straight line onto the side of the body, passing through as many holes as possible and then marked and drilled the new ones in place. It's interesting to note that the indentations on the replacement panels, for the holes, were all in the wrong places.<br /><br /><br /></span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhkylvbsOJxgkg4bSusFlKvYXlPMyTPQAIxn3hHmyXaZJt5A0yPc8-xezoy1SY95DQGEuslHbJCEQRGsxWM0RVMTFM3d0Mr5ObVqzRi7NazV5UJdtDxkyqGqsijmhJYlxVGqmDQcciVkfI8SqBCATFz4dwlh9dKZVSKd68TIvYsIHLVE4qLhBHkKxRQjg=s4032" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/a/AVvXsEhkylvbsOJxgkg4bSusFlKvYXlPMyTPQAIxn3hHmyXaZJt5A0yPc8-xezoy1SY95DQGEuslHbJCEQRGsxWM0RVMTFM3d0Mr5ObVqzRi7NazV5UJdtDxkyqGqsijmhJYlxVGqmDQcciVkfI8SqBCATFz4dwlh9dKZVSKd68TIvYsIHLVE4qLhBHkKxRQjg=s320" width="320" /></a></div><p></p><p><span style="font-family: arial; font-size: medium;"><br /> </span><span style="font-family: arial; font-size: large;">I could now refit the rear boot lid and that just leaves the bonnet (Hood) to be fitted and the body can go off for paint.</span></p><span style="font-family: arial; font-size: medium;">So, I have actually booked the body in for paint in two weeks time. </span><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;">Now having booked that, it has now occurred to me that, as I had so much trouble getting the spare wheel to fit, will the new wheels and tyres fit under the wheel arches?? So my next job is to fit the body onto the chassis and try the wheels in place. FINGERS CROSSED!!</span></div><div><span style="font-family: arial; font-size: medium;"><br /></span></div><div><span style="font-family: arial; font-size: medium;"><span face="Arial, Tahoma, Helvetica, FreeSans, sans-serif" style="background-color: white; color: #222222; line-height: 18.48px;">Copyright 22.01.22 all rights reserved.</span><br style="background-color: white; color: #222222; line-height: 18.48px;" /><br style="background-color: white; color: #222222; line-height: 18.48px;" /><span face="Arial, Tahoma, Helvetica, FreeSans, sans-serif" style="background-color: white; color: #222222; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; line-height: 18.48px;" /><b style="background-color: white; color: #222222; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html" style="background-color: white; color: #2288bb; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; line-height: 18.48px;" /><br style="background-color: white; color: #222222; line-height: 18.48px;" /><b style="background-color: white; color: #222222; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #2288bb; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; line-height: 18.48px;" /><br style="background-color: white; color: #222222; line-height: 18.48px;" /><b style="background-color: white; color: #222222; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #2288bb; text-decoration-line: none;">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; line-height: 18.48px;" /><br style="background-color: white; color: #222222; line-height: 18.48px;" /><b style="background-color: white; color: #222222; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #2288bb; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a></span></div><div><br /></div>Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-72912178101287919102021-06-05T04:30:00.000-07:002021-06-05T04:30:00.137-07:0020. Karmann Ghia Restoration - Do Things Fit?<p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwAPelIoZPQA5XWLX83W3DNhV56A9U5sWevw8tVFnsIV5tFuq94SRbGnzchSmC-WrfFrIPQ7j_I6F0Iyz8j94AuPOwnxNtHYGyPZkwayvw1WSgT0j6PG9wfG_6Eh4uBZB3_umSa7HSispt/s2048/IMG_4519.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwAPelIoZPQA5XWLX83W3DNhV56A9U5sWevw8tVFnsIV5tFuq94SRbGnzchSmC-WrfFrIPQ7j_I6F0Iyz8j94AuPOwnxNtHYGyPZkwayvw1WSgT0j6PG9wfG_6Eh4uBZB3_umSa7HSispt/w400-h300/IMG_4519.JPG" width="400" /></a></div><span style="font-family: arial;">I've now reached the stage where I need to check if things fit, on my Karmann Ghia restoration, before the body goes off for painting. So the first thing to take a look at is the bumpers. Now I had already bought replacement, stainless steel, bumpers and whilst waiting for my friend to do more welding, I had successfully assembled them and been saving them for this moment. </span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWRXlDPcDy7A3Rf2_bbnyCf-dUe8J4C5gPV9uKabVB1Ykb4zGvJ5vOIVQGc4Toe4_FHPK1P77nJIBDpP3JDZEHpwkiRvLmrWY12O6WtjsjFZCvp3FjsHlfB9_l14F43H2_pGjZ9tEJbVGw/s2048/IMG_4492.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWRXlDPcDy7A3Rf2_bbnyCf-dUe8J4C5gPV9uKabVB1Ykb4zGvJ5vOIVQGc4Toe4_FHPK1P77nJIBDpP3JDZEHpwkiRvLmrWY12O6WtjsjFZCvp3FjsHlfB9_l14F43H2_pGjZ9tEJbVGw/s320/IMG_4492.JPG" width="320" /></a></div><p></p><p><span style="font-family: arial;">So, starting at the back of the car, the first problem to overcome was that the bumper mountings were currently being used to support the body on the rotating dolly. The answer was to hang the back of the body on ratchet straps from the hoist. The dolly could then be removed leaving the bumper mounting brackets clear. So, full of anticipation, I took the new rear bumper and offered it up to the body, only to find that it would not fit around the car body. The bumper was, in fact, about 3cm too narrow. The ends of the bumper, that wrap around the body, just hit the body and would not pass along the sides of the car. </span></p><p><span style="font-family: arial;"></span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8A5-r8fTTryBik8LY80lRTgwbBf7Twg7y-caTe1B9HJKR8F4voH1Q6Y-8ZscEnbpPDz69hNe7SzjHEA4eD_4742d4C1eBl5vv6jhCxowOPw-hXD9fvDIqyWFNxTpK7j7B3PewLr73pWg8/s2048/IMG_4509.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8A5-r8fTTryBik8LY80lRTgwbBf7Twg7y-caTe1B9HJKR8F4voH1Q6Y-8ZscEnbpPDz69hNe7SzjHEA4eD_4742d4C1eBl5vv6jhCxowOPw-hXD9fvDIqyWFNxTpK7j7B3PewLr73pWg8/s320/IMG_4509.JPG" /></a></div><br /><br /><p></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;">Now these bumpers have no adjustment, so this left me scratching my head for a while before I decided to make them adjustable by cutting slots in the fixings behind the overriders, where they can't be seen. This involved converting the square holes into slots using a Dremel and small cutting discs. During the process of cutting these slots in both bumpers I got through 24 miniature cutting discs. </span></p><p><span style="font-family: arial;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5KqGT-1OH-Y7XIKbVVAAqFYj9BOvItXS9Xpjgw_JJ-ZnFvTnMIUlAUFDSKpnIfPQkmNIC-XU6aHPfTuUccI2Rfgclf4yPqqKCPL1_EHuhw5689mY75LGD-W-yMelxr3bxTPfZPGZqx6Ni/s2048/IMG_4515.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5KqGT-1OH-Y7XIKbVVAAqFYj9BOvItXS9Xpjgw_JJ-ZnFvTnMIUlAUFDSKpnIfPQkmNIC-XU6aHPfTuUccI2Rfgclf4yPqqKCPL1_EHuhw5689mY75LGD-W-yMelxr3bxTPfZPGZqx6Ni/s320/IMG_4515.JPG" /></a></div><p></p><p><span style="font-family: arial;">Once cut, I could then extend the bumpers until they fit around the car body. As you can see, each side needed extending about 1cm. <br /></span></p><p><span style="font-family: arial;">Once the bumper was extended I could then look at the problem of fixing the front ends of the bumper to the body. Now originally this was </span><span style="font-family: arial;">achieved</span><span style="font-family: arial;"> by a bolt passing through the body, under the rear wing, then through a spacer and into a captive nut on the bumper. Now this presented another problem as the hole on one side had been plated and on the other side the wing had been replaced and there was no hole in the new part. So how to get the holes in the right places and how to get them level with no way of simply measuring the position.</span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4x-dQwnXgW70m3PmTAQb8igZOF_M4pBeYAqCSJiYBjKLuJpmRLhLNoXBYRM2NCA5fK1IgL73UWGqul9Dq-5wo4nzUqxi2G-iQxOH-KF4xX50yv7O3dmTps4XosLyGxfcaGg19pEcdDMtZ/s2048/IMG_E4499.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4x-dQwnXgW70m3PmTAQb8igZOF_M4pBeYAqCSJiYBjKLuJpmRLhLNoXBYRM2NCA5fK1IgL73UWGqul9Dq-5wo4nzUqxi2G-iQxOH-KF4xX50yv7O3dmTps4XosLyGxfcaGg19pEcdDMtZ/s320/IMG_E4499.JPG" width="320" /></a></div><span style="font-family: arial;">After studying the problem I noticed that on the side that had been plated, I could still make out where the hole used to be. So I used a laser on a tripod to level the car on the hanging straps and then set the laser on the position of the original mounting hole. After that I moved the tripod to the other side and pointed the laser at the new wing and that gave me the correct position for the hole on that side. Now I could drill the two holes and mount the bumper on its brackets. Now, leaving the adjustable slot bolts loose, I could move the bumper ends until they lined up with the holes and, after making some new aluminium spacers, bolt the ends of the bumper to the body.<br /></span><p></p><p><span style="font-family: arial;"></span></p><div class="separator" style="clear: both; text-align: center;"><span style="font-family: arial;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8ppvwShtUAN5PcfjFQcScXiO-VXr89zW8vWuaTPuCBZweCA3SV7qAu8YokPJBS5tLEzCpjNitKLYSkpyBmjUlmQLZiKoRFYyJ0XboKfL12cP6z32zN73ZwUAzSo80KMdvWEwh9oi7i3OL/s2048/IMG_4501.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8ppvwShtUAN5PcfjFQcScXiO-VXr89zW8vWuaTPuCBZweCA3SV7qAu8YokPJBS5tLEzCpjNitKLYSkpyBmjUlmQLZiKoRFYyJ0XboKfL12cP6z32zN73ZwUAzSo80KMdvWEwh9oi7i3OL/s320/IMG_4501.JPG" width="320" /></a></span></div><span style="font-family: arial;">The story doesn't end here, because the rear bumper has two more mountings that fix behind the overriders directly to captive nuts on the body. Or at least they would if the fixings were there. But I had replaced the rear valance. The new valance had no fixings or holes and the support brackets had been cut off the old engine trays. Fortunately I had saved them. So I had to carefully cut the old brackets off the pieces of old engine tray then cleaned and rustproofed them and then welded new captive nuts into them. The next job was to get them in the right places. </span><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7fYrzS2m348-KGYm8P5I0N1nMunLW718DwADxUh2EYdpxHJD3_erzlx_wLAKHanv_IwQLkFd6sxQv3Oj32jUpVGRw7AXoHoNKDItE8SL7dVANDftOZXlVvm19fL1Yfh2gKYtJc8PqK6EN/s2048/IMG_4503.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7fYrzS2m348-KGYm8P5I0N1nMunLW718DwADxUh2EYdpxHJD3_erzlx_wLAKHanv_IwQLkFd6sxQv3Oj32jUpVGRw7AXoHoNKDItE8SL7dVANDftOZXlVvm19fL1Yfh2gKYtJc8PqK6EN/s320/IMG_4503.JPG" width="320" /></a></div><span style="font-family: arial;">This was achieved by marking the holes through the bumper brackets onto the rear valance and then removing the bumper from the body again. I could then drill the holes in the valence and then offer the renovated brackets and bolt them in place through the new holes. I could then weld the brackets in place and paint them and the Bumper could then go back on and it finally fits.<br /></span><p></p><p><span style="font-family: arial;">Now all I had to do was do it all over again for the front bumper, which of course did not fit either. But after cutting slots, drilling holes and making more spacers, the front bumper fits too. I think four days to fit two bumpers must be a record?</span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXiT_RYgkLDV-GDr2xy2K6d3Y5lGpSvrXjqFIYmeXEGmtEbQI3oCaxhWqBVzw0_9XeA4twS_Dk9jtshadENrquwY_A8xJhi545w9XxThSENmsWEI-6sAzrrkMowqUfZO93O0Yv5UtEshNj/s2048/IMG_E4522.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1537" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXiT_RYgkLDV-GDr2xy2K6d3Y5lGpSvrXjqFIYmeXEGmtEbQI3oCaxhWqBVzw0_9XeA4twS_Dk9jtshadENrquwY_A8xJhi545w9XxThSENmsWEI-6sAzrrkMowqUfZO93O0Yv5UtEshNj/s320/IMG_E4522.JPG" width="320" /></a></div><span style="font-family: arial;">So one more job on this episode was to make and fit the support platform that is under the rear seat. Now I had some material left from the panel that I bought to replace the rear bulkhead and it already had pressing ribs in it to give it strength. After measuring the panel I found that I just had enough and so confidently measured and cut the piece out that I needed. I offered it in place and found that it fit perfectly. So now I had to bend it. I took it to my press only to find that it was too long to fit in the press. So I had to cut my perfect panel in half so that I could bend the front fold over on it. </span><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZuFj3hXNCS-ylIleAMxE4HmuEw9ksgDDzIIcUwzpFO9goV9slBzpR2nNtMtSsiaxuxpUdOLtuyOQRIheC9gEIc1Ry9Y0WDGXlp-DH8DmarwEmWAlN3JzcRhNzTfG6AVjl1b3gNDfdqEQ6/s2048/IMG_4542.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZuFj3hXNCS-ylIleAMxE4HmuEw9ksgDDzIIcUwzpFO9goV9slBzpR2nNtMtSsiaxuxpUdOLtuyOQRIheC9gEIc1Ry9Y0WDGXlp-DH8DmarwEmWAlN3JzcRhNzTfG6AVjl1b3gNDfdqEQ6/s320/IMG_4542.JPG" width="320" /></a></div><span style="font-family: arial;">Well I soon discovered that bending a panel with pressing ribs in it on a small manual press is not easy, but eventually I managed to bend the two halves and then weld them into place in the body and paint them. </span><p></p><p><span style="font-family: arial;">So there it is in place. </span></p><p><span style="font-family: arial;">My next job is to repair the two kickboards under the rear seat, which have bad rot that needs cutting out and replacing. More about that on the next episode. <br /><br /></span></p><p><span style="font-family: arial;"><br /></span></p><p><span face="arial, tahoma, helvetica, freesans, sans-serif" style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Copyright 05.06.21 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span face="arial, tahoma, helvetica, freesans, sans-serif" style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html" style="background-color: white; color: #2288bb; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #2288bb; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #2288bb; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; text-decoration-line: none;">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #2288bb; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a></p><br />Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com2tag:blogger.com,1999:blog-738504069791591427.post-83047130791824337852021-03-30T04:35:00.000-07:002021-03-30T04:35:22.088-07:0019. Karmann Ghia Restoration - Body Prep<p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1w6CF2BdPyNYVmeyO2PjF6TsgxDDcwWOwazvmLSRZC0Of2RxHZAZbk_PEe1tFp1vL5WTb6KraBdaUYiejkwMYvXwyMoiyd6LKn4BE9wFE33KQydcJIqhSLlXrDqC6wM2Q0wxe68VnZcJg/s2048/IMG_E4412.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1w6CF2BdPyNYVmeyO2PjF6TsgxDDcwWOwazvmLSRZC0Of2RxHZAZbk_PEe1tFp1vL5WTb6KraBdaUYiejkwMYvXwyMoiyd6LKn4BE9wFE33KQydcJIqhSLlXrDqC6wM2Q0wxe68VnZcJg/w400-h300/IMG_E4412.JPG" width="400" /></a></div><br /><p></p><p><span style="font-family: arial;">Well it's time for hours and hours of body preparation and some final welding. So starting at the front of my Karman Ghia Convertible I began the slow process of rubbing down and filling. I decided to slowly work my way around the car and started with the front valance. Because this car has had so many replacement panels, blending in the joints between old and new panels required multiple layers of filler and shaping then more filler etc.</span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-sWX-wplORsra9sv5sYXb8-6QVme6o9FnkQj1n2gVO6gFAAYu14uNCGFBoWuhlZ5tEVEfWgRxlyV6quMypypl17DEZcmFofpsPjW2j1mobs2NZ4wOXUCSyt2zD-Lt1MWgLWl7-Ec36SMD/s2048/IMG_4376.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-sWX-wplORsra9sv5sYXb8-6QVme6o9FnkQj1n2gVO6gFAAYu14uNCGFBoWuhlZ5tEVEfWgRxlyV6quMypypl17DEZcmFofpsPjW2j1mobs2NZ4wOXUCSyt2zD-Lt1MWgLWl7-Ec36SMD/s320/IMG_4376.JPG" width="320" /></a></div><span style="font-family: arial;">But slowly the car began to turn from orange to grey. One of the biggest problems was to get the two rear wings the same shape. As I mentioned before, this car had had accident damage on the left side so when I stood at the back of the car and looked at the two rear wings, it was obvious that the right wing had a good bulbus curve on it and that the left rear wing was much flatter. Now the problem was how to replicate the curve on the right wing onto the left.</span><p></p><p><span style="font-family: arial;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHtcXvg1C18ayhEQGR4wI8yT86aZuXsxDIUSQxgOjaMlM3830q8GYpiKcxtLUlnHqnKN7vLJhCsCDKj3gAp8M3w3wD6Nlkj1JIWIFzWpGg3LrlQkXczD50-7qdKnerZ_2ZUSLttej61l7T/s1000/Shape+Guage.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1000" data-original-width="1000" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHtcXvg1C18ayhEQGR4wI8yT86aZuXsxDIUSQxgOjaMlM3830q8GYpiKcxtLUlnHqnKN7vLJhCsCDKj3gAp8M3w3wD6Nlkj1JIWIFzWpGg3LrlQkXczD50-7qdKnerZ_2ZUSLttej61l7T/s320/Shape+Guage.jpg" /></a></div><p></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;">To achieve this I bought a long 20" Shape Gauge and used it to capture the shape of the right wing and then transferred the gauge over to the left wing and built up the filler over multiple layers until the gauge fitted over the curve the same on both wings.<br /><br /><br /><br /><br /><br /> </span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmt0QR6FHic4VxGgGEcY8_WPEYqDtWJHq2PmiCdP0nXNmd4gD5X4mBVs0Oujq1sIUgM209pKWrorxK8hsC-M1pTTXlxEijiEFWgPQ1cicaOCindwhqCKEX2-uLm2T9JZOoPphoNpz3oO3A/s2204/Left+%2526+Right+Rear+wings.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="827" data-original-width="2204" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmt0QR6FHic4VxGgGEcY8_WPEYqDtWJHq2PmiCdP0nXNmd4gD5X4mBVs0Oujq1sIUgM209pKWrorxK8hsC-M1pTTXlxEijiEFWgPQ1cicaOCindwhqCKEX2-uLm2T9JZOoPphoNpz3oO3A/w640-h240/Left+%2526+Right+Rear+wings.jpg" width="640" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-dw1Qt4PgW4QcMxWpmjrJbiLt1qgcmaz0MMNK42y4WQUce4LP1Dz5vuU3JZanEdunRF0ARzblaTOImT1IaS-8F9kUHBO7mj5Jh3MAXxHUmP0GW7C6D2oeQpIV5Bi9S8a2uSpFGCir0y5J/s2048/IMG_4433.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-dw1Qt4PgW4QcMxWpmjrJbiLt1qgcmaz0MMNK42y4WQUce4LP1Dz5vuU3JZanEdunRF0ARzblaTOImT1IaS-8F9kUHBO7mj5Jh3MAXxHUmP0GW7C6D2oeQpIV5Bi9S8a2uSpFGCir0y5J/s320/IMG_4433.JPG" /></a></div><p></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;">The next big problem was the bulkhead panels behind the back seat and over the gearbox. After very long consideration of the possibilities of making patches for this panel, which was really badly perforated, I finally decided to buy a new panel and cut the areas out that needed replacing.<br /></span></p><p><span style="font-family: arial;">So out came the angle grinder again and large pieces of the new panel were grafted in.</span></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;"><br /></span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmsbBz03WPUh9JRNtcWRPHVYcwyEmKmI4Bp928woBOygloDAlSlUqSxIc1IFo8xwHcPiISXB1CVhztKN8kydHGlrhDadLnilD84wYgmgqqJTQcdtf-BBHU7O2v-y4J1zRE6M9PiJmiLKAa/s2048/IMG_4434.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmsbBz03WPUh9JRNtcWRPHVYcwyEmKmI4Bp928woBOygloDAlSlUqSxIc1IFo8xwHcPiISXB1CVhztKN8kydHGlrhDadLnilD84wYgmgqqJTQcdtf-BBHU7O2v-y4J1zRE6M9PiJmiLKAa/s320/IMG_4434.JPG" width="320" /></a></div><span style="font-family: arial;">You will notice that the step in front of the replaced panel, that supports the seat, is also in a bad way. So the next step was to cut this out too and fabricate a new one.</span><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">In recent weeks I have been approaching various paint sprayers with a view to finally getting the finished coat on the body. I have been amazed at the enormous differences between quotes, but I think that I have finally decided upon the right supplier.</span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">One final bit is that my tyres have finally arrived and I was able to get them fitted to the wheels, but fitting the wheels is a long way away at the moment.</span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE5UgQWVoFlqJ2Vk8mFV16oVL3ggIg2UZz_XSJSEcba6dXGKp5gqZ0Pty9XbrgWVHPVrxfiq2jr5ddegjJkc3mW7WHpG4AMTcuBP6tdclaf3lkRufqLA5g-VkdXCHq7hEzK8XNqPISKe1t/s2048/IMG_4309.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE5UgQWVoFlqJ2Vk8mFV16oVL3ggIg2UZz_XSJSEcba6dXGKp5gqZ0Pty9XbrgWVHPVrxfiq2jr5ddegjJkc3mW7WHpG4AMTcuBP6tdclaf3lkRufqLA5g-VkdXCHq7hEzK8XNqPISKe1t/w480-h640/IMG_4309.JPG" width="480" /></a></div><br /><span style="font-family: arial;"><span face="arial, tahoma, helvetica, freesans, sans-serif" style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Copyright 30.03.21 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span face="arial, tahoma, helvetica, freesans, sans-serif" style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html" style="background-color: white; color: #2288bb; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #2288bb; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; text-decoration-line: none;">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #2288bb; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; text-decoration-line: none;">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #2288bb; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a><br /></span><p></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;"><br /></span></p><p><span style="font-family: arial;"><br /></span></p></div>Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-52749116179216735172020-12-03T06:36:00.003-08:002020-12-04T02:59:57.510-08:0018. Karmann Ghia Restoration - The Body Comes Home<p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiASDKhscgFspkER8ITJORNk9LzpQbOa7B6XGrI7tfG0aOqq81tFxJpiQgEiDO3wr9Hq_CDPqgfYwc2f-MJmxfSFszK0PUvyGjxtRAGlR6fq0TzapCtN7GWJxEY_av268A_0K-QZOEW4u6L/s2048/IMG_4243.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiASDKhscgFspkER8ITJORNk9LzpQbOa7B6XGrI7tfG0aOqq81tFxJpiQgEiDO3wr9Hq_CDPqgfYwc2f-MJmxfSFszK0PUvyGjxtRAGlR6fq0TzapCtN7GWJxEY_av268A_0K-QZOEW4u6L/s320/IMG_4243.JPG" width="320" /></a></div><p><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7qPOL85OVz27U9Wa0bAp5s1nw98AwDGB1q3UmsINL1f-sB8SOmzJEtAsHUaT30BuYrbnU2SSwf-oThFTPVXU5hst1kdaheQuAUbxvSl7e-RnHslEWZt7Oo3E-Mj0vj1ZIaCt-wEZx3R0n/s2048/IMG_4038.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em; text-align: center;"></a></p><p></p><div class="separator"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgV9xJ91YYvu4DOIyqbsONrX_qOAi9_52ATpq0YE2VmvvfrFkyP_fuuA9TP-igR5Z3mFs6ym_iSCh3ueshbkxYb_tOw0qZRkKAIFekUvmWI2fipL2s9Lkt57nh1KW2Dte7vohrXIi9kl-l4/s2048/IMG_4039.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgV9xJ91YYvu4DOIyqbsONrX_qOAi9_52ATpq0YE2VmvvfrFkyP_fuuA9TP-igR5Z3mFs6ym_iSCh3ueshbkxYb_tOw0qZRkKAIFekUvmWI2fipL2s9Lkt57nh1KW2Dte7vohrXIi9kl-l4/s320/IMG_4039.JPG" width="320" /></a></div><p><br /></p><p><br /></p><p><br /></p>Well, there were a couple more welding jobs to do, which includes slowly working our way around the body. So starting at the front there were two areas that needed attention on the front valance. This involved cutting away the lower corners, welding in new shaped metal and then sanding off the welds to give a smooth new finish.<p></p><div><br /></div><div><br /></div><div><br /></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKrOmdtBK6QDRlbf5tQOaABZW6e3BO_ziRA2sILplqLMyu1OaZHNkR0DJheNM0wJNYU0AXYEhdQmVW1satbEunmhbpLGcbYp-20FxcQQmoG-BbLz3-144jJ_4uqL0pAgRdeVkMwvjDo2MK/s2048/IMG_4120.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKrOmdtBK6QDRlbf5tQOaABZW6e3BO_ziRA2sILplqLMyu1OaZHNkR0DJheNM0wJNYU0AXYEhdQmVW1satbEunmhbpLGcbYp-20FxcQQmoG-BbLz3-144jJ_4uqL0pAgRdeVkMwvjDo2MK/s320/IMG_4120.JPG" /></a></div><br /></div><div>The next stage was to make a start on rebuilding the bulkhead over the gearbox area. This particular area of metal is badly perforated but we decided that it made more sense to patch this area than try and replace the whole panel as it is under the car and over the gearbox and will never be seen. This will add more strength to the perforated areas, rather than cut them out and replace them. <div> <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXxSA54Wy8ViZsIB-P0-VeAwFpL-xisCiVOhfE1wz-7rmyqj8ijLv7o7lO3OWqxLTSfiv9omFVupfQoNfop2sRBYnKJP0XlV3ns9OIvcNVpC0wXMLCjHc9wATGixj4JoeJrvMNTXLR84Fd/s2048/IMG_4135.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXxSA54Wy8ViZsIB-P0-VeAwFpL-xisCiVOhfE1wz-7rmyqj8ijLv7o7lO3OWqxLTSfiv9omFVupfQoNfop2sRBYnKJP0XlV3ns9OIvcNVpC0wXMLCjHc9wATGixj4JoeJrvMNTXLR84Fd/s320/IMG_4135.JPG" /></a></div><p><br /></p><p><br /></p><p><br /></p>As you can see, the final result was very successful and there are several other small areas of this panel that will need similar attention once the body is back home in my workshop. <br /><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5eO0FTkXNfe58Cs7F20ka8FMhAPQYW0cibAIwKtlpp2hoMbz9v_6lpRmnrA2VxJtJ5bfru1_Uhq1bAEPlcNUzzjl6Ld-8F7PM9PXuPyoLhFg-KN49WCs30DpG4I0Frlb-WYwqK5Z-cFXt/s2048/IMG_E4174.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5eO0FTkXNfe58Cs7F20ka8FMhAPQYW0cibAIwKtlpp2hoMbz9v_6lpRmnrA2VxJtJ5bfru1_Uhq1bAEPlcNUzzjl6Ld-8F7PM9PXuPyoLhFg-KN49WCs30DpG4I0Frlb-WYwqK5Z-cFXt/s320/IMG_E4174.JPG" /></a></div><div style="text-align: left;">As we moved around to the back of the car, one area that needed attention was the bottom corner of the rear boot seal area. As you can see from the photo, the metalwork in this area had completely rotted away and had previously been rebuilt with body filler. This involved making several templates for five different pieces to fabricate the missing bits.</div><div style="text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbjjAhSLxRdtXD78Z7dKhT30tss6tbpM0UFAQ0QaBPFCRbUVYPZcAomDEQEMidlW8eQcEE10zenWHeadzOEzNTYC9tWHA7k4CQCGIuynM4UOtL9sYvTxfQd4FJp6BpFIfN_fVYWXor1IjR/s2048/IMG_4285.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbjjAhSLxRdtXD78Z7dKhT30tss6tbpM0UFAQ0QaBPFCRbUVYPZcAomDEQEMidlW8eQcEE10zenWHeadzOEzNTYC9tWHA7k4CQCGIuynM4UOtL9sYvTxfQd4FJp6BpFIfN_fVYWXor1IjR/s320/IMG_4285.JPG" width="320" /></a></div><br /><div style="text-align: left;">After some very careful welding the rebuilt corner was finally in place. Now true to form, just as I think that we are making progress a major problem is discovered. </div><div style="text-align: left;"><br /></div><div style="text-align: left;">After fitting the rubber seal and closing the engine cover lid, it was discovered that there was a 2cm difference between the body and the engine cover lid on opposite corners. After investigation it was revealed that the whole left hand corner of the body had been pushed forward during a previous accident and instead of pulling it out during that repair, they had simply made up the difference with vast thicknesses of body filler. Now with the filler removed the true extent of the damage was revealed. </div><div style="text-align: left;"><br /></div><div style="text-align: left;">The very hard decision was made to turn the body back upside down, cut all of the welds to all of the panels in the rear quarter, including the engine compartment and then use a hydraulic ram to push the offending rear panel out to the correct position so that the engine compartment lid fit properly. This was done and then all of the connecting panels were rewelded. This whole process took 6 hours to do, but at least it is now right.</div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOvhhUn8EKfs1fVnvdwyM0PgSxjMFy1mTJSXi11U47XD2-1Lam7C09kQbya9C7zQdZ4C5idXOyAczj6oVANXrGHpwBQyreiOCmrkx9e-R9d5FPZlXR8s5jxU4Jm-tNgUxRpIG3ye-bpeZ5/s2048/IMG_4233.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOvhhUn8EKfs1fVnvdwyM0PgSxjMFy1mTJSXi11U47XD2-1Lam7C09kQbya9C7zQdZ4C5idXOyAczj6oVANXrGHpwBQyreiOCmrkx9e-R9d5FPZlXR8s5jxU4Jm-tNgUxRpIG3ye-bpeZ5/s320/IMG_4233.JPG" /></a></div><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;">Well only two more bits to do and then the body can be transported back to my workshop, and that is fitting the headlight bowls. This involved some very delicate TIG welding so that the welds did not interfere with the headlight rims.</div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;">So after two and a half years, at last, the body was transferred onto the transporter and it was on it's way home! </div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXu_1YAsp_tKKU0L3bK6rrRJ3Kbv-afrzAg7XH4_Kkv7pwAyRfMKfdImcXPjrdgRU6VSMajsj4lpWs_Joo5LKWCffPPSG8YFw3c35d7czFrRU_XTSSVYMqP-gzuRzfOrnMVeTIgCS-nL96/s2048/IMG_E4244.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXu_1YAsp_tKKU0L3bK6rrRJ3Kbv-afrzAg7XH4_Kkv7pwAyRfMKfdImcXPjrdgRU6VSMajsj4lpWs_Joo5LKWCffPPSG8YFw3c35d7czFrRU_XTSSVYMqP-gzuRzfOrnMVeTIgCS-nL96/s320/IMG_E4244.JPG" width="320" /></a></div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMyNOTzLVCYR2swipXulc7GMo-k8k0AVrW0OTeKgKeiMsO0LG1cMbonUeLWRmtm4p9r9y4rk6ptFwpwB0JOYMXeb4bAEsx4J9pipVWHAcIEsJxfG3076d72b0KmGviLbgweHHKBQBO9RTc/s2048/IMG_4246.JPG" style="clear: right; display: inline; float: right; margin-bottom: 1em; margin-left: 1em; text-align: center;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMyNOTzLVCYR2swipXulc7GMo-k8k0AVrW0OTeKgKeiMsO0LG1cMbonUeLWRmtm4p9r9y4rk6ptFwpwB0JOYMXeb4bAEsx4J9pipVWHAcIEsJxfG3076d72b0KmGviLbgweHHKBQBO9RTc/s320/IMG_4246.JPG" /></a></div></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><br /><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;">With the body finally back home, I can now concentrate on preparing the body for paint. This will require a good deal of preparation on the underside before progressing to the upper bodywork. I'm under no illusion, the first and worst job will be to remove 50 year old underseal from the original panels that have not needed replacing and I am sure that this will reveal more holes and more welding needed. </div><div style="text-align: left;"><br /></div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizMR1V01_LL3S8MIKl5eVoM2T57vLatWbCMAST2PLZUz55DoYxdvMEWSpH_O4uLFfj-bJp1ZyXnnRef2gHNGW9JIAMOj1yyScSEHqrhDkjCAjkDiWnfP6rXcuBpZYGv2wFVvKfFt6_okel/s2048/IMG_4255.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="230" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizMR1V01_LL3S8MIKl5eVoM2T57vLatWbCMAST2PLZUz55DoYxdvMEWSpH_O4uLFfj-bJp1ZyXnnRef2gHNGW9JIAMOj1yyScSEHqrhDkjCAjkDiWnfP6rXcuBpZYGv2wFVvKfFt6_okel/w307-h230/IMG_4255.JPG" width="307" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDKd7x9kJbdG35QQwgU2nr99MrG6LABSSXycQbV_2e7tJIzU3UTii7ovgy2ZeiVBrD3e2EXITyJHR-OUGDlQjEaWOjDjlY2CzPDuy0igWWSvfmTo2XERinOVBiVQbQq4_j9HhAvaNaDO-G/s2048/IMG_4256.JPG" style="clear: left; display: inline; margin-bottom: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDKd7x9kJbdG35QQwgU2nr99MrG6LABSSXycQbV_2e7tJIzU3UTii7ovgy2ZeiVBrD3e2EXITyJHR-OUGDlQjEaWOjDjlY2CzPDuy0igWWSvfmTo2XERinOVBiVQbQq4_j9HhAvaNaDO-G/s320/IMG_4256.JPG" width="320" /></a><br /></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7eGgZjAMN5b8nsUOdMGvB-dZL4_TdbJAw6SM4iaKWWY7CTGrQ-ypc8c7abXH7rxvf-JfebqECjdthPGNfbnL9YLY4yDOhj5ujDAznqs9c88McuX8RVpS0Wf6fPtjV4pRXI5zJyNO0pNMy/s2048/IMG_4247.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7eGgZjAMN5b8nsUOdMGvB-dZL4_TdbJAw6SM4iaKWWY7CTGrQ-ypc8c7abXH7rxvf-JfebqECjdthPGNfbnL9YLY4yDOhj5ujDAznqs9c88McuX8RVpS0Wf6fPtjV4pRXI5zJyNO0pNMy/s320/IMG_4247.JPG" width="320" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf2LzADn6rel2AqZaovfcquj5wIIO_IKXymbCkhp5kRLJaWX2cN9BvMBsEn2Wuvac-Pw0o7wPiYf11q5sWbhl8jPJEz1vN14xJKx1B9wxKb3NAmjpVfO6xHW5dx5lTDBP6n0t3vGTnm8QS/s2048/rear+under+wing.jpg" style="clear: right; margin-bottom: 1em; margin-left: 1em; text-align: center;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf2LzADn6rel2AqZaovfcquj5wIIO_IKXymbCkhp5kRLJaWX2cN9BvMBsEn2Wuvac-Pw0o7wPiYf11q5sWbhl8jPJEz1vN14xJKx1B9wxKb3NAmjpVfO6xHW5dx5lTDBP6n0t3vGTnm8QS/s320/rear+under+wing.jpg" /></a></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><br /></div>The process for preparing under the car is as follows: </div><div style="text-align: left;">Remove old underseal with a heat gun and scraper. </div><div style="text-align: left;">Rotary wire brush to remove remaining debris and rust.</div><div style="text-align: left;">Treat with rust killer (Black)</div><div style="text-align: left;">Seam Seal all joints</div><div style="text-align: left;">Spray with deep etch undercoat paint (grey)</div><div style="text-align: left;">Spray with Stone Chip paint. (White)</div><div style="text-align: left;"><br /></div><div style="text-align: left;">When the car finally goes to the paint shop it will receive a full undercoat over all surfaces and then a final top coat colour.</div><div style="text-align: left;"><br /></div><div style="text-align: left;">Well that's it for now, much more to come.</div><div style="text-align: left;"><br /></div><div style="text-align: left;"><span face="arial, tahoma, helvetica, freesans, sans-serif" style="background-color: white; color: #222222; line-height: 18.48px;">You can contact me on hopcroftscoot@gmail.com</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><span face="arial, tahoma, helvetica, freesans, sans-serif" style="background-color: white; color: #222222; line-height: 18.48px;">Copyright 03.12.20 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><span face="arial, tahoma, helvetica, freesans, sans-serif" style="background-color: white; color: #222222; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a><br /></div><div style="text-align: left;"><br /></div></div></div></div><blockquote style="border: none; margin: 0px 0px 0px 40px; padding: 0px;"><div><div class="separator" style="clear: both; text-align: center;"><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"></div></div></div></div></blockquote>Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com2tag:blogger.com,1999:blog-738504069791591427.post-36851232746164298842020-07-04T07:27:00.001-07:002020-07-04T13:15:27.929-07:0017. Karmann Ghia Restoration - Fitting the Engine & Gearbox<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNqdDnm_3ilLREnD_QHV14ympZFuSngLQo8snyEt_pFmh0AuHXIlK2NA4HgCzGZfPepeb-jX8XTeXrmlj6RuUyWTJA4JFmbUKDOxmBMEB4qOhuh563GtP1UKTsblw7tjyBToJkgj27y7W1/s1600/IMG_3972.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNqdDnm_3ilLREnD_QHV14ympZFuSngLQo8snyEt_pFmh0AuHXIlK2NA4HgCzGZfPepeb-jX8XTeXrmlj6RuUyWTJA4JFmbUKDOxmBMEB4qOhuh563GtP1UKTsblw7tjyBToJkgj27y7W1/s640/IMG_3972.JPG" width="640" /></a></div>
<br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6egegW_-TMVw__WMBOJKd2QnDus0gvkj268WyiZBq3qwxLZ1h9nPBsrJ-jcUKm5o_eGfhw8quZBD0_N7x3En_WE5Ckkl-7XCdyADcx5EdKXVkCFYNZHg8u9ng11m1c94QbzvFM6zpoMth/s1600/IMG_3825.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6egegW_-TMVw__WMBOJKd2QnDus0gvkj268WyiZBq3qwxLZ1h9nPBsrJ-jcUKm5o_eGfhw8quZBD0_N7x3En_WE5Ckkl-7XCdyADcx5EdKXVkCFYNZHg8u9ng11m1c94QbzvFM6zpoMth/s320/IMG_3825.JPG" width="320" /></a><span style="font-family: arial, helvetica, sans-serif;">Well, following my last blog, my next job was to replace the rear torsion bar end cap rubbers, that I had managed to damage. Having learnt about the mistakes I made earlier, this did not pose too much of a problem. The trick was to take the tension off the torsion bar. Then fit the rubber followed by the end cap, with the bolts just loose enough to still allow the spring plate to be re-tensioned. And then, once the bar was tensioned and the spring plate was back on its rest, finally tighten the four end cap bolts. This worked a treat and now I'm happy with the rear suspension.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNGUUVdobhKceoTImr81qa9g-V4CNl4nTIyqobpXYjIZpJPNS1pBh_VSzF5sF15VpZ3_0JhEpWEHQDg9YjrYSljLVlt3hwqOmvTKV9a0HqKmX7iE0BNi870sDKoFDZgHE2UdHxMibSq7ZT/s1600/IMG_3950.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNGUUVdobhKceoTImr81qa9g-V4CNl4nTIyqobpXYjIZpJPNS1pBh_VSzF5sF15VpZ3_0JhEpWEHQDg9YjrYSljLVlt3hwqOmvTKV9a0HqKmX7iE0BNi870sDKoFDZgHE2UdHxMibSq7ZT/s320/IMG_3950.JPG" width="240" /></a><span style="font-family: arial, helvetica, sans-serif;">So now it's time for the main event, and that is fitting the Gearbox and Engine. Well, fitting the gearbox is easy. It simply slides into place onto the front mounting rubber and mounts at the rear with the cross-member fitted with two more mounting rubbers. Care has to be taken to ensure that the gear change rod fits comfortably into the universal joint just inside the chassis. </span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">The two big bolts fixing the cross-member to the chassis need to be really tight as they not only hold the gearbox in place but also take the weight of the engine. So I was careful to look up the correct torque and tighten them to the right setting.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPF_7AjuSPijNU6O05HlghiD7hgM_BL5g8ug-Uwo07b5nZNiRD09CH3Rcg11Dpe3KFeONgT4WHVP8YYVMll06H9juf9KQ5f4xGv0VB4R6Vb3XmJzQ4X5pn-2kSDIx_HN1iDw3PKOeT8n9A/s1600/IMG_3955.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPF_7AjuSPijNU6O05HlghiD7hgM_BL5g8ug-Uwo07b5nZNiRD09CH3Rcg11Dpe3KFeONgT4WHVP8YYVMll06H9juf9KQ5f4xGv0VB4R6Vb3XmJzQ4X5pn-2kSDIx_HN1iDw3PKOeT8n9A/s320/IMG_3955.JPG" width="240" /></a><span style="font-family: arial, helvetica, sans-serif;">It was now a case of fastening the gear change rod into the universal joint.There is a small indentation in the rod from the gearbox and the grub screw on the coupling needs to locate into this indentation perfectly. This wasn't quite as easy as I'd hoped and in the end, I had to disassemble the coupling, whilst still in place, and slide it into place on the gearbox shaft and then rebuild the coupling all down the small hole in the chassis. But that done it worked and the grub screw could be tightened up and locking wire fitted.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">I could now test the gear change for the first time since the gearbox has been overhauled and, to my concern, I could not select 1st gear, no matter how I tried. 2nd, 3rd, 4th and Reverse were all fine. I decided not to panic and wait until the engine was running and turning the gears inside the box and then try again.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKHTDwuMTbvm56VRzlOVOlD2BGS0eD-rSk5me250BiCrehM_xpQAfOmcKD1U-ZH1YVUPdZ7FMcf8qrvv_lihlSPhiBVuuo397vxhz3NemE2nTvB3i6-xRMZUFa0BpFQQDefyvHJg6TxAfN/s1600/IMG_3956.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKHTDwuMTbvm56VRzlOVOlD2BGS0eD-rSk5me250BiCrehM_xpQAfOmcKD1U-ZH1YVUPdZ7FMcf8qrvv_lihlSPhiBVuuo397vxhz3NemE2nTvB3i6-xRMZUFa0BpFQQDefyvHJg6TxAfN/s320/IMG_3956.JPG" width="240" /></a><span style="font-family: arial, helvetica, sans-serif;">Three more jobs now and the gearbox installation is done. </span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">First I had to fill the gearbox with oil. So I bought the correct gearbox oil and filled the gearbox until it just came out of the filler hole. </span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">Second I needed to fit the earth strap between the gearbox and the chassis around the front rubber mounting. Now I know I stripped the proper braided earth strap off the car when I removed the gearbox in the first place. But now I can't find it. So I ordered a new one from VW Heritage and they are out of stock. Now I remember the problems you can get if this earth strap is not in place as all the electrical power, when you operate the starter motor, has to find its way back to the chassis somehow and it finds that route down the clutch and accelerator cables and I've actually seen them glow red hot, which ruins the cables. So although I've ordered a new earth strap, I decided to make a temporary heavy duty one, just in case I forget a few months down the line.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSzV7nravH4Z6RnfsJ97UcoIcz09ErYVCM-nvs-_W3k9qMkwbMq_HVENPXZ37cGEmDjTlki8_UoI2VmG-Ir3lvDH4tfQsNeOvP5lu1XDuFRbxFfuZ3C9uwocU3nDvNOnrehHrQ0gV2SQlY/s1600/IMG_3954.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSzV7nravH4Z6RnfsJ97UcoIcz09ErYVCM-nvs-_W3k9qMkwbMq_HVENPXZ37cGEmDjTlki8_UoI2VmG-Ir3lvDH4tfQsNeOvP5lu1XDuFRbxFfuZ3C9uwocU3nDvNOnrehHrQ0gV2SQlY/s320/IMG_3954.JPG" width="240" /></a><span style="font-family: arial, helvetica, sans-serif;"></span><br />
<span style="font-family: arial, helvetica, sans-serif;"><span style="font-family: arial, helvetica, sans-serif;"><br /></span></span>
<span style="font-family: arial, helvetica, sans-serif;"><span style="font-family: arial, helvetica, sans-serif;"><br /></span></span>
<span style="font-family: arial, helvetica, sans-serif;"><span style="font-family: arial, helvetica, sans-serif;"><br /></span></span>
<span style="font-family: arial, helvetica, sans-serif;"><span style="font-family: arial, helvetica, sans-serif;"><br /></span></span>
<span style="font-family: arial, helvetica, sans-serif;"><span style="font-family: arial, helvetica, sans-serif;"><br /></span></span>
<span style="font-family: arial, helvetica, sans-serif;">The final job on the gearbox was to fit the new clutch thrust bearing. This bearing has two spring clips holding it in place and no matter how I tried, I couldn't work out how they fit. Fortunately, there is always the internet and after a little studying I soon figured it out and on it went.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9melh5niWzGkJWBIqxCcVOtr8t1GwIGLJr6aXTZIXLVZfx7aXZ3QGp-PLPCVLh6O4G_Lm3LJuJdwP1kY3qMcYGnBp8Oo9OQM36yWCBPAk75az9gmJxnrcpamzUxeId7TkF0khg_GYKuuD/s1600/IMG_E3971.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9melh5niWzGkJWBIqxCcVOtr8t1GwIGLJr6aXTZIXLVZfx7aXZ3QGp-PLPCVLh6O4G_Lm3LJuJdwP1kY3qMcYGnBp8Oo9OQM36yWCBPAk75az9gmJxnrcpamzUxeId7TkF0khg_GYKuuD/s400/IMG_E3971.JPG" width="400" /></a><span style="font-family: arial, helvetica, sans-serif;">The next job was to install the new drive shafts. I had already checked the condition of the constant velocity joints on the old ones and decided to replace them. It came as a surprise that two new complete drive shafts were actually cheaper than four constant velocity joint service kits. So two new shafts it was. After filling the constant velocity joints with graphite grease, the shafts could be fitted. These are held in place with six "Torque" screws on each joint and it is not easy tightening these up to the correct torque settings without damaging the small internal star socket on the end as the size is quite small and the torque quite high. </span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB1VQZE2ZYlSXhUCzKA33ShMf0GDKy4r7RFk0D4DjUxBVFP1jWbL7vuvyqEZYE1B5y6xCPrYS0jwYjeCGpbXldyguayObJgEApiL0RE4BQLxO2Zo5lTv4KJbQ-NjroUxwcZHeuBwWxAnLh/s1600/Starter+Motors2.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1363" data-original-width="1016" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB1VQZE2ZYlSXhUCzKA33ShMf0GDKy4r7RFk0D4DjUxBVFP1jWbL7vuvyqEZYE1B5y6xCPrYS0jwYjeCGpbXldyguayObJgEApiL0RE4BQLxO2Zo5lTv4KJbQ-NjroUxwcZHeuBwWxAnLh/s320/Starter+Motors2.jpg" width="238" /></a><span style="font-family: arial, helvetica, sans-serif;"></span><br />
<span style="font-family: arial, helvetica, sans-serif;"><span style="font-family: arial, helvetica, sans-serif;"><br /></span></span>
<span style="font-family: arial, helvetica, sans-serif;"><span style="font-family: arial, helvetica, sans-serif;"><br /></span></span>
<span style="font-family: arial, helvetica, sans-serif;"><span style="font-family: arial, helvetica, sans-serif;"><br /></span></span>
<span style="font-family: arial, helvetica, sans-serif;">One final job now and I can move onto the engine, and that is the starter motor. Now I know that the starter motor works OK as I had started the engine before I stripped it for renovation and it always seemed to be fine. So it was just a case of cleaning and painting it.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">Well, as you can see, it was very dirty and greasy. But with a good clean and a coat of chassis black it came up a treat and a quick test on the bench proved that it was still working fine. </span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmkJzS8MCEUC4iPsl08jM7L3gSDu4yhN216JLaWQAfrggnIrclmXmGSKt-C-RKRREjzDIS7kyo-7ySRmjO2zKADGG5FLQv8feVmtJlphWHT9c_E17jRxcFUS34ST0yPFDnQ-dZMDirQ7Ii/s1600/IMG_E3972.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmkJzS8MCEUC4iPsl08jM7L3gSDu4yhN216JLaWQAfrggnIrclmXmGSKt-C-RKRREjzDIS7kyo-7ySRmjO2zKADGG5FLQv8feVmtJlphWHT9c_E17jRxcFUS34ST0yPFDnQ-dZMDirQ7Ii/s320/IMG_E3972.JPG" width="320" /></a><span style="font-family: arial, helvetica, sans-serif;">So now, at last, It's time to fit the engine. </span><br />
<span style="font-family: arial, helvetica, sans-serif;">Now I rebuilt this engine back in January 2018, but up until now I have had no way of testing it. Now I was going to get my chance. The Engine slid into its mountings easily and the four bolts soon had it firmly in place. Next I had to rig up a temporary fuel tank. This was achieved by placing a 1 gallon petrol can at the front of the chassis and running a flexible hose into it from the fuel pipe on the front of the chassis. I then needed a 12v cable, from the battery feed to the starter motor to the HT coil. And finally I needed to devise a way to stand at the back of the engine and work the starter.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">I did this by mounting a large red push button switch into a plastic box with a length of cable with two spade connectors on the end of it. These connectors went on the main battery feed to the starter and the other one to the solenoid connector. Now when I press the push button with my foot, the solenoid is activated and the starter turns the engine. </span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">Well it was time for the first attempt and this didn't go so well. I had petrol leaks and no sign of life from the engine. However, after a backfire, I realised that the timing must be out and started to investigate. I soon discovered that I had the HT leads 90 degrees out, so the spark was going to the wrong cylinders. A quick alteration on the distributor and, after curing the fuel leaks, the engine started and it sounded great!!!</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwHkKIu85GoDNgKI-msC0K71K1UvKpgnDiM4WGn_QgpmLjGpo-QqA6_qdD1cf29l_dbPyj35PQdNKBZ3EMitgmB4bdgftKtJzQDX81EBz1WrsnWVQ7WJz5wXhXf1YwrwP3ihX4gdjfmqAV/s1600/IMG_E3981.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwHkKIu85GoDNgKI-msC0K71K1UvKpgnDiM4WGn_QgpmLjGpo-QqA6_qdD1cf29l_dbPyj35PQdNKBZ3EMitgmB4bdgftKtJzQDX81EBz1WrsnWVQ7WJz5wXhXf1YwrwP3ihX4gdjfmqAV/s400/IMG_E3981.JPG" width="400" /></a><span style="font-family: arial, helvetica, sans-serif;">Now the bad news. It had an oil leak! Investigation indicated that the push rod tubes were leaking on the left side. Now despite me having replaced all of the push rod tubes and seals with new ones, I decided to do it again. So I ordered all new tubes and seals again and some special aircraft grade sealant and stripped the engine again.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXCG8IDWRG-TprmAqvRlf-RC0IXIT5PTUF8CrB0YEdAqaEzkZ9O_lBscPHNModLGFKRQAV36x5c3L2TnQiVXQZrXfoYn6BezL6PoOWc0YRKuAIlupNsCxSkEKAlqSe44gN5d4N5wuyDXVb/s1600/IMG_4005.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXCG8IDWRG-TprmAqvRlf-RC0IXIT5PTUF8CrB0YEdAqaEzkZ9O_lBscPHNModLGFKRQAV36x5c3L2TnQiVXQZrXfoYn6BezL6PoOWc0YRKuAIlupNsCxSkEKAlqSe44gN5d4N5wuyDXVb/s320/IMG_4005.JPG" width="240" /></a><span style="font-family: arial, helvetica, sans-serif;">The new tubes and seals arrived and I rebuilt the engine with great care. I started it again and it still leaked. I said a few choice words and stripped it again. </span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">This time I decided to spend more cash and buy the special push rod tubes that are spring loaded. I must admit they are far superior. It was during the rebuild again that I finally spotted the true problem. I noticed a small drop of oil on the bottom of the oil cooler and realised that it was not the push rod tubes that were leaking at all. The oil was running off the bottom of the oil cooler inside the fan housing and dripping down the side of the engine block over the push rod tubes. </span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvGk0yPTjbMc95TSL96nXnmoXrTwxUMxM01_hLLgaZowXWa9_Lb4yN34xQNOryNX4tEa3Z-Bsjo8uF4EfnBm8xUzjdmnkaHcxyDja-VX6oTP1QJcY2KAmfkwMBfKZJmIrU1orW_ceuhdxN/s1600/IMG_4006.JPG" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvGk0yPTjbMc95TSL96nXnmoXrTwxUMxM01_hLLgaZowXWa9_Lb4yN34xQNOryNX4tEa3Z-Bsjo8uF4EfnBm8xUzjdmnkaHcxyDja-VX6oTP1QJcY2KAmfkwMBfKZJmIrU1orW_ceuhdxN/s320/IMG_4006.JPG" width="240" /></a><span style="font-family: arial, helvetica, sans-serif;"><br /></span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">So having bought 24 push rod tubes and 48 seals in total I now knew the true cause of the problem and ordered a new oil cooler and seals.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="font-family: arial, helvetica, sans-serif;">So at last the engine was rebuilt and this time no leaks and to prove it below is a short Youtube film showing the engine running and more good news: With the engine running, I could now select 1st gear easily. </span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<iframe allowfullscreen="" class="YOUTUBE-iframe-video" data-thumbnail-src="https://i.ytimg.com/vi/bKPL2UXZz-E/0.jpg" frameborder="0" height="266" src="https://www.youtube.com/embed/bKPL2UXZz-E?feature=player_embedded" width="320"></iframe></div>
<br />
<span style="font-family: arial, helvetica, sans-serif;">Well that's it for this episode, I'm hoping that the next one will be the preparation of the body for painting.</span><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<span style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">You can contact me on hopcroftscoot@gmail.com</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">Copyright 04.07.20 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2012/07/before.html">http://60sclassicmotorbikes.blogspot.com/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html">http://60sclassicmotorbikes.blogspot.com/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide">http://miniaturelandrover.blogspot.com/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html">http://motorcycletrailersandcaravans.blogspot.com/2018/01/1-motorcycle-trailers-problem.html</a><br />
<span style="font-family: arial, helvetica, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: arial, helvetica, sans-serif;"></span></div>
</div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-74543477435904532952020-03-21T06:42:00.000-07:002020-03-21T06:53:23.190-07:0016. Karmann Ghia Restoration - Big Trouble with the front Axle<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTDjvyWjBZgpRYzR2-BHvyRkMfwop3cMgilyCXvWszEsZIlYAQxRYpwd8XLvg3m4BKavTPpkFtKvEC_hJkjyHLykqO9dW_-rScB3THiDV6YSi58UQC2xQK2v9PvKQlL_VcLWRztHraKHKs/s1600/IMG_3707.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTDjvyWjBZgpRYzR2-BHvyRkMfwop3cMgilyCXvWszEsZIlYAQxRYpwd8XLvg3m4BKavTPpkFtKvEC_hJkjyHLykqO9dW_-rScB3THiDV6YSi58UQC2xQK2v9PvKQlL_VcLWRztHraKHKs/s400/IMG_3707.JPG" width="400" /></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ6ubTq7GRvwHNzjmYeeEApslzvoHvdGPmdkNzi8_oQU8RBo8HZRMDF48DSLRZY2sI8Hkn0nlA8SpDSphkPIAkuuyJyi-LRqbaoTnBq2GzZudu3cM6kHJZhGTKXnz8AS2BNJVvfttDJ0uc/s1600/IMG_3708.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ6ubTq7GRvwHNzjmYeeEApslzvoHvdGPmdkNzi8_oQU8RBo8HZRMDF48DSLRZY2sI8Hkn0nlA8SpDSphkPIAkuuyJyi-LRqbaoTnBq2GzZudu3cM6kHJZhGTKXnz8AS2BNJVvfttDJ0uc/s320/IMG_3708.JPG" width="320" /></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"></span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">Time to look at the front axle and like most projects I started with great enthusiasm. So I stripped the front axle of all the brakes and suspension parts and removed the axle beam from the chassis. </span><br />
<div class="separator" style="clear: both; text-align: center;">
</div>
<span style="font-family: "arial" , "helvetica" , sans-serif;">
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCRNtKThnefsRydszQuwPTWOhZ_qq2hSAplBUGutcCnO49IAap6vATcKDFf1R41mAZ7YZ-6oA8OWorvTcbi25MYxFgWLcSv3o40-noC8TnPVaa2qTf16tahGvO9w70zMfRzL7JhiLeGpjO/s1600/IMG_E3752.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCRNtKThnefsRydszQuwPTWOhZ_qq2hSAplBUGutcCnO49IAap6vATcKDFf1R41mAZ7YZ-6oA8OWorvTcbi25MYxFgWLcSv3o40-noC8TnPVaa2qTf16tahGvO9w70zMfRzL7JhiLeGpjO/s320/IMG_E3752.JPG" width="320" /></a><br />
<br />
<br />
<br />
<br />
My next job was to remove 50 years of road dirt from the axle beam which took a very long time and then finally give the beam a coat of rust converter and then chassis black.<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq4mHOo9-gOv820O97IpDETNF5-Xxq_601fLwHnGC70eBTqWDvkFXIBP8XoIT8-ISc-HY0DXA0kyLyBFMCRc2XDoDuAP0ExcG687aUaR1vxGtcmEtfzjsGxPTDtAijHOw9iu8RCaSHk5WB/s1600/IMG_E3762-E.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="710" data-original-width="1600" height="142" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq4mHOo9-gOv820O97IpDETNF5-Xxq_601fLwHnGC70eBTqWDvkFXIBP8XoIT8-ISc-HY0DXA0kyLyBFMCRc2XDoDuAP0ExcG687aUaR1vxGtcmEtfzjsGxPTDtAijHOw9iu8RCaSHk5WB/s320/IMG_E3762-E.jpg" width="320" /></a><br />
It was not until I had done all of this work, and laid the axle down on the bench that I noticed that the axle appeared to be BENT!<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipaaQoPHtuNI9BUp-kLRTtw97bnedx7COnuxdw-XimitiDMJQa3RzOGxYpZ3wbjxFzxOxbp81wLxwvlmoR9SnpqNfpGdt17kHAAEzcqkkFrhUfouibFhF5W4O96rhyVjKdOMgogFtjH3I2/s1600/IMG_3763.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipaaQoPHtuNI9BUp-kLRTtw97bnedx7COnuxdw-XimitiDMJQa3RzOGxYpZ3wbjxFzxOxbp81wLxwvlmoR9SnpqNfpGdt17kHAAEzcqkkFrhUfouibFhF5W4O96rhyVjKdOMgogFtjH3I2/s320/IMG_3763.JPG" width="320" /></a>Careful measurement confirmed that the ends were indeed bent back from the centre by about 5mm. Disaster! I immediately went on the internet to see if it was a big problem. The answer was that the axle must be straight. The good news was that the internet said that, with a good press, it was possible to straighten it.<br />
<br />
So I took the axle to my friends workshop and we carefully supported the ends of the axle on wood and then applied pressure to the centre struts of the axle, via another piece of wood in his press.<br />
<br />
After a fair bit of pressure, the axle tubes straightened and we checked the tubes with a straight edge to ensure they were now level.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSKfHCd3iLE-lu7js5uqbx2L8946qBSO0Fz12dB72i-NxZTo7RGAI4qrvCF2fSwgyy7rC3wocZUtQ1mdFTW4G9y-Yk3W1yVBRdLeOn6gSb4Jik7QUnK5XD6PaW_WKw899u2_PZ_Cym9hG3/s1600/IMG_3764.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSKfHCd3iLE-lu7js5uqbx2L8946qBSO0Fz12dB72i-NxZTo7RGAI4qrvCF2fSwgyy7rC3wocZUtQ1mdFTW4G9y-Yk3W1yVBRdLeOn6gSb4Jik7QUnK5XD6PaW_WKw899u2_PZ_Cym9hG3/s320/IMG_3764.JPG" width="240" /></a><br />
We were feeling pretty pleased with ourselves that we had achieved until I got the axle back to my workshop and I happened to turn the axle over and spotted what had happened to the axle end caps.<br />
<br />
They had both crushed, under the weight of the press and were now beyond use. All of that work was now wasted and I had to find a replacement front axle.<br />
<br />
That was not as easy as I thought, as no standard replacement axles were available, even in the USA.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRa_fWVrlWozRmSItgb3v6fa3Kso1N7iXjMxlRdckQf7k-yfDv4wrjOrFHcDO-LD_oz7c1IueCSC1SdYGhMGdeQ_jy6gS7u-0NmALRlZppebP68hqfNsJ-fdK5RULP2maj41tcWP5bMqcM/s1600/IMG_3767.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRa_fWVrlWozRmSItgb3v6fa3Kso1N7iXjMxlRdckQf7k-yfDv4wrjOrFHcDO-LD_oz7c1IueCSC1SdYGhMGdeQ_jy6gS7u-0NmALRlZppebP68hqfNsJ-fdK5RULP2maj41tcWP5bMqcM/s320/IMG_3767.JPG" width="320" /></a></div>
<br />
So, in the end, I had to settle for an adjustable front axle. It's basically the same but the centre clamp points for the torsion bars are adjustable, allowing you to lower the suspension, if desired. Now as I don't want to lower my suspension these adjusters will just have to be set at the top (standard position). But there it is, fitted to the chassis and now I've got to rebuild it.<br />
<br />
<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIvVkP_YO8c-Q5IfpZm_Bc-HlSovdGXvNtOr5eCWCLiJ2huY7sdxSoGbCdx_gQUw1kXCefkUsNgc8yf3Klg8xFKtxKircPQK7CzGPxl-sxixMqozwmHuxijO_ZPmnvbabQAFaCSBzNTkMn/s1600/IMG_3769.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIvVkP_YO8c-Q5IfpZm_Bc-HlSovdGXvNtOr5eCWCLiJ2huY7sdxSoGbCdx_gQUw1kXCefkUsNgc8yf3Klg8xFKtxKircPQK7CzGPxl-sxixMqozwmHuxijO_ZPmnvbabQAFaCSBzNTkMn/s320/IMG_3769.JPG" width="320" /></a></div>
<br />
Stripping the old axle revealed another problem. Two of the leafs in the torsion bars were broken in the top tube. I doubt if I would have ever found that had the axle not been replaced. So now I had to order new torsion bars.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjshNrtmliSHd6J01Ji5V5DP0kneDt-vrdhjoqwvhyphenhyphen6_IH8sJFVPiEKNsoE92bksHmuuBmlhpXVfsfO9whscfCb3DsEYtUb9sIzrzbmPiMIRFLWFsP5FmWZodMuXucNa3E_jpTo9ie8Z7Dy/s1600/IMG_3772.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjshNrtmliSHd6J01Ji5V5DP0kneDt-vrdhjoqwvhyphenhyphen6_IH8sJFVPiEKNsoE92bksHmuuBmlhpXVfsfO9whscfCb3DsEYtUb9sIzrzbmPiMIRFLWFsP5FmWZodMuXucNa3E_jpTo9ie8Z7Dy/s320/IMG_3772.JPG" width="240" /></a></div>
<br />
<br />
Along with the new the new torsion bars, I ordered all new ball joints and track rod ends. Now here comes the next mistake. The trailing arms cleaned up beautifully and I took them, along with the new ball joints back to my friend's workshop to have the old ball joint pressed out and the new ones pressed in. It took 8 tons of pressure to do this.<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX0UeNYjMMUTGSsxITJ24wwXI7DNbbrmM6rhVy07gqMazgNKL5COGzGdkfPTJp0P5gAjGDGkZWpG4ulDEIj2mFXeJeo-kyUqkFC0Ymz6g0PJyk_d-OpRtflIhuvq6Y7fm53lQZoYypwWW5/s1600/IMG_3791.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX0UeNYjMMUTGSsxITJ24wwXI7DNbbrmM6rhVy07gqMazgNKL5COGzGdkfPTJp0P5gAjGDGkZWpG4ulDEIj2mFXeJeo-kyUqkFC0Ymz6g0PJyk_d-OpRtflIhuvq6Y7fm53lQZoYypwWW5/s320/IMG_3791.JPG" width="240" /></a><br />
<br />
I took them back to my workshop and fitted them onto the new axle along with the renovated stub axles and new shock absorbers.<br />
<br />
I wasn't over concerned, as everything was new, but the ball joints did seem very tight and so, just to be sure, I went back on the internet only to discover another problem.<br />
<br />
The ball joints have notches in their caps and, according to the web, these notches have to be orientated front to back on the car. I had noticed the notches but had not checked what they were for. Now I had to go back to the car and check where the notches had finish up after we had pressed them in.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvexPY39OBlfcwML4wT21Qwnk9q1RcKKJX_pSkR1G5ih14XuXRwe3aWIn2scYQAevMHnEspbvwu2tLblmUUDlBKGataVSqWYwvUESRNTzQEH_drv9ZqA3ky6vVupjvYL3VVGTiyJ7KCoGd/s1600/IMG_E3795.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvexPY39OBlfcwML4wT21Qwnk9q1RcKKJX_pSkR1G5ih14XuXRwe3aWIn2scYQAevMHnEspbvwu2tLblmUUDlBKGataVSqWYwvUESRNTzQEH_drv9ZqA3ky6vVupjvYL3VVGTiyJ7KCoGd/s320/IMG_E3795.JPG" width="320" /></a>As luck would have it, three of the four ball joints were in the right orientation (Pure luck) but the upper right was 90 degrees out. So I had to order another ball joint and strip that side again, take it back to my friend, and replace the ball joint again. I didn't want to chance refitting the first one again in case two lots of pressing had damaged it.<br />
<br />
It was about time I had a bit of luck and that came with the steering box. I fully expected to have to overhaul it. However inspection revealed absolutely no wear and no play. So it was just a case of cleaning it up and fitting it to the axle. The new axle has no mounting lugs, so I've had to estimate it's position and I'll have to adjust that once the body and steering column are back in place.<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrcqztw0b5v4zE0Kj99BdZ55NgqvKo87lOsqTJOtY0PAC7O-I1uAs0BMQwWfvOLNUtd1chwIoNHYmGUNGDd5r0K0U1AZQnC-Ryu2fPgrmTkvc3EnuxT_VNarbBxoWVAPWoI0AoAP-RH3Oc/s1600/IMG_3803.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrcqztw0b5v4zE0Kj99BdZ55NgqvKo87lOsqTJOtY0PAC7O-I1uAs0BMQwWfvOLNUtd1chwIoNHYmGUNGDd5r0K0U1AZQnC-Ryu2fPgrmTkvc3EnuxT_VNarbBxoWVAPWoI0AoAP-RH3Oc/s320/IMG_3803.JPG" width="320" /></a>Time to clean up and refit the anti-roll bar with all new rubbers and clamps. No great problems there in fact I think it fits better that it did originally.<br />
<br />
What was difficult was refitting the grease nipples, which would not cut into the holes in the new axle and in the end, I finished up fitting new ones. I also treated myself to a new , air powered, grease gun and I've been pumping grease into this new axle for some time now and still haven't managed to fill the new empty tubes yet. I now need to buy more grease.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX5hk-FS1pYnDOIbOole-beEBBdKVKO_P4p5NC0j-xok56753CEoW-IqjnG2qcAB95u6UdOHdB_riFLbHLnTfZcSsVa10g4oAv1sPujGeVL2D6M07b2RQavniKrUQ8CoyeYly_W6AsEF2U/s1600/IMG_3808.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX5hk-FS1pYnDOIbOole-beEBBdKVKO_P4p5NC0j-xok56753CEoW-IqjnG2qcAB95u6UdOHdB_riFLbHLnTfZcSsVa10g4oAv1sPujGeVL2D6M07b2RQavniKrUQ8CoyeYly_W6AsEF2U/s320/IMG_3808.JPG" width="320" /></a><br />
<br />
It's now time to renovate the track rods and replace the track rod ends. No great problems here.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_nzKec0502LHReozQig4Ll47HyHtUCT4CQN8vqzKHG5EYLOapvmRIjAtiijpQvkOClVD9jpaiGt7pAhvoTltMJ5Ua2mQ6SEQ4f4C6CoTFg8QK0gpq0REiRlvMn015e6axgxqX1bd78ZOv/s1600/IMG_3810.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_nzKec0502LHReozQig4Ll47HyHtUCT4CQN8vqzKHG5EYLOapvmRIjAtiijpQvkOClVD9jpaiGt7pAhvoTltMJ5Ua2mQ6SEQ4f4C6CoTFg8QK0gpq0REiRlvMn015e6axgxqX1bd78ZOv/s320/IMG_3810.JPG" width="320" /></a></div>
<br />
<br />
And complete with a new steering damper they were soon fitted.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC4J6XrkN3hosXuZ8Od2g_MgwGl7wzpWqHGtKhSVZMU3lbyeU3lmyh_FrfIJzxdcE0kNHCCC2db0hoDogLOikDQEF12Ki-u5ijgZZ2DdvGWNKRQ_JYaDzhYVXrxqHViAlkVC0G4t8VVjh0/s1600/IMG_3820.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC4J6XrkN3hosXuZ8Od2g_MgwGl7wzpWqHGtKhSVZMU3lbyeU3lmyh_FrfIJzxdcE0kNHCCC2db0hoDogLOikDQEF12Ki-u5ijgZZ2DdvGWNKRQ_JYaDzhYVXrxqHViAlkVC0G4t8VVjh0/s320/IMG_3820.JPG" width="240" /></a></div>
<br />
<br />
<br />
<br />
<br />
<br />
Now, at last I could fit the brake back plates and the new discs, complete with all new wheel bearings and oil seals.<br />
<br />One problem, after fitting the discs was that the grease caps, that came with the discs didn't fit over the bearing clamp nut and the old caps are not fit to use. So I've had to put a new pair on back order.<br />
<br />
<br />
<br /><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikdvjzDTUemLg083uZ3Be23aKgos_2HKVEu3LfI1euqyKetyapqcVMHfYZPx8oUfIS6r1mN3Vfm21ZJT1uFWnm4CjT1Yqp4pNfOlmjC81rGscmCamV-6kc1OY4Hs4Jk-EFfKPuDouq3sys/s1600/IMG_3823.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikdvjzDTUemLg083uZ3Be23aKgos_2HKVEu3LfI1euqyKetyapqcVMHfYZPx8oUfIS6r1mN3Vfm21ZJT1uFWnm4CjT1Yqp4pNfOlmjC81rGscmCamV-6kc1OY4Hs4Jk-EFfKPuDouq3sys/s320/IMG_3823.JPG" width="240" /></a><br />
Now it had been my intention to paint the new brake caliper "Red". However, when I opened the boxes, I found, to my surprise, that the new calipers were chrome plated. Now I don't know how good the chrome is but I felt it was worth leaving them as they are and see how they weather. I have already bought the red caliper paint, so if they do begin to rust I can always paint them later.<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
My next job is to replace the rear suspension, torsion bar and cap rubbers, that I have ruined, and then I'm going to reinstall the gearbox, that has already been overhauled.<br />
<br />
<br />
<span style="background-color: white; color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">You can contact me on hopcroftscoot@gmail.com</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">Copyright 21.03.20 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" style="background-color: white; color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a><br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
</div>
</span></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-42934925015491294202020-03-08T05:56:00.000-07:002020-03-21T04:24:12.984-07:0015. Karmann Ghia Restoration - Chassis Rebuild<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTUy24jBkOo8HMOqiRpUeoOzSJVbEvvkmBhm47UYz4dbBVKnrMyY_C51wOTDkJHN_Mo3hmWKik7qUgCOhNaavEFtXEFsYJriDg6AFRrxpXXlWUJMYrFHFoGgBWg-KzRB-m_S4A2_cDsrDZ/s1600/IMG_E3663.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTUy24jBkOo8HMOqiRpUeoOzSJVbEvvkmBhm47UYz4dbBVKnrMyY_C51wOTDkJHN_Mo3hmWKik7qUgCOhNaavEFtXEFsYJriDg6AFRrxpXXlWUJMYrFHFoGgBWg-KzRB-m_S4A2_cDsrDZ/s640/IMG_E3663.JPG" width="640" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">At last, the chassis is back in my own workshop. Now I can start the mechanical restoration, to make the chassis ready for when the body arrives.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ6wJsuzUzzfrLyGOU-I34cY_dItMbatkjYqkhZXkoDgHI0QmGnIRTlje-_As6xGOAa0zBplT1d7y3njnrjLzX7tbMuXGzvGRfPl6waxXaAouYwAeYkjxXzAlBaiuKwguHqj8uzZk8iaWC/s1600/IMG_E3664.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ6wJsuzUzzfrLyGOU-I34cY_dItMbatkjYqkhZXkoDgHI0QmGnIRTlje-_As6xGOAa0zBplT1d7y3njnrjLzX7tbMuXGzvGRfPl6waxXaAouYwAeYkjxXzAlBaiuKwguHqj8uzZk8iaWC/s320/IMG_E3664.JPG" width="320" /></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">So the first thing to do is clean up all the areas that are still original and that means hours of wire brushing, cleaning and painting.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE7CA0FLW7gg1bNjZSNY_TAB7LDoqocUKv8fG58ML1C0EDeR5YLrbqpJXEfCwgqqbLYMO9t6IrAnuYaNtHHhmoipxBcnqodyJcZBS2Ac-smRk7b-PMT3rybuGfL7snrPPJq8Tw3aK3b8LZ/s1600/IMG_3733.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE7CA0FLW7gg1bNjZSNY_TAB7LDoqocUKv8fG58ML1C0EDeR5YLrbqpJXEfCwgqqbLYMO9t6IrAnuYaNtHHhmoipxBcnqodyJcZBS2Ac-smRk7b-PMT3rybuGfL7snrPPJq8Tw3aK3b8LZ/s320/IMG_3733.JPG" width="320" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">After removing 50 years of road dirt, the next job was to apply a coat of rust converter and then once dry a coat of "chassis black" paint. I'm a particular fan of Chassis Black as it provides excellent thick metal coverage combined with good road dirt protection and a good gloss finish</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj85QNgsO0J_NurVSvdIVPzt040FPkFWLVTe19W-P2CclFaHh8EfGqIFHeOG3Kzzg8alsCbLFRTz1qOkXzlySIX59jrsJQs1NmObJyTVbL3pwHbeEAdBM3xJUil4V356kA0m19L8p5JfrA/s1600/Original+Picture09.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj85QNgsO0J_NurVSvdIVPzt040FPkFWLVTe19W-P2CclFaHh8EfGqIFHeOG3Kzzg8alsCbLFRTz1qOkXzlySIX59jrsJQs1NmObJyTVbL3pwHbeEAdBM3xJUil4V356kA0m19L8p5JfrA/s320/Original+Picture09.JPG" width="320" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">My next job is to raise the rear suspension. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">If you look at this original picture, you can see that the front of the car is high and the back is low. Now it is my intention to fit a tow bar to this car when it is done and tow my <a href="https://motorcycletrailersandcaravans.blogspot.com/2018/03/" target="_blank">motorcycle trailer</a> with it. This will enable me to show both the car and two of <a href="https://60sclassicmotorbikes.blogspot.com/2012/07/before.html" target="_blank">my motorcycles</a> at vintage rallies. I had lifted the back of the car on it's suspension to see how much higher it needed to be for it to sit level before I started to strip the car and it appeared to need about 63mm (2.5").</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">After reading about the rear torsion arm information on the internet, I found that one notch on the inner splines actually changes the height of the car by exactly 63mm. This can be reduced by moving the outer splines one notch should I find that it's too much when I finally put the car back on the chassis.</span><br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmoMFiiiXT7lLtXhAHYWknYsyzdTfx_gpAs65MGbpmFiqMdHJ2pqZZiX9XmjjEPrmBxuch9727kI4Rnm6pZHuFgqv6sI6jD83qhDPxTrn5ZXX77LbbUsxeCgVuU5MP_pXoxF27UuR6DBR5/s1600/IMG_E3717.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmoMFiiiXT7lLtXhAHYWknYsyzdTfx_gpAs65MGbpmFiqMdHJ2pqZZiX9XmjjEPrmBxuch9727kI4Rnm6pZHuFgqv6sI6jD83qhDPxTrn5ZXX77LbbUsxeCgVuU5MP_pXoxF27UuR6DBR5/s320/IMG_E3717.JPG" width="240" /></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">So, after removing the rear brakes, Unbolting the trailing arms and swinging them downwards, I removed the torsion bar end caps. My next problem was how to release the tension on the spring plate and after turning the torsion bar one click, how to pull the spring plate back up again onto its rest.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">Now normally, with the weight of the car on the chassis, it is just a case of using a jack to push the spring plate back up again. But with no weight on the chassis, all a jack does is lift the whole chassis. So I had to devise a simple spring compressor as shown on this picture.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">This worked great, but I should have investigated the reassembly instructions further, because I should have refitted the end caps before retensioning to torsion bar.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiehL45GhQ77VD3fq3TSHE78zacbOPMdOaVWjpYtU9SyE6O6UJ4CFoAkCzG2ftkx6NPqTAfhiXU3AI65lNUeKyC-mFChhm_6SPKYsaqNkN0FnR1cQ0STPabVNj0KjEBWQxQdstbpZrT-CZK/s1600/End+cap+tool.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiehL45GhQ77VD3fq3TSHE78zacbOPMdOaVWjpYtU9SyE6O6UJ4CFoAkCzG2ftkx6NPqTAfhiXU3AI65lNUeKyC-mFChhm_6SPKYsaqNkN0FnR1cQ0STPabVNj0KjEBWQxQdstbpZrT-CZK/s320/End+cap+tool.jpg" width="240" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;">The result was that, with the spring plate under tension and back on its rest, the end cap would not line up with its fixing holes. I then made another bad decision. I decided to make another tool to force the end caps back on.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">This turned out to be a very bad decision, because inside the end cap is a large rubber mounting doughnut. The four threaded rods forced the cap on OK but crushed the rubber doughnut and damaged it beyond use. So I have had to strip it again and I am now awaiting the arrival of two new doughnuts. After reading further I discovered that what I should have done is refit the end cap before retensioning the torsion bar. But you live and learn.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjql3W_-e_HShO2-hqBec6srbT2Mu5QCMcabJxSXUezpwM5PHEF4k2REUtnFH4X8xJUAOyoshi6CQfqsJ9NSvZnQQMfNv6H6c1nnshhRvhKw3cRV5FP0jQ2fp2Q6CidpNcsPgLMGJ8vNbg8/s1600/IMG_3746.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjql3W_-e_HShO2-hqBec6srbT2Mu5QCMcabJxSXUezpwM5PHEF4k2REUtnFH4X8xJUAOyoshi6CQfqsJ9NSvZnQQMfNv6H6c1nnshhRvhKw3cRV5FP0jQ2fp2Q6CidpNcsPgLMGJ8vNbg8/s320/IMG_3746.JPG" width="240" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;">Anyway I left the end caps where they were for the time being and proceeded with the reassembly of the rear brakes. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">The first job was to clean up the back plates and rustproof and paint them. Next the shoes and springs were cleaned along with the brake adjusters. The back plate was then clamped into place with the axle end caps fitted with new oil seals and then the new wheel cylinders and cleaned brake shoes could all be fitted. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgzGB3hs3vOuwV0A2K7peu46gk_yM-lmfj6SOefZUJ3D4cUz1vShkOK7YlGp2YbN2U6_eT5BXhyphenhyphenFRMjJ643UBwOETHEOm7jU6aAegLyWuCReBPxthiHtuHNAwp9wEePkn2q3fmdCwUV8HX/s1600/IMG_3750.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgzGB3hs3vOuwV0A2K7peu46gk_yM-lmfj6SOefZUJ3D4cUz1vShkOK7YlGp2YbN2U6_eT5BXhyphenhyphenFRMjJ643UBwOETHEOm7jU6aAegLyWuCReBPxthiHtuHNAwp9wEePkn2q3fmdCwUV8HX/s320/IMG_3750.JPG" width="240" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">The good news was that the brake linings were in excellent condition and the drums only needed cleaning and painting.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEil0IeMKeVlOPrBLvheVsOZm0dSoRBu2eqbJ3VnFNjNI-b092pFINbgUOB-FBjInPM23aB3whib4dJ4VofDx3VvND_wj_eFZ-sDtOo7Xd4k2OLpnxMWZuVHpJvLj8rknXR_H4Jwk2oTexqp/s1600/IMG_3408.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEil0IeMKeVlOPrBLvheVsOZm0dSoRBu2eqbJ3VnFNjNI-b092pFINbgUOB-FBjInPM23aB3whib4dJ4VofDx3VvND_wj_eFZ-sDtOo7Xd4k2OLpnxMWZuVHpJvLj8rknXR_H4Jwk2oTexqp/s320/IMG_3408.JPG" width="320" /></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">It's now time to look at the pedal cluster and like everything on the car, it's showing it's age. So a complete strip was necessary. Some parts needed straightening and then they all needed painting and lubricating with copper slip grease.</span><br />
<div class="separator" style="clear: both; text-align: center;">
</div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYyBXuXS1OfNFWCClGKEauKHp6PSwpBqEUcpOnMVaexUXl3J85XNazkzia95lMwNMr5GepR7l_YuF8O9DCEgMuSV05j-wN4gr8FTT_xHUJjxfPiCBcCe_SWu20Bl6Z3yRIgQi2BxVRE6nL/s1600/IMG_3409.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYyBXuXS1OfNFWCClGKEauKHp6PSwpBqEUcpOnMVaexUXl3J85XNazkzia95lMwNMr5GepR7l_YuF8O9DCEgMuSV05j-wN4gr8FTT_xHUJjxfPiCBcCe_SWu20Bl6Z3yRIgQi2BxVRE6nL/s320/IMG_3409.JPG" width="240" /></a></span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">Now with all new rubbers fitted it could be fitted back onto the chassis. Before doing that I remembered an old modification that we used to do back in the 1960's and that was to drill a small hole in the end of the hook where the clutch cable hooks on. The idea of this is that, when fitting, you hook the clutch cable over the hook and then fit a small split pin through the drilled hole. This stops the clutch cable slipping off the hook whilst fitting.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
</div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib04MuBGKaV-zOJQ9iZSekTIjGkzVC4I_TiejLi6JEbAMfsg7TcyjeHeIyZouL0Oo_lgZoqoeSAbC6J-ImT3G-CzLvd6MBqOBKW9zOeqdXwAteVhcswgPGLOwTO0jyuH5IOptLaobY1Idw/s1600/IMG_3748.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib04MuBGKaV-zOJQ9iZSekTIjGkzVC4I_TiejLi6JEbAMfsg7TcyjeHeIyZouL0Oo_lgZoqoeSAbC6J-ImT3G-CzLvd6MBqOBKW9zOeqdXwAteVhcswgPGLOwTO0jyuH5IOptLaobY1Idw/s320/IMG_3748.JPG" width="320" /></a> </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"> Now I could fit the new dual circuit master cylinder and all of the new brake pipes. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic9oPgfD98PzhguvE-PJYTHoYcKaicmymrIzquTPLO6G-SkvB07a3YzNCzWVoWP9hFkv-9rtt9s5kH5p_wB2-n-a__ctHZNvLIkR4eONwKWcF5CSHaOhZ3VNKBsGFxK5CDevm7thTGUjYC/s1600/IMG_3740.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic9oPgfD98PzhguvE-PJYTHoYcKaicmymrIzquTPLO6G-SkvB07a3YzNCzWVoWP9hFkv-9rtt9s5kH5p_wB2-n-a__ctHZNvLIkR4eONwKWcF5CSHaOhZ3VNKBsGFxK5CDevm7thTGUjYC/s320/IMG_3740.JPG" width="320" /></a></span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">I decided that, with a car of this age, it was a good idea to replace all brake components and so all flexible pipes were also replaced just to be on the safe side.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">Well that's it for this episode but on the next one there is big trouble with the front axle.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><span style="color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; line-height: 18.48px;">You can contact me on hopcroftscoot@gmail.com</span><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><span style="color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; line-height: 18.48px;">Copyright 08.03.20 all rights reserved.</span><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><span style="color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; line-height: 18.48px;">My Other Blogs:</span><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" style="color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" style="color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><b style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" style="color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; line-height: 18.48px; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a></span></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com2tag:blogger.com,1999:blog-738504069791591427.post-22023193686570861662019-09-22T04:39:00.001-07:002019-10-17T07:26:09.487-07:0014. Karmann Ghia Restoration - Body Off<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaWO05J99UVjI6bbYjqqt5iBnYR8OMrpHWU-xxyKlj_JJOytqnVf4JMKs5GZcE-6TfOvfCf3nrKIcf31IO9vwNKZ8_cMtIYhky030bjeeChLaRzC7gQyANWEeD0AN80Ps5b4CEbjrHqmNv/s1600/IMG_3040.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaWO05J99UVjI6bbYjqqt5iBnYR8OMrpHWU-xxyKlj_JJOytqnVf4JMKs5GZcE-6TfOvfCf3nrKIcf31IO9vwNKZ8_cMtIYhky030bjeeChLaRzC7gQyANWEeD0AN80Ps5b4CEbjrHqmNv/s640/IMG_3040.JPG" width="640" /></a></div>
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">Progress has been really slow, over the past few months. Mostly due to my friend, Colin, closing down his business and taking a job elsewhere. So although my Karmann Ghia is still at his factory unit, he is mostly unavailable and the unit is locked up. However some progress has been made and work is continuing, if at a slower pace.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRGTzc_uoX4qcEwQF9WSyyVsqwTrFYxSU5od-5oeU9XOir2wpcOlnaJhyphenhyphenJsMi1syhfW3FwBw1mlD69ItAFqqOm8Mp7_3egFGzV_LL7UOqJyOKG1vHyG4mG6tGPFWTRpuUfaJjoT54_OOS1/s1600/IMG_E3011.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRGTzc_uoX4qcEwQF9WSyyVsqwTrFYxSU5od-5oeU9XOir2wpcOlnaJhyphenhyphenJsMi1syhfW3FwBw1mlD69ItAFqqOm8Mp7_3egFGzV_LL7UOqJyOKG1vHyG4mG6tGPFWTRpuUfaJjoT54_OOS1/s320/IMG_E3011.JPG" width="320" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;">I said, at the end of the last blog, that there was only a couple of small jobs to do and then the body could come off. Well as usual, one of those "small jobs" turned out to be a big job. We were looking at the offside rear wheel arch. Which showed signs of rusting through and waves in the metal where previous repairs had been done and then covered with filler. We decided that as we had repaired all the other bad areas properly, that this area should also have the same approach. So I ordered a new wheel arch panel and we cut out the old damaged area.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXroC0BlfpXDSdCswLwbspT4FyeTHYELRWfJprHuDzz2eqncvS75iwO6vhcAjrs9dQvs3vQ9ZuAzzkRPzmoAwbCGg2Zwkl3y_mJOijEeX78NNqb0rYEt7VsKMVrunz7kLvF_UJ3vmyx-le/s1600/IMG_3014.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXroC0BlfpXDSdCswLwbspT4FyeTHYELRWfJprHuDzz2eqncvS75iwO6vhcAjrs9dQvs3vQ9ZuAzzkRPzmoAwbCGg2Zwkl3y_mJOijEeX78NNqb0rYEt7VsKMVrunz7kLvF_UJ3vmyx-le/s320/IMG_3014.JPG" width="320" /></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;">This area was then treated with rust killer and the new panel was welded into place. There are still a few small areas to repair but they are now to be left until the body has been removed from the chassis.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDjrHD5JRe4_odJxD6H9Lkl7dOyVQr8j5gwXgq-BAZ3iucE-dy8qhr6DPee-I3MiYtUv77lVkS0xUf11FQefxwhtFk61MPIoxRJF1Zlslkt9yc1_2QMjlzoviHrGEx-3rr8GOYBNNaGdSR/s1600/Stands.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="547" data-original-width="696" height="251" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDjrHD5JRe4_odJxD6H9Lkl7dOyVQr8j5gwXgq-BAZ3iucE-dy8qhr6DPee-I3MiYtUv77lVkS0xUf11FQefxwhtFk61MPIoxRJF1Zlslkt9yc1_2QMjlzoviHrGEx-3rr8GOYBNNaGdSR/s320/Stands.jpg" width="320" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;">We have now reached the point that all this replacement of metalwork has been for. When we started work it was immediately apparent that with so much body rot, if we took the body off the chassis, the body would simply break in half and if that happened, our chances of getting the doors to fit, after it was welded back together, was pretty slim. So the bracing bars and all of the replacement panels were necessary to strengthen the body first. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">So now it's time to think about removing the body from the chassis. Now in the mean time, Colin has been given some excellent engine stands (shown here in yellow) and with a little modification, we intend to use these stands to mount the body on, once removed from the chassis. This will enable the body to be rotated for the final underside welding and will also remain on the body during the paint spraying process.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">So the first job was to devise a method of mounting the body onto the stands and for that we needed supports at both ends of the body.</span><br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh02z-61KeLq7yWSfuQTxtpJhaL8f6n_4v_U-NOaXFqWUyr9wQOnmBtk2qr7ewPukPEKU2HSZn-rg2iLcq75as5XZgWhymKaTRM2Km2SwI7l_2TMFeZrO40RKUOnaJkp3MRQBbO6sO5tCb_/s1600/IMG_3038.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh02z-61KeLq7yWSfuQTxtpJhaL8f6n_4v_U-NOaXFqWUyr9wQOnmBtk2qr7ewPukPEKU2HSZn-rg2iLcq75as5XZgWhymKaTRM2Km2SwI7l_2TMFeZrO40RKUOnaJkp3MRQBbO6sO5tCb_/s320/IMG_3038.JPG" width="240" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPohvfAIqiBfECngUfjMBpFLllhVl2YKA_c32ydaGnOuzRMxRccWHBz5EGg_hD3qV60v1Ht2VGHk8WCS8hbZpknkOJCLNFPgGPcwdSmPilHF6NRZtZfgBZavT_rgKWUzhKivJCB6QPLVPH/s1600/IMG_3037.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPohvfAIqiBfECngUfjMBpFLllhVl2YKA_c32ydaGnOuzRMxRccWHBz5EGg_hD3qV60v1Ht2VGHk8WCS8hbZpknkOJCLNFPgGPcwdSmPilHF6NRZtZfgBZavT_rgKWUzhKivJCB6QPLVPH/s320/IMG_3037.JPG" width="320" /></a></div>
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">And here they are. These heavy duty brackets were fabricated and fitted the the bumper mountings at the front and rear. Now once the body is off, these brackets can be mounted onto the stands allowing us to rotate the body as on a "spit roast".</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinGzuYyZFTsE_lZNm9Xt01BLGoCV29E87zuVYM3TwDu2FJM7_k25Bm52wEfxdf_b3p9oKOmuIANdH4ujOD5GUpzRSVVOR84bQGMNZx1RPEEhCe9n7xBEdQWC44jD-j9Ajl0DS3625Wr-Kb/s1600/IMG_3043.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: "arial" , "helvetica" , sans-serif;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinGzuYyZFTsE_lZNm9Xt01BLGoCV29E87zuVYM3TwDu2FJM7_k25Bm52wEfxdf_b3p9oKOmuIANdH4ujOD5GUpzRSVVOR84bQGMNZx1RPEEhCe9n7xBEdQWC44jD-j9Ajl0DS3625Wr-Kb/s320/IMG_3043.JPG" width="320" /></span></a><span style="font-family: "arial" , "helvetica" , sans-serif;">And so, with all of the bolts removed, that fix the body to the chassis, and three strong men, the body is finally lifted off.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">I must admit, it does seem strange to see the body and the chassis in two different places. But this is what we have been working towards.</span><br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTS-2_uZlsYD23kHNAEo5C1ys2GMx6DmP5DisjiRsaGKFKzO58ikNGXavcXF8FSbbgYQH3yua4M2svWZ1KqI4oWYbvLTCLEADmPNhjKhKb3NtZOwTxa0rgPOtVV993padJXmdZLC0wqpa8/s1600/IMG_3072.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTS-2_uZlsYD23kHNAEo5C1ys2GMx6DmP5DisjiRsaGKFKzO58ikNGXavcXF8FSbbgYQH3yua4M2svWZ1KqI4oWYbvLTCLEADmPNhjKhKb3NtZOwTxa0rgPOtVV993padJXmdZLC0wqpa8/s320/IMG_3072.JPG" width="240" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;">So now we can turn out attention to the chassis. Now both chassis pans are rotten and I had bought replacement pans some time ago and it was now time to unwrap them. To my surprise, although both had come from VW Heritage, they were quite different from each other. The right chassis pan seemed correct in every aspect, but the left one had no body mounting holes in it, no jacking point reinforcement, no captive nuts and a strange extra curved pressing that you can see on the front foot-well area. I spoke to VW Heritage and they were as puzzled as me. However they arranged to collect the rogue panel and send me a replacement. Great Service.</span><br />
<div class="separator" style="clear: both; text-align: center;">
</div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt3ECQviVOa0NMCBWaT1gqZH37M5Ai3VnDxKEW1bO17LIqnoOZcaKXyncLosX7hPmM7Mb9t9kxL-SXzzPcHx0UpLrdtsDDkV-eKRwadGx1RGPgqs3yJG5kItPg3JcfvOPaNWzz5DNWaecK/s1600/IMG_3063.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: "arial" , "helvetica" , sans-serif;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt3ECQviVOa0NMCBWaT1gqZH37M5Ai3VnDxKEW1bO17LIqnoOZcaKXyncLosX7hPmM7Mb9t9kxL-SXzzPcHx0UpLrdtsDDkV-eKRwadGx1RGPgqs3yJG5kItPg3JcfvOPaNWzz5DNWaecK/s320/IMG_3063.JPG" width="240" /></span></a><span style="font-family: "arial" , "helvetica" , sans-serif;"> The next job was to remove the seat runners. This sounds like a small job, but it actually massive and very complex. Firstly you have to take very careful measurements of their position on the chassis and each of the three pieces relationship to each other, as there are no marked mounting points on the new chassis pans. Get it wrong and the seat won't fit or slide. Then you have to drill out hundreds of spot welds in order to remove the seat rails and their cross-member.</span><br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEEkKMQrL_Jko3Ci6khG3yQZ4eHuI6aHxTOHKamb3IoOcl5ZkPsn_tGLq7zsEt3_RjUnjqjUSFl0V06nCYulLEX48po2mBmnjWwEPeLBsE9gofomnfzw23UgMNzK2N3m4PU-yEr2sZOYD6/s1600/Chassis+skeleton.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1201" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEEkKMQrL_Jko3Ci6khG3yQZ4eHuI6aHxTOHKamb3IoOcl5ZkPsn_tGLq7zsEt3_RjUnjqjUSFl0V06nCYulLEX48po2mBmnjWwEPeLBsE9gofomnfzw23UgMNzK2N3m4PU-yEr2sZOYD6/s320/Chassis+skeleton.jpg" width="240" /></a><br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">Now with the seat runners removed the old chassis pans can be cut out. I have removed the background from this picture to make it easier to see just how much has to be cut away leaving only the backbone of the car ready to receive it's new panels.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcgam4Vy2504hG6giF-9aBEWc_HUJME97clsmaAt2S1K7QgqPL5lQ8b10aJZA7KnSk-a2MGmc6lhAnKDm-CmZYkRAam4L-8XKFN6TV-BOJQXCC0N1PdZKBJXQ4NSfMJ3LYAoVBoUuBl0iP/s1600/IMG_3100.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: "arial" , "helvetica" , sans-serif;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcgam4Vy2504hG6giF-9aBEWc_HUJME97clsmaAt2S1K7QgqPL5lQ8b10aJZA7KnSk-a2MGmc6lhAnKDm-CmZYkRAam4L-8XKFN6TV-BOJQXCC0N1PdZKBJXQ4NSfMJ3LYAoVBoUuBl0iP/s320/IMG_3100.JPG" width="320" /></span></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">It now took hours of slow and laborious work to prepare the skeleton chassis ready to receive the new floor pans.</span><br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTDeYZ1sd3K_Szulq-stCWann0HxrVCLerTxdxaOSQSwn3TWHph5ir8uLoQ2YG_uNOGsccDgF-Kkkf5UblSX0DvwHZGoePx-XcyrY1aMlXikmWoaFIV0TPjra1BZWh_Qi-HEXhoD84KJdA/s1600/IMG_3086.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTDeYZ1sd3K_Szulq-stCWann0HxrVCLerTxdxaOSQSwn3TWHph5ir8uLoQ2YG_uNOGsccDgF-Kkkf5UblSX0DvwHZGoePx-XcyrY1aMlXikmWoaFIV0TPjra1BZWh_Qi-HEXhoD84KJdA/s320/IMG_3086.JPG" width="240" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">But things look a lot better now that the new floor pans are in place and ready to receive the old seat runners.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk8lBX0hMte0XkYJ91BtLdJbUvRd47fwo8klFvz5WgQ-kYgAtwJVTdTW8jo6ICy6pAR7KKhpdbB8jY49NDH7dJeTPoFGzfT1rsuvAZhOzVDlpCzBpwHfxo_dq-2_Gx3cXrg3s5VAN0VE_W/s1600/IMG_3185.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: "arial" , "helvetica" , sans-serif;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk8lBX0hMte0XkYJ91BtLdJbUvRd47fwo8klFvz5WgQ-kYgAtwJVTdTW8jo6ICy6pAR7KKhpdbB8jY49NDH7dJeTPoFGzfT1rsuvAZhOzVDlpCzBpwHfxo_dq-2_Gx3cXrg3s5VAN0VE_W/s320/IMG_3185.JPG" width="320" /></span></a><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">Runners measured for position and clamped into place.</span><br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqnHvyC6oC7UAFeMn4FFMYesH9OvRvtZLmqRSV3ZciWWuqDttgMaa5HY1sRn2UMWfBdFTozwer8k57jdbdyjl_9Ah11qmYciIeYj-6DxIOf5H_Mo3f_M1dJ8s2j-rsSBJ4cEjEGntxg5hS/s1600/IMG_3187.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqnHvyC6oC7UAFeMn4FFMYesH9OvRvtZLmqRSV3ZciWWuqDttgMaa5HY1sRn2UMWfBdFTozwer8k57jdbdyjl_9Ah11qmYciIeYj-6DxIOf5H_Mo3f_M1dJ8s2j-rsSBJ4cEjEGntxg5hS/s320/IMG_3187.JPG" width="320" /></a><br />
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">The slow job of welding up hundreds of holes made drilling out the original spot welds.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-3NAWqlv4beLM0RjY9iBARPs-rW5xsyRtlGHdpZpI7Soz_uZqJlbX7BeRjSGMTJ99DyEsWLTA_uNtaFrPNE61apdNEYWu6eTV5HTXcJcvKrFLmSVUrOC2YS9mef9wL8G03Q3CFJ1Igj_P/s1600/IMG_3188.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><span style="font-family: "arial" , "helvetica" , sans-serif;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-3NAWqlv4beLM0RjY9iBARPs-rW5xsyRtlGHdpZpI7Soz_uZqJlbX7BeRjSGMTJ99DyEsWLTA_uNtaFrPNE61apdNEYWu6eTV5HTXcJcvKrFLmSVUrOC2YS9mef9wL8G03Q3CFJ1Igj_P/s320/IMG_3188.JPG" width="320" /></span></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">Well that's one side done. Now I've got to do it all over again on the other side.</span><br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhy0CmRPjnWzU10g8me0q7c7XZ30yBzOci4f980K7kLOw9iHRWmZw72FZGB9RR5u3YREtbxTjdgu61CFHLthjAYjMuMmol0CN3CNdpjKoGKdnGqpJ-_1ZHtbkyju4guBbMfnvgcGqc0XaJG/s1600/IMG_3103.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhy0CmRPjnWzU10g8me0q7c7XZ30yBzOci4f980K7kLOw9iHRWmZw72FZGB9RR5u3YREtbxTjdgu61CFHLthjAYjMuMmol0CN3CNdpjKoGKdnGqpJ-_1ZHtbkyju4guBbMfnvgcGqc0XaJG/s640/IMG_3103.JPG" width="480" /></a></div>
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">Well that's the progress so far, here's hoping that things will move a little faster over the winter months.</span><br />
<br />
<span style="background-color: white; color: #222222; font-family: "arial" , "helvetica" , sans-serif; font-size: 13.2px;"><span style="font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">You can contact me on hopcroftscoot@gmail.com</span><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">Copyright 22.09.19 all rights reserved.</span><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">My Other Blogs:</span><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" style="color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" style="color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" style="color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a></span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;"></span></div>
</div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com3tag:blogger.com,1999:blog-738504069791591427.post-23575661666280857812019-04-16T04:39:00.000-07:002019-04-17T02:22:59.182-07:0013. Karmann Ghia Restoration - Moving to the back<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2HpXNSQh7qf_LrJ1c5C3XgVYSjZsGESnpFpR9_iiXzf4jLxEnnhKlxGiONfpIgxyDdx2cJ69vxltzwlc7FUeDppa4EUBtGRzJOuncX4fWBrfel_N8_zLHhiPP5HNOf_kk6yA6DqHcCG_m/s1600/IMG_2899.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2HpXNSQh7qf_LrJ1c5C3XgVYSjZsGESnpFpR9_iiXzf4jLxEnnhKlxGiONfpIgxyDdx2cJ69vxltzwlc7FUeDppa4EUBtGRzJOuncX4fWBrfel_N8_zLHhiPP5HNOf_kk6yA6DqHcCG_m/s400/IMG_2899.JPG" width="400" /></a></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;">It's been a long time since</span><span style="font-family: "arial" , "helvetica" , sans-serif;"> the</span><span style="font-family: "arial" , "helvetica" , sans-serif;"> last blog on my 1971 Karmann Ghia Convertible restoration. It's not that I haven't been working on it. It's just that things have not been going so well, as you will read later, and I had to wait until significant progress could be reported.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">Well, as you can see, from the picture above, the right side rear quarter went together quite well and the inner wing was also rebuilt. And so it was time to move to the back of the car and the engine compartment.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">Now Colin (my friend who is doing the bodywork with me) said that from now on "the work would be easy". He really should not have said that. All we had left was the final 4 body panels and that just involved cutting out the old ones and welding in the new ones.</span><br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiCSPtPgKcYxj1HIqKORjix9ocx9GyMUQ2uCqIfErVU64iQr2MsSZqiXbTXIobayxVp8Pw0hnS2T_7ltE58Cu2zDudKlmaBSmbUVLTHVX9-xHLkdFXN-rQkh0Z0-OixHrteECXw7nyx9Ph/s1600/IMG_2935.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiCSPtPgKcYxj1HIqKORjix9ocx9GyMUQ2uCqIfErVU64iQr2MsSZqiXbTXIobayxVp8Pw0hnS2T_7ltE58Cu2zDudKlmaBSmbUVLTHVX9-xHLkdFXN-rQkh0Z0-OixHrteECXw7nyx9Ph/s320/IMG_2935.JPG" width="320" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfwQiccO0_6GK55BlWYkV3w5OE4d227gFyTOxCoJtAwou2xvCQio-7F773cBbrzsTTVqKGV5i97cF3B89uauWB5EEe5ajcuTnljM0NLOaDBItqVIo_vCEGeEfQinXUqDjpoQwNn6jkGuHj/s1600/IMG_2937.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfwQiccO0_6GK55BlWYkV3w5OE4d227gFyTOxCoJtAwou2xvCQio-7F773cBbrzsTTVqKGV5i97cF3B89uauWB5EEe5ajcuTnljM0NLOaDBItqVIo_vCEGeEfQinXUqDjpoQwNn6jkGuHj/s320/IMG_2937.JPG" width="320" /></a></span></div>
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">The four panels involved were the left and right engine compartment side trays, the rear engine compartment tray and the rear valance. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">So, as you can see, we proceeded with great confidence and cut them out. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjD2PIJcBUdrZTWtJrEoCpHE9byqHAx0_ucEcVPt6SOWqjf630CvyTWQ08OCto78eR4KWSmWPknBxaPgW0IXPiiK7PQhq_Kto0lJwbvErPDO-EYUqMgq41O5L8_2rQYDaWDU9_KHBYlSEjz/s1600/IMG_2938.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjD2PIJcBUdrZTWtJrEoCpHE9byqHAx0_ucEcVPt6SOWqjf630CvyTWQ08OCto78eR4KWSmWPknBxaPgW0IXPiiK7PQhq_Kto0lJwbvErPDO-EYUqMgq41O5L8_2rQYDaWDU9_KHBYlSEjz/s320/IMG_2938.JPG" width="320" /></a></span></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;">The next job was to fit the engine compartment lid so that the gap around it could be set and then offer up the rear valance.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj10bV06zAShtZ_ZGUhcSpRqrgIoAnAJIOqpDPv_aSNIW4j5oe0yM1OuN9eNJ8e5gg5LxB8cnk2NttNT4UOmiZZ14zT9YoAiZgH0bupE19C9ifZ_r27oSAxbg4TIS1W2_8V9MFPiGmUJYJj/s1600/IMG_2939.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj10bV06zAShtZ_ZGUhcSpRqrgIoAnAJIOqpDPv_aSNIW4j5oe0yM1OuN9eNJ8e5gg5LxB8cnk2NttNT4UOmiZZ14zT9YoAiZgH0bupE19C9ifZ_r27oSAxbg4TIS1W2_8V9MFPiGmUJYJj/s320/IMG_2939.JPG" width="320" /></a></span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">With the rear valance in place, the distance between the two rear wings was now set and we could proceed with the engine panels.</span><br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHLECBfrugNoZslP_chjhrUaMJyohKGqjZfNoXvRceXGO_YNzniNoe2YutftrnXJngKy3mIOGqweExybBI5kHqzdU7POq7nXDgQrdKMBpeBEPzQTHUGTf_5GerHyrVExZgWbjbKb9eJ8t_/s1600/IMG_2959.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHLECBfrugNoZslP_chjhrUaMJyohKGqjZfNoXvRceXGO_YNzniNoe2YutftrnXJngKy3mIOGqweExybBI5kHqzdU7POq7nXDgQrdKMBpeBEPzQTHUGTf_5GerHyrVExZgWbjbKb9eJ8t_/s320/IMG_2959.JPG" width="320" /></a></span></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"> The first job was to weld the valance to the back engine tray. These we spot welded together and at this point things were going well.</span><br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZUA4ERg_xtvaB93EcSxjR2ULD3CvcpDszi9guxLIJ9LvspzHchcoOYyTqMuYg01GKENqxw-88WSHaTIrX4RiT8qa1eKEpK6Wnz3bM6xdlBhu-YtHzQxD03WIjMpwBp8QvKZkY2NsqmVtz/s1600/IMG_2947.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZUA4ERg_xtvaB93EcSxjR2ULD3CvcpDszi9guxLIJ9LvspzHchcoOYyTqMuYg01GKENqxw-88WSHaTIrX4RiT8qa1eKEpK6Wnz3bM6xdlBhu-YtHzQxD03WIjMpwBp8QvKZkY2NsqmVtz/s320/IMG_2947.JPG" width="240" /></a></span></div>
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;">Then we tried adding the engine side trays and found that they did not fit. I had bought the rear tray and valance from VW Heritage in the UK but could find no one in the UK who had the side trays. After searching the Internet I found the two side trays in Germany and ordered them in.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">At first glance they looked good but now it was apparent that they were not correct at all. My first instinct was to search again, which I did, but no one had any more panels. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFcULhif8bh8ice9bB_sB06IJhELS_DdR0ddFGjuGG811NRxNJ8GTc5AfG6T3j-YPsw1SdwEaBhLjIlzF7eeLjeZsIgcl9onjrMN0P1v8h7v7qRBO6k23jbSL0aK-_kkKK8U8ExsMcN4Q9/s1600/IMG_2944.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFcULhif8bh8ice9bB_sB06IJhELS_DdR0ddFGjuGG811NRxNJ8GTc5AfG6T3j-YPsw1SdwEaBhLjIlzF7eeLjeZsIgcl9onjrMN0P1v8h7v7qRBO6k23jbSL0aK-_kkKK8U8ExsMcN4Q9/s320/IMG_2944.JPG" width="320" /></a>The main problem was where the tray meets the inner wheel arch. Between the flange on the tray and the inner wing was a gap of up to 25mm (1"). I started to look at pictures on the Internet of Karmann Ghia engine compartments and discovered that where my inner wings have an indentation, all of the ones in pictures were rounded and would have fit these panels. Could it be that my Karmann, being Brazilian, was different from the German ones? What ever the answer I was stuck with the problem. These are the trays that I've got and no others are available. So somehow we've got to get them to fit.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqZuSfwG0UaNIqZ7CtwD7Ghs2rzD_3iWPFf6mQDbBh2bUIGfhluAxTpRfaAWDPr8xg4mwzodTPFaZaxkEU1JlCPoKZuB_cmWerX5Bhx-yErIk6pOgGEpOExvsLAKFcNmqxhUBYKrkLIMhm/s1600/IMG_2957.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqZuSfwG0UaNIqZ7CtwD7Ghs2rzD_3iWPFf6mQDbBh2bUIGfhluAxTpRfaAWDPr8xg4mwzodTPFaZaxkEU1JlCPoKZuB_cmWerX5Bhx-yErIk6pOgGEpOExvsLAKFcNmqxhUBYKrkLIMhm/s320/IMG_2957.JPG" width="320" /></a> Just when we thought this was bad enough, we noticed something else. The engine seal runners on the side trays were in different places from the seal runner on the rear tray. The picture on the right shows the two trays upside down, laying on the bench, so that the top surfaces which you see in the engine compartment are level with each other. You can see that the seal runners don't line up at all.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPQpcXeNiBaLUdrPFVPckHENBW-rAMLFVvlRhUAwk4ZFwK-x2Uk-Iposuhsd93tAXNFpoRTn7od9EuTXmd9kqyp8A6uIfDF4ELXBvxgtSVNxJwMr12fjyfErhtBePaSsTHHkQosWGQvARK/s1600/IMG_2958.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPQpcXeNiBaLUdrPFVPckHENBW-rAMLFVvlRhUAwk4ZFwK-x2Uk-Iposuhsd93tAXNFpoRTn7od9EuTXmd9kqyp8A6uIfDF4ELXBvxgtSVNxJwMr12fjyfErhtBePaSsTHHkQosWGQvARK/s320/IMG_2958.JPG" width="320" /></a>We referred to the panels that we had cut out and found that the original seal runners were in the position shown on the new side trays. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">So now we had the task of removing the runner from the rear tray, extending the trays flange and then welding the runner back on again. And, to make things worse, the runner on the rear tray was also the wrong shape. So we had to make a tool and reshape the runner to match the side trays.</span><br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsbU7KNrJF1PyucNZiNvxpWLQcQnka_0uJ7_GN3I3CEmxP0VHBEDTKgpu_61B0l_zeYCZZfC0iKC6PeYF1UmFVavn_NryqRfB9AG6r9442ot-l5_kB-yPCTEY2SkDgl-RjmXgpC0rsfWu6/s1600/IMG_2962.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsbU7KNrJF1PyucNZiNvxpWLQcQnka_0uJ7_GN3I3CEmxP0VHBEDTKgpu_61B0l_zeYCZZfC0iKC6PeYF1UmFVavn_NryqRfB9AG6r9442ot-l5_kB-yPCTEY2SkDgl-RjmXgpC0rsfWu6/s320/IMG_2962.JPG" width="320" /></a></span></div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX4bEhJxHof-6qQ5hwcZxtNf3ExkeDrMEMSlzawvanVg4qAAo7Qkn4f30tjMh9ut4nxWVziCBMYs8nLtXpeZ5qK1z5Th-01AoxxaWqf6-wFZMsZRUGRuMmMdj6sOhwgYy4WdOLa-JfbMyl/s1600/IMG_2968.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX4bEhJxHof-6qQ5hwcZxtNf3ExkeDrMEMSlzawvanVg4qAAo7Qkn4f30tjMh9ut4nxWVziCBMYs8nLtXpeZ5qK1z5Th-01AoxxaWqf6-wFZMsZRUGRuMmMdj6sOhwgYy4WdOLa-JfbMyl/s320/IMG_2968.JPG" width="320" /></a><span style="font-family: "arial" , "helvetica" , sans-serif;">Finally the trays could be welded together and into the car, but this still left the problem of the large gaps between the side trays and the inner wings. Colin and I talked about this at length. His idea was to box over the hole from the top of the flange on the tray to the wing, leaving a low shelf. My idea was to cut the flange off the tray and weld a new flat piece onto the tray. We were not really happy with either idea, as it would be obvious that they were a compromise. Then Colin came up with an alternative. That was to make and fit sloping panels down from the inner wings to the trays. In effect swageing them in. </span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">To see what it would look like, cardboard templates were made, held in place with masking tape and sprayed with primer. They looked excellent and so Colin now had to make these very complex shaped panels. This took some time, but here they are.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;">It was then a case of fitting them in place and TIG welding them in. A coat of primer and the finished job looks excellent.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_BjKRb2tQDPkIn4_WSNMeNeWS5m5wNsRk1t0wf4Ld3lmCeg4AsU7SJ08WfgdcWAiKO3lzmIzgYSWciUc82oNaIc6_ggVHhytF9fDKkLUHYYg7yevyF7jN2S-L1yyUJMtI0jqjFOdC6YFk/s1600/IMG_2969.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_BjKRb2tQDPkIn4_WSNMeNeWS5m5wNsRk1t0wf4Ld3lmCeg4AsU7SJ08WfgdcWAiKO3lzmIzgYSWciUc82oNaIc6_ggVHhytF9fDKkLUHYYg7yevyF7jN2S-L1yyUJMtI0jqjFOdC6YFk/s640/IMG_2969.JPG" width="640" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;"></span></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"> Well the car is now solid, all steel and no filler and there's only a couple of small jobs to do now and then the body can come off.</span><br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span><span style="font-family: "arial" , "helvetica" , sans-serif;"><span style="background-color: white; color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">You can contact me on hopcroftscoot@gmail.com</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">Copyright 16.04.19 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: "arial" , "tahoma" , "helvetica" , "freesans" , sans-serif; font-size: 13.2px; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" style="background-color: white; color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #888888; font-family: arial, tahoma, helvetica, freesans, sans-serif; font-size: 13.2px; line-height: 18.48px;">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a></span><br />
<div>
<br /></div>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>
</div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com4tag:blogger.com,1999:blog-738504069791591427.post-31863783216798565472019-01-14T06:02:00.000-08:002019-01-14T06:02:14.376-08:0012. Karmann Ghia Restoration - Side Two<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjg8q_KWtucdSQQwHCWCSWUAcA6wDErXRwwYzwHhy7yXA4U0HY5M7mlz9y_LF28rKMDvhTfC0N94rEcMevOwGKufrCttGl4clbBsObHOcTopTvy8MC5oBS2RR-yrc-BkBmln0Xu9f957sBl/s1600/IMG_0259.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjg8q_KWtucdSQQwHCWCSWUAcA6wDErXRwwYzwHhy7yXA4U0HY5M7mlz9y_LF28rKMDvhTfC0N94rEcMevOwGKufrCttGl4clbBsObHOcTopTvy8MC5oBS2RR-yrc-BkBmln0Xu9f957sBl/s320/IMG_0259.jpg" width="320" /></a></div>
<br />
<span style="font-family: Arial, Helvetica, sans-serif;">It's time to look at the second side of my 1971 Karmann Ghia Convertible. I was full of hope for this right side as the paintwork showed very little signs of rust and the accident damage that was discovered on the left side of the car did not extend to the right side. Just maybe the right side would be much easier to do than the left. </span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;">Closer inspection showed just a little rust bubbling on the sill and at the bottom of the front and rear quarters, and so it was with great confidence that the task of replacing the right had sill began. </span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNAmqBSoNhC-9dQ2egFfmIp5j2yl9ADUP9uN-06bVVPfBy1pqPhY9uo55JU0ARzJX8Yf3pu_SkgZHoNT-VbFwKlbydMZb8y4SABelyvFEvtbRTr97OiXmmZ66gX4_769i278-XINkDLgxy/s1600/IMG_E2741.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNAmqBSoNhC-9dQ2egFfmIp5j2yl9ADUP9uN-06bVVPfBy1pqPhY9uo55JU0ARzJX8Yf3pu_SkgZHoNT-VbFwKlbydMZb8y4SABelyvFEvtbRTr97OiXmmZ66gX4_769i278-XINkDLgxy/s320/IMG_E2741.JPG" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;">Colin, of Unit Two Services, Ilkeston, Nottingham, (who's workshop I am still occupying) set about the sill with an angle grinder to see what secrets hid beneath. It was not good news! The strengthening beam had rotted away along with the bottom of the "A" pillar and the rear inner wing. The decision was made to cut away the bottom of the front wing and the bottom of the rear quarter panel and see how far the rot had gone..</span><br />
<br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7_HBDxxTTtBSsnSqYQsbA7MBucZnyAzpjQRhcSCmI8dPO0gx1-vstBqhc-64Yp1UmjhH2VZfsQIlm6gNMiy_4nTtQ1iiRjSY7mfSlOIR0K27zPsllfB60FsCp9ZX1SVuQeA6KKcn_ZDwG/s1600/IMG_E2742.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7_HBDxxTTtBSsnSqYQsbA7MBucZnyAzpjQRhcSCmI8dPO0gx1-vstBqhc-64Yp1UmjhH2VZfsQIlm6gNMiy_4nTtQ1iiRjSY7mfSlOIR0K27zPsllfB60FsCp9ZX1SVuQeA6KKcn_ZDwG/s320/IMG_E2742.JPG" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;"></span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></span>
<span style="font-family: Arial, Helvetica, sans-serif;">The more we cut away, the worse it got. </span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyQ-Jnq-HxPRZwtGCNPowDIGKPBK5k0OXiNXfll6LmkxfDQ84p2X3ELrZkJlZA-9BLU7xtzamHUUYLqimMlBDZpXcneGoWkPhkHxFotLjusYXSJSe3iEdEYDHcbCh5qR_K8SaQ1W8SPKqV/s1600/IMG_2743.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyQ-Jnq-HxPRZwtGCNPowDIGKPBK5k0OXiNXfll6LmkxfDQ84p2X3ELrZkJlZA-9BLU7xtzamHUUYLqimMlBDZpXcneGoWkPhkHxFotLjusYXSJSe3iEdEYDHcbCh5qR_K8SaQ1W8SPKqV/s320/IMG_2743.JPG" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">Until our hopes of an easy restoration on the right hand side disappeared. Not only was the strengthening beam rotten but also the back of the heater tunnel and the heater tunnel itself.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtoVzgCliQiwuP8POtBR0Elb4ZKjYpLTgFWSxaD0ho1DmGUmyMCnu8RN8s59Tnyc2yOOaR1Y9uP_hU59lu0YrGgjpSZK_PYZXonjUaVFbX1V0nOKqUua56_-_iL_T22LdEGhWwNg4HWlUS/s1600/IMG_E2762.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtoVzgCliQiwuP8POtBR0Elb4ZKjYpLTgFWSxaD0ho1DmGUmyMCnu8RN8s59Tnyc2yOOaR1Y9uP_hU59lu0YrGgjpSZK_PYZXonjUaVFbX1V0nOKqUua56_-_iL_T22LdEGhWwNg4HWlUS/s320/IMG_E2762.JPG" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;">Until the only decision had to be that another full reconstruction had to be done on this side as well. So everything was cut away, back to the chassis itself and reconstruction had to commence again.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
</div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuW85OOd8S-6_Yj174kBwk3LihN_uMM9S4KajAl6CK1I0MfMghqkNQYyNNxjwWDVHV34L0KZ-6mZdyfk_h9x0O5vUAVuKrREEqLIFLJ5bphHHHco5e5Zs6xfAJhRoLRf11wGQJigsXL4bM/s1600/IMG_2802.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuW85OOd8S-6_Yj174kBwk3LihN_uMM9S4KajAl6CK1I0MfMghqkNQYyNNxjwWDVHV34L0KZ-6mZdyfk_h9x0O5vUAVuKrREEqLIFLJ5bphHHHco5e5Zs6xfAJhRoLRf11wGQJigsXL4bM/s320/IMG_2802.JPG" width="320" /></a><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrf0VuzXo2o98ZMQ5kdP3Qwj8ybFkAmFrjquINiPEEUmLuVezFbPtnudFJQ4d1Qb91sFS3a1TpQ0ZtkQKjoPzUz-bGdsefmmsLjQIYpCcaAYCocSJXW1KgMJjzGnSW1q5hEYY8w6Ve57dT/s1600/IMG_2842.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrf0VuzXo2o98ZMQ5kdP3Qwj8ybFkAmFrjquINiPEEUmLuVezFbPtnudFJQ4d1Qb91sFS3a1TpQ0ZtkQKjoPzUz-bGdsefmmsLjQIYpCcaAYCocSJXW1KgMJjzGnSW1q5hEYY8w6Ve57dT/s320/IMG_2842.JPG" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;">At last a stroke of luck! When Colin made the heater tunnel for the left side, he also made another blank one for the right side, just in case. Now we had got to use it. So the holes were cut in it for the front heater vent and the oval hole for the heater tube under the rear seat. The replacement tunnel was then fitted into place and marked, through the floor pan, for the fixing plates and captive nuts. The new heater tunnel could then be bolted into place along with a new rear inner wing end plate and front "A" pillar end plate.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;">At the same time the repaired perforated rear heater tube had to be fiddled into place, because once the heater tunnel is bolted in you can no longer fit this tube. Once the tunnel is bolted in, the tube can be welded to the tunnel and to it's mating tube at the other end.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZfFkRkgl6GtLt4MkU2baH0_MiM1Jh9EP8TFP9CvzjwGx6kSX2REZmvGUmvy09Wd7jv2nEaqKZT7rEJkjYdqf7dWR12UUiY8rCgYJPLZB5ElLWziMSsdgmluUDw9wn0I0dc8dhlecWTzz2/s1600/IMG_2853.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZfFkRkgl6GtLt4MkU2baH0_MiM1Jh9EP8TFP9CvzjwGx6kSX2REZmvGUmvy09Wd7jv2nEaqKZT7rEJkjYdqf7dWR12UUiY8rCgYJPLZB5ElLWziMSsdgmluUDw9wn0I0dc8dhlecWTzz2/s320/IMG_2853.JPG" width="320" /></a></div>
<span style="font-family: Arial, Helvetica, sans-serif;">Now once the heater tunnel was back in place, the back of the tunnel and the new strengthening beam could be welded in and the car was now regaining some of its strength.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRhTxiOFCZoebEVE_BrhhSJeosrV-7WzpVNVXm7WwFfiz38oFDiC0Ac08s2Sr2jC0lkR60eDVCHAgUTzb5bQ4pEgNuwpgMwJM1cPtT8EUQp8OENl8FXfGYKDEKzZctA43v08_vjxDh0Yte/s1600/IMG_2854.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRhTxiOFCZoebEVE_BrhhSJeosrV-7WzpVNVXm7WwFfiz38oFDiC0Ac08s2Sr2jC0lkR60eDVCHAgUTzb5bQ4pEgNuwpgMwJM1cPtT8EUQp8OENl8FXfGYKDEKzZctA43v08_vjxDh0Yte/s320/IMG_2854.JPG" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">Now, at last, the new sill could be fitted and welded into place.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPiillWKOGQiUAjH_v2S68SQ_9nhiwXpvuAwUMr_nhXxmm0Od5xZ439_pU6-Y4oFhU2sAc0AyWpftslLlWbdK2VG6PmUWSsCdwk20DjyVmgIRLievk_-uOfQl1dQV96efSxy_LNZ4Lqo_z/s1600/IMG_2855.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPiillWKOGQiUAjH_v2S68SQ_9nhiwXpvuAwUMr_nhXxmm0Od5xZ439_pU6-Y4oFhU2sAc0AyWpftslLlWbdK2VG6PmUWSsCdwk20DjyVmgIRLievk_-uOfQl1dQV96efSxy_LNZ4Lqo_z/s320/IMG_2855.JPG" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">It was now time to turn our attention to the "A" pillar. Behind the lower hinge is a shaped box section that adds strength to the bottom of the pillar. This prevents the car bending at the crucial place, where the vertical pillar meets the sill and also supports the door. You would never see this unless you cut away the bottom of the front wing to reveal it. Care had to be taken when rebuilding this to ensure that it was both strong and did not hit the inside of the new bottom wing outer panel.</span><br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI-1fl9tmqMiZ9k7SMKBlJtk7V8pW2Ydy8-s6ihT4O7AWpLyK_P6VKFwAqpMJ6r4MdqdU63tRw86EK6owN8YwIIdaa-WII8-932Nq3OxHzlwZ7oXfSkHjhVTV3GyLuCQ3Og8E2nxA_sSR_/s1600/IMG_2892.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI-1fl9tmqMiZ9k7SMKBlJtk7V8pW2Ydy8-s6ihT4O7AWpLyK_P6VKFwAqpMJ6r4MdqdU63tRw86EK6owN8YwIIdaa-WII8-932Nq3OxHzlwZ7oXfSkHjhVTV3GyLuCQ3Og8E2nxA_sSR_/s320/IMG_2892.JPG" width="320" /></a></span></div>
<span style="font-family: Arial, Helvetica, sans-serif;"> The new bottom wing panel could now be fitted. Care was taken to cut this new panel in below the indentation for the Karmann Ghia badge as I still have this badge and want to refit it once the car is painted.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;">So there it is we are nearly there with the right side. Just the rear inner wing to construct and a new rear quarter panel to fit and then, at last, we can move onto the rear of the car.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7bmbIjinJrmnu7VuqBnuJFIMsh1kQTgoBxXKJf00oFNxxHPleskNKDst4yCQ2eiyFDEH5womoNX1t0lv5_9IHJCvpUkyFLFnpZwlygj362a-wJckgjGfelagZ-qZrAsYY7f1BhritsnEx/s1600/IMG_2893.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7bmbIjinJrmnu7VuqBnuJFIMsh1kQTgoBxXKJf00oFNxxHPleskNKDst4yCQ2eiyFDEH5womoNX1t0lv5_9IHJCvpUkyFLFnpZwlygj362a-wJckgjGfelagZ-qZrAsYY7f1BhritsnEx/s640/IMG_2893.JPG" width="640" /></a></span></div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><span style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">You can contact me on hopcroftscoot@gmail.com</span><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Copyright 14.01.19 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" style="background-color: white; color: #888888; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #888888; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #888888; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #888888; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration-line: none;">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a></span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com4tag:blogger.com,1999:blog-738504069791591427.post-14032696182484623492018-08-30T06:03:00.003-07:002018-08-30T06:03:46.469-07:0011. Karmann Ghia Restoration - Moving Forwards<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6Y2oHskTmhf-vNmF-VbkGfDl_e7ioZtcWilG5UioJpklq4uriUD3lPoeyp36h-pWCixmXpxG1aZX8UfOi6FJNSd3xJV1yVgFt_RN5MGuYBm0IMJ6yvu-MXy2zN0XtduV9UvZEy3qMv4RQ/s1600/Near+side01.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6Y2oHskTmhf-vNmF-VbkGfDl_e7ioZtcWilG5UioJpklq4uriUD3lPoeyp36h-pWCixmXpxG1aZX8UfOi6FJNSd3xJV1yVgFt_RN5MGuYBm0IMJ6yvu-MXy2zN0XtduV9UvZEy3qMv4RQ/s320/Near+side01.jpg" width="320" /></a></div>
<div style="text-align: center;">
<br /></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">It's hard to believe, looking at this early picture of my 1971 VW Karmann Ghia Convertible, that the left side front wing area could hold so many problems. But what was hiding under the surface was about to reveal itself.</span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheq1gTfD_pLTPqr3lyLa7biG0oCye8LXBRYO6gNFy2bAm2UJcTQPuxodAjtkErAwXdu1R9zKH32o_1KSCRFUKq1ebtHoQBcXlVAHv-s0mFBu2D1ty5rxZLWT_NAtmnaoXDWQDVq45dD2QC/s1600/IMG_2456.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheq1gTfD_pLTPqr3lyLa7biG0oCye8LXBRYO6gNFy2bAm2UJcTQPuxodAjtkErAwXdu1R9zKH32o_1KSCRFUKq1ebtHoQBcXlVAHv-s0mFBu2D1ty5rxZLWT_NAtmnaoXDWQDVq45dD2QC/s320/IMG_2456.jpg" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;">On the last blog the rear of the left side had been reconstructed and it was now time to move forward to the left side front wing. After removing the front wheel the first thing that became apparent was a suspicious looking metal plate that had been welded to the inner wing. This plate, measuring about 75mm tall and 200mm long, reached from the back of the "A" pillar and stretched in towards the centre of the car. It was decided to remove the plate and take a look at what it was hiding. The answer was "Nothing", literally. No inner wing, no back to the heater channel, no inner heater channel, no floor to the heater channel. Nothing was left in there and all that was giving the appearance of a heater channel on the inside of the car was rust held together with paint and carpet glue. This was serious. The front section of the heater channel (which carries no heat as it is redirected up to the dashboard before this section) provided strengthening support for the "A" pillar and the chassis. </span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg40Hu0dNRUoB7-u4-d-iGGH3iYCbXyEIuqKj3DaAxuvK3d7b-qLm6MgQMTBgJD9wHxt_YfWDyFQx2vWfLBEb2Qf4DGNo0GmWcm_0bvftfhzHWWNvvMX3QvRZRlsYUjAu-BthT-p5xUwD1n/s1600/IMG_2457.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg40Hu0dNRUoB7-u4-d-iGGH3iYCbXyEIuqKj3DaAxuvK3d7b-qLm6MgQMTBgJD9wHxt_YfWDyFQx2vWfLBEb2Qf4DGNo0GmWcm_0bvftfhzHWWNvvMX3QvRZRlsYUjAu-BthT-p5xUwD1n/s320/IMG_2457.jpg" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;">So there was no choice but to cut it all out and start another reconstruction. To do this the bottom section of the front wing had to be cut away along with the front corner of the floor pan and, of course the rotten remains of the inner heater channel. The remains of the heater channel were retained to allow it to be copied and maybe salvage a small part of the curved section.</span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRhPzPVZvnLPBh_Vgq0TVPc_xP8cBke1jBvvRIr6gJ54hONNnKRj27Hab2-6Ct7H7ezAX8jGeDu94Xmwn5uuFPyDOOZUItMqsCR3AI4Do3Jgy0LJdVYSO_fUKh6hIw7Xrm_bFStwLqR_in/s1600/IMG_2458.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRhPzPVZvnLPBh_Vgq0TVPc_xP8cBke1jBvvRIr6gJ54hONNnKRj27Hab2-6Ct7H7ezAX8jGeDu94Xmwn5uuFPyDOOZUItMqsCR3AI4Do3Jgy0LJdVYSO_fUKh6hIw7Xrm_bFStwLqR_in/s320/IMG_2458.jpg" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">Now a new floor of the heater channel could be made and welded into place. </span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSzMhUIfqss9VS8lEPxAIr-fvP1Q1_j3AexrB2kgrSFC9QmbvfZoEuYO2X8-9uO6WxIcRiLLLHm2PjkMt3j1GR0EthH7hbFc1Q2rw3qvocNxzdASxoRascHQuBCf1m3NPguk1zywQDUnje/s1600/IMG_2463.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSzMhUIfqss9VS8lEPxAIr-fvP1Q1_j3AexrB2kgrSFC9QmbvfZoEuYO2X8-9uO6WxIcRiLLLHm2PjkMt3j1GR0EthH7hbFc1Q2rw3qvocNxzdASxoRascHQuBCf1m3NPguk1zywQDUnje/s320/IMG_2463.jpg" width="320" /></a></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">Closely followed by new side plates and a new inner wing back plate. </span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"> On this picture you can see the cut-out section of the floor pan just offered back into place to make sure it still fits. Although it will never go back as I've already bought a complete new floor pan for the left side. Whilst in place, the holes for the bolts that hold the floor pan to the bottom of this new heater channel floor plate could also be marked, ready for drilling and the fitting of new captive nuts.</span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8IWwWKPv0NbxSyy4gmPyq5w0z5FP_n_6RK-ioV_d5movfO2Rq_1Mman7wh46cdM8rtpTI74XRZjGsJfV6gBPRa4Yo6cEUGBBMbmAOVkPukwawtCXU9iR4KfS4QJwbtOowvmDlwR6JKAb9/s1600/IMG_2464.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8IWwWKPv0NbxSyy4gmPyq5w0z5FP_n_6RK-ioV_d5movfO2Rq_1Mman7wh46cdM8rtpTI74XRZjGsJfV6gBPRa4Yo6cEUGBBMbmAOVkPukwawtCXU9iR4KfS4QJwbtOowvmDlwR6JKAb9/s320/IMG_2464.jpg" width="320" /></a></div>
<br />
<span style="font-family: Arial, Helvetica, sans-serif;">Now for the hard bit, the reconstruction of the curved section of the heater channel. As I mentioned on previous blogs, my car is currently at my friends business, Unit 2 Services, Ilkeston, Derbyshire, and Colin, who owns the business is pretty good with sheet metal, but I didn't realise ho good until now. Colin salvaged the usable curved section of the heater channel and grafted in a new corner section. The next problem was to cut a 50mm round hole in the new top plate. Now neither of us had a 50mm cutter so Colin drew a circle on the plate and then proceeded to cut a perfectly round hole with a hammer and chisel. I could not believe it, but there it was perfect. </span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUHiSjl0rQGx-_EsCJgRI8iv4K9gXP6uSEW0P3e18SHtK4IskMvqkdseCUqqNB0EQUTyp9zhmo-Fnr50C75zoh9bWMDoK7y8Qm565CJOmQk_lOHhzxD9EBeTZs-3XJvLgKX8OKyzTNFuq1/s1600/IMG_2486+%2528200%2529.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUHiSjl0rQGx-_EsCJgRI8iv4K9gXP6uSEW0P3e18SHtK4IskMvqkdseCUqqNB0EQUTyp9zhmo-Fnr50C75zoh9bWMDoK7y8Qm565CJOmQk_lOHhzxD9EBeTZs-3XJvLgKX8OKyzTNFuq1/s320/IMG_2486+%2528200%2529.jpg" width="320" /></a></div>
<span style="font-family: Arial, Helvetica, sans-serif;">The next stage was even more amazing. We now needed a 49mm tube to fit through the hole with a flange on the bottom. Colin had some 2" tube that was slightly too big. So first he beat a 5mm 90 degree flange around one end of the tube. Then, using "Pi" he calculated the circumference of the existing tube and the circumference of the tube required and took one from the other to calculate how much metal to cut out of the tube, which was about 5mm. He then cut the 5mm out of the side of the tube. Now all that was left was to close up the gap in the tube. But that would leave a oval tube. The next bit amazed me. Colin beat the flange (not the tube) with the wedge end of an engineering hammer and slowly the tube shrank closing up the gap and leaving a perfectly round tube. Wow!! </span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5aVyfjuWDbUmLm4nMPKBwvFrCmJCKU2b_LvluzgSFkk80TVryiCK8aDlUBmj-2LKMU0VoZpUjxXNyIjnUeXYCUQ1Elai-QyeOfzcwn3gOXESFydBCOjI0X63H95BTvAPtx_UplcHYShCk/s1600/IMG_E2502.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5aVyfjuWDbUmLm4nMPKBwvFrCmJCKU2b_LvluzgSFkk80TVryiCK8aDlUBmj-2LKMU0VoZpUjxXNyIjnUeXYCUQ1Elai-QyeOfzcwn3gOXESFydBCOjI0X63H95BTvAPtx_UplcHYShCk/s320/IMG_E2502.jpg" width="320" /></a></div>
<span style="font-family: Arial, Helvetica, sans-serif;">Finally the new section was welded in, closely followed by the new bottom outer wing section.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;">Well you would think that the problems under the front left wing were now over, but they weren't.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;">Another problem was lurking at the front and this was the fresh air intake box. The grills, on the front on the Karmann Ghia, allow fresh air to be directed up to the dashboard. </span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_5bH8YwNXmWXJ-rIvnZb3YIHK7blkWxinn_6UhQ1tnoU7naIH62j1jkfSCZgAbFdiYK9c0s9ApNaRoEb30YLg-jrsZH1uA94JflyTGUeprCPnGi2daWhu6EnVY8W3xb7YMGZhsiuSEJbt/s1600/IMG_2407.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_5bH8YwNXmWXJ-rIvnZb3YIHK7blkWxinn_6UhQ1tnoU7naIH62j1jkfSCZgAbFdiYK9c0s9ApNaRoEb30YLg-jrsZH1uA94JflyTGUeprCPnGi2daWhu6EnVY8W3xb7YMGZhsiuSEJbt/s320/IMG_2407.jpg" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">This is done via ducting boxes under the front wings and, true to form, the one on the left side was rotten. The rotten areas had to be cut out and new sections fabricated. Unfortunately, I did not take a picture of the repaired air box. but I'm sure you can visualise it, and it is now solid and back in place.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwiUXfPp_q853kt2vzwC2iAp00elH2c8tG1b4OYJTLzWq_r_dDonMHAl14GDAj1568UPfJHuYPOxa2R4PuA5JIaFBKc0_HmD2Wg70thDp_FZJtdZnSKzaiJ936EBNyI_R8lSTaQzozDVzp/s1600/IMG_2500.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwiUXfPp_q853kt2vzwC2iAp00elH2c8tG1b4OYJTLzWq_r_dDonMHAl14GDAj1568UPfJHuYPOxa2R4PuA5JIaFBKc0_HmD2Wg70thDp_FZJtdZnSKzaiJ936EBNyI_R8lSTaQzozDVzp/s320/IMG_2500.jpg" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;">Well things are going to jump forward at this point, as Colin decided to go into work over the August Bank Holiday and do some work on his own and to my surprise, when I turned up the following Wednesday, the car had turned around on the lift and was now facing the other way for the first time in a year, and it had gained the following.</span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">Two Headlight sections</span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3B-0QZTd3NThn4lHlv3DRhJwXQePL8QwNcnK4-M2oKPOY2QvQm0_OKvsDYJup02qH9OrXQJy0vEx2wtrXBBGIO8HioAE9pgQyvfMr6fQmgUP078fFB-F8T7xldiYyRlFLGbm1kecWswLT/s1600/IMG_2504.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3B-0QZTd3NThn4lHlv3DRhJwXQePL8QwNcnK4-M2oKPOY2QvQm0_OKvsDYJup02qH9OrXQJy0vEx2wtrXBBGIO8HioAE9pgQyvfMr6fQmgUP078fFB-F8T7xldiYyRlFLGbm1kecWswLT/s320/IMG_2504.jpg" width="320" /></a><span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">And a new Spare wheel well . He had also patched all of the small holes around the air intakes and the edge of the bonnet (hood). </span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">By the way, all of the "black" that you can see appearing on the repaired sections of the car is rust proofing treatment.</span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">So this is an enormous jump forward and we will soon be moving onto the right side of the car and a look at the other sill.</span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">Finally the gearbox has come back from being overhauled and looks great.</span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUemYyc5P0vzBW7-h-CB0yH4HlQvCMnVGTlQCNRWbNlFl8__znryjzdpZ5d_eR0oc_dYgckvNM20GZV01gMWc9oYxykLXFup4ReznpuwUmDgbV7qBhS3UvwMflNKM6KAEx8O05UpGvEu6I/s1600/IMG_2510.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUemYyc5P0vzBW7-h-CB0yH4HlQvCMnVGTlQCNRWbNlFl8__znryjzdpZ5d_eR0oc_dYgckvNM20GZV01gMWc9oYxykLXFup4ReznpuwUmDgbV7qBhS3UvwMflNKM6KAEx8O05UpGvEu6I/s320/IMG_2510.jpg" width="320" /></a></div>
<div>
<span style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">You can contact me on hopcroftscoot@gmail.com</span><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Copyright 30.08.18 all rights reserved.</span><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><span style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">My Other Blogs:</span><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 BSA A10 Super Rocket Motorcycle:</b><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" style="background-color: white; color: #888888; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">1961 Ariel Arrow Super Sport Motorcycle :</b><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" style="background-color: white; color: #888888; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration: none;" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Miniature Land Rover Defender:</b><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" style="background-color: white; color: #888888; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration: none;" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><b style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;">Motorcycle Trailers / Caravans:</b><br style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px;" /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" style="background-color: white; color: #888888; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px; line-height: 18.48px; text-decoration: none;">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a></div>
</div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-27156149827792189442018-04-14T06:22:00.001-07:002018-04-14T06:22:56.070-07:0010. Karmann Ghia Restoration - Reconstruction Surgery<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiCEAf7NF5cFPppMpO0D-4j6bw-3AOeX-KnEazq71feaz3smtjzEkyZHsBoLnVpiwCeEj576-NZuw7TMRrFc0wb8o3UZxQXWhB570A2P7Mua2Fzk37ux0ulUkGMHu52KubGQ_Ai56Uk46A/s1600/IMG_2272.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiCEAf7NF5cFPppMpO0D-4j6bw-3AOeX-KnEazq71feaz3smtjzEkyZHsBoLnVpiwCeEj576-NZuw7TMRrFc0wb8o3UZxQXWhB570A2P7Mua2Fzk37ux0ulUkGMHu52KubGQ_Ai56Uk46A/s320/IMG_2272.JPG" width="320" /></a></div>
It's time for some serious reconstruction of the bodywork on my 1971 VW Karmann Ghia convertible. So far I have been stripping and cutting into the old bodywork just to see what faces me and, as you saw from my previous blog, it's pretty bad. Most of the problems have been caused by an accident that the car had some time in its past and a very poor repair that was done to put it right, that allowed water to get inside the bodywork. The car is currently at my friends workshop (Unit Two Services, Ilkeston, Derbyshire) and I've been up there, with my friend Colin, every Monday, Wednesday and Friday trying to make progress whilst not trying to hamper Colin's business, which has to carry on at the same time.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6zMql6-eMTBskHMJCE6zJkhSIXFeYja7A82H2KkKb053a206zp3BgZX-L_7dHiLEJGlBkyyHfUY6LjJYksj8_ohVUKzW9uoxlSjUREN7ydH8w4i8CI8z7ZiE-23baOHD3C-ZneSTGn6e-/s1600/IMG-2194.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6zMql6-eMTBskHMJCE6zJkhSIXFeYja7A82H2KkKb053a206zp3BgZX-L_7dHiLEJGlBkyyHfUY6LjJYksj8_ohVUKzW9uoxlSjUREN7ydH8w4i8CI8z7ZiE-23baOHD3C-ZneSTGn6e-/s320/IMG-2194.JPG" width="320" /></a><br />
So the first decision is to attack the left sill, which was exposed on the last blog.Cutting the old sill away revealed the complexity of the metalwork that makes it up. Because this car is a convertible, all of the strength, that stops this car bending in the middle, is built into the sills and in the case of my car, that strength is gone.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicrrsZ-ELpEYLDahsimixgjDfWDORjMFcMxHv2jaByWoSNSlFTwwPLPFXcfcbVwqsZ7XdA_l6pGdA-H2z5Xa1KoFmYDEPrZqwXMfALarA2-9kDEDIWWKfdh3M4m6lWFxmwVZTl0uQGK5j6/s1600/Sill+Diagram.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="701" data-original-width="1600" height="140" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicrrsZ-ELpEYLDahsimixgjDfWDORjMFcMxHv2jaByWoSNSlFTwwPLPFXcfcbVwqsZ7XdA_l6pGdA-H2z5Xa1KoFmYDEPrZqwXMfALarA2-9kDEDIWWKfdh3M4m6lWFxmwVZTl0uQGK5j6/s320/Sill+Diagram.jpg" width="320" /></a>Colin decided that it would be a good idea to make the new parts out of thicker metal, to give the sill extra strength. This diagram shows the make up of the sill. The RED line shows the inner Heater Tunnel, a very complex shape and the backbone of the sill. Colin made a new one out of 2mm steel, complete with the captive nuts to allow the body to bolt to it. The BLUE line shows the back of the heater tunnel. This was made with 1.5mm steel and is welded to the heater tunnel. Next comes the GREEN line. This is the strengthening Beam, also welded to the heater tunnel and then finally the PURPLE line, which is the outer sill itself and the bit that you see on the surface, which I have already bought as a replacement panel.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPGwSZ7PzBpyDtQmq8dPKnOM4NxHkTKJo_gaxN0Z4ZoLZD6BB2Zkebv3QXV_Ve33AXWLPeUJAniU0o78EosUmQPaY1lM6eVybKCRhTAmdZL6mSRJraIKKK8YAcurvXPBD0E6IgqJwl-dJe/s1600/IMG_2228.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPGwSZ7PzBpyDtQmq8dPKnOM4NxHkTKJo_gaxN0Z4ZoLZD6BB2Zkebv3QXV_Ve33AXWLPeUJAniU0o78EosUmQPaY1lM6eVybKCRhTAmdZL6mSRJraIKKK8YAcurvXPBD0E6IgqJwl-dJe/s320/IMG_2228.JPG" style="cursor: move;" width="320" /></a></div>
<br />
Here you can see the completed heater tunnel, ready for fitting to the car. As you can see, it's not just a straight piece of metal as it has to include the oval connection tube for the heater pipe and a cut-out at the front for the heater vent. You can also spot a piece of perforated oval tubing, at the side of the heater tunnel. This was for repairing the "Y" shaped tube that joins the heater tunnel to the heater pipe coming from the engine under the back seat. <br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgomtybhJKsnu1hhFumgEARI47G9wjJt8I-hIaEFMfwnPpaOx6Ia7M6yhNtIj8TfpnLftzh_LWOhbgddEo6g5GQ-GUrH00gdrLnEcRBO_QfVWZCh3R-2YbrW-VE0NgVRdiMvDrLWRRrIEVV/s1600/IMG_2230.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgomtybhJKsnu1hhFumgEARI47G9wjJt8I-hIaEFMfwnPpaOx6Ia7M6yhNtIj8TfpnLftzh_LWOhbgddEo6g5GQ-GUrH00gdrLnEcRBO_QfVWZCh3R-2YbrW-VE0NgVRdiMvDrLWRRrIEVV/s320/IMG_2230.JPG" width="320" /></a></div>
On this next picture you can see the new heater tunnel in place with the new connecting "Y" shaped oval heater tube in place. This heater tube is wrapped with wadding to seal it and the purpose of the perforation is sound deadening, to prevent the sound of the engine fan transmitting into the car. It is "Y" shaped because it also branches off to provide a hot air outlet under the back seat and has an actuation flap inside it.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbP-afYQHBwikJxAWddkn4yFE96tiOVb1Cg009BHieMC4_4ElmoncDBzomUmznyNnhJLT0EMLKIZXPY4YCNihqDh4dVzlLBUvxTxvlr7W2J2XHhTqsTdK5yRuwUj74x89_dOsWWdM5UOtG/s1600/IMG_2232.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbP-afYQHBwikJxAWddkn4yFE96tiOVb1Cg009BHieMC4_4ElmoncDBzomUmznyNnhJLT0EMLKIZXPY4YCNihqDh4dVzlLBUvxTxvlr7W2J2XHhTqsTdK5yRuwUj74x89_dOsWWdM5UOtG/s320/IMG_2232.JPG" width="320" /></a></div>
Now with the heater tunnel bolted into place, it's time to make and fit the back of the heater tunnel. This is a simple "U" shape and is welded directly onto the back of the heater tunnel. As each part is added the sill becomes stronger and stronger.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSI0ktCbNsvqW-RNEdwO-9r0cvg2FbjnJjAP8ca6ETa447aq605dDA2Iv24XMP6OnpKB3fdlu8XT-r9ZcbvTL6tC9MdRMO2fLVGYnH1cnLK5v8H91xVeBem9DCEUfDlIrvAY9Grm5kLXxY/s1600/IMG_2234.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSI0ktCbNsvqW-RNEdwO-9r0cvg2FbjnJjAP8ca6ETa447aq605dDA2Iv24XMP6OnpKB3fdlu8XT-r9ZcbvTL6tC9MdRMO2fLVGYnH1cnLK5v8H91xVeBem9DCEUfDlIrvAY9Grm5kLXxY/s320/IMG_2234.JPG" width="240" /></a></div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiavn6UYvQ4VpFlB-KvqCMHyZ7qw-eDNRKHsJ9w_Q8w3VEM5PVDwHbHz67uL7G0Z8AoUw6vYlqF5jFAWIeWLgUJWzlMrhwZMIHlzJzLDF447gYQPigyFzv-yuNHjj5lAakKO9h5M9wgf4na/s1600/IMG_2237.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiavn6UYvQ4VpFlB-KvqCMHyZ7qw-eDNRKHsJ9w_Q8w3VEM5PVDwHbHz67uL7G0Z8AoUw6vYlqF5jFAWIeWLgUJWzlMrhwZMIHlzJzLDF447gYQPigyFzv-yuNHjj5lAakKO9h5M9wgf4na/s320/IMG_2237.JPG" width="320" /></a><br />
<br />
<br />
<br />
<br />
So here's Colin setting about making the next part, the Strengthening Beam. As you can see, he's a bit better equipped than me for making parts like this and with an industrial guillotine and folding press, he can make short work of producing a new part.<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Once made the new strengthening beam can be welded into place, covering the heater tunnel back plate and forming a third level of strengthening.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhIEPbvoCzL_a1ZlIQjtxw8iyBJhOd23WO5RJx5C0jQo-4ofPRkCBS_aiYPSAh3BqvMByjOBSIkU068rnnSjdh3wjcI71mOfWCDQTeBDMcXuA8yofa8keZyi8uliRY4o4Pq1meGD5M1VGt/s1600/IMG_2238.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhIEPbvoCzL_a1ZlIQjtxw8iyBJhOd23WO5RJx5C0jQo-4ofPRkCBS_aiYPSAh3BqvMByjOBSIkU068rnnSjdh3wjcI71mOfWCDQTeBDMcXuA8yofa8keZyi8uliRY4o4Pq1meGD5M1VGt/s320/IMG_2238.JPG" width="320" /></a></div>
So finally the new outer sill can be added and spot welded into place. The fixing of all of these new panels required the rebuilding of the rear inner wing and the front door pillar to give the new parts something to fix to at the ends. These repairs just required flat pieces of metal being welded in and then beaten into shape. They can then be trimmed off as finished panels are added.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRunBujfnm64gBhiKIYZ9fubOFuNmxCPJCEDFO7RU529mkwOeiHnDVJtWIbhci5GIG_EVIZg6kPVat6kI2kab65dPUB7czfekFQ9ek3Iub9ZSXzUwXZZEgcfxD0uAOhlz6jYd9ro8qJqFY/s1600/IMG_2263.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRunBujfnm64gBhiKIYZ9fubOFuNmxCPJCEDFO7RU529mkwOeiHnDVJtWIbhci5GIG_EVIZg6kPVat6kI2kab65dPUB7czfekFQ9ek3Iub9ZSXzUwXZZEgcfxD0uAOhlz6jYd9ro8qJqFY/s320/IMG_2263.JPG" width="320" /></a></div>
Now it's time to address the rear quarter panel and this involves adding new parts to the inner rear wing to support it. To my surprise Colin not only cut the new inner wing panels but also curved them to follow the shape of the wing. As I watch this man work, I become more and more aware that the level of skill required for this work is way above my capability. But it's really interesting to watch and I'm learning something new every day.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiYskvW63SA2Jty3kRCxvwKcO_wBEup2sRu_L-9SiB_AGeHZKHFParxIuRPYsvtGYMVBdqwVzHDUX_iwx2R3P9J9TRFUWCi7lumHtcZTEkKiL6mzX_W6_IVqTxzChADXoQTd_ieszoTUTG/s1600/IMG_2264.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiYskvW63SA2Jty3kRCxvwKcO_wBEup2sRu_L-9SiB_AGeHZKHFParxIuRPYsvtGYMVBdqwVzHDUX_iwx2R3P9J9TRFUWCi7lumHtcZTEkKiL6mzX_W6_IVqTxzChADXoQTd_ieszoTUTG/s320/IMG_2264.JPG" width="320" /></a></div>
The new rear quarter panel can now be offered into place and cut into the old bodywork to fit correctly. Only as you add these panels does the car actually resume its original shape. The accident, that damaged the left side of the car had pushed the side of the car in by about 1cm. Pulling the original body out to fit the new panels puts the original rounded shape back in again.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6_Ec6AcQBgUwjlaW5nND3LG8siXV0eduzxKCYs3g0Czf007EGdhsf7ObTNcKmxaTs40cTsyQHpkVDG_BS6l2xVnwjb4aUuPY-guBPkx7eHnrIvGsaDnSAsj8-DBoVWOYZHJU4lvgt3l9Z/s1600/IMG-2273.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6_Ec6AcQBgUwjlaW5nND3LG8siXV0eduzxKCYs3g0Czf007EGdhsf7ObTNcKmxaTs40cTsyQHpkVDG_BS6l2xVnwjb4aUuPY-guBPkx7eHnrIvGsaDnSAsj8-DBoVWOYZHJU4lvgt3l9Z/s320/IMG-2273.jpg" width="320" /></a></div>
It's time to turn our attention to the back quarter panel. Now whilst I have got a replacement panel, there was nothing substantial to fix it to, as the inner wing and box section had rotted away. This boxed in rear section is very important and needs to be strong because, not only does it support the outer bodywork panel, it also provides all of the strength for the rear bumper mounting. So, true to form, Colin set about reconstructing the rear box section with new steel to both the inner wing and the bumper support.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglbzTkgyjA9ZJM1BMsScDd_cTOs4B_TMAOykpNuc8iUV5Z_ajHHzlaRQcVYdnwfEfZPWSD1LUpA42W64EjyefmWAyDBNtsrdrx1Um45ZyEeWWEakXmk1V7LST1HwH-9DdZ0AtTmAUrrl-M/s1600/IMG_2272.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglbzTkgyjA9ZJM1BMsScDd_cTOs4B_TMAOykpNuc8iUV5Z_ajHHzlaRQcVYdnwfEfZPWSD1LUpA42W64EjyefmWAyDBNtsrdrx1Um45ZyEeWWEakXmk1V7LST1HwH-9DdZ0AtTmAUrrl-M/s320/IMG_2272.JPG" width="320" /></a></div>
Now the new back quarter panel can be clamped in place and the new wheel arch clamped over too, to see how it all fits.<br />
<br />
As you can see it fits beautifully and the car really looks how it should at last. <br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbv9YhAdIuHck2Q8P2a0BrUT3FYdASqx3ViJr3UATLM3DKhU8j72kxO_3YBzSD2d3gV3iB7aYWHRsrrRcTwrkfXH7fSGk6TbVOZESkRGNgw1Kz8SO1EFcZC4g2QVdNG2eLFDsuOTIrG4Hc/s1600/IMG-2275.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbv9YhAdIuHck2Q8P2a0BrUT3FYdASqx3ViJr3UATLM3DKhU8j72kxO_3YBzSD2d3gV3iB7aYWHRsrrRcTwrkfXH7fSGk6TbVOZESkRGNgw1Kz8SO1EFcZC4g2QVdNG2eLFDsuOTIrG4Hc/s320/IMG-2275.jpg" width="320" /></a></div>
Here you can see the panels finally spotted into place. Now comes the full welding along all of the seams and then the sanding down of the welds to create a smooth panel.<br />
<br />
<br />
Well that's it for the bodywork for this episode but I did have one more event that was a bit of a step backwards and one bit of progress.<br />
<br />
The backward step was that I had sent off my gearbox for aqua-blasting. I had hoped that, as the gearbox worked perfectly, I could simply clean it and not strip it. When it returned it was lovely and clean but I did notice some gritty deposits in the bell housing etc. So I decided to take the differential side plate off one side, just to check that none of this grit had got into the inside of the gearbox. Bad news! The bearings were full of grit as was the rest of the differential, so it was reasonable to expect that it had also got inside the gearbox proper. So I've had to send it off for a complete strip with all new bearings and seals.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiANivV42rhTcFPwj-5YtDgrF5yoN7YsahUK17IHJTl3xY7OIkoIVi1vGyAge8oMHPUVGHbMp-u4CIVFOmiCtUwXW3eW4PFsW3pVKYwzDRED6SQDZ0IXJVtyGOmdW5unKsVrHYzKSzpJyXc/s1600/DSCF2573.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiANivV42rhTcFPwj-5YtDgrF5yoN7YsahUK17IHJTl3xY7OIkoIVi1vGyAge8oMHPUVGHbMp-u4CIVFOmiCtUwXW3eW4PFsW3pVKYwzDRED6SQDZ0IXJVtyGOmdW5unKsVrHYzKSzpJyXc/s320/DSCF2573.JPG" width="320" /></a>The progress was with the engine. The dairy tubes, that I had been waiting for, finally arrived and I was finally able to take the whole engine up to Colin's to have the heater pipes made. By cutting the tubes at different angles, Colin was able to make the twisted tubes needed to connect the heater boxes to the fan housing tubes. <br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCADBUd3w-ewjwDWiWhoZa5_6vFKtm0s_dDL1cxOJ4QIcdDtAJHnmz7QWCvegV-ZKwNqKM42RaypMxYwvZqNh5nMMqLnSb-zNHcWnIbtpT_3s0rGzjmoG3dtkwFgy4JOKjCC9EJ1TX-Quh/s1600/heater+pipe.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCADBUd3w-ewjwDWiWhoZa5_6vFKtm0s_dDL1cxOJ4QIcdDtAJHnmz7QWCvegV-ZKwNqKM42RaypMxYwvZqNh5nMMqLnSb-zNHcWnIbtpT_3s0rGzjmoG3dtkwFgy4JOKjCC9EJ1TX-Quh/s320/heater+pipe.jpg" width="240" /></a><br />
<br />
<br />
The fitting of these tubes finally allowed the heater pipes to be fitted and the engine to be completed and it is now off the stand and got 4.5 pints of mineral oil in it.<br />
<br />
I've now got the long wait, before it can be fitted in the car and see if it actually goes!!<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT9xnTeefMwmyFz2Emve7cokwwYH7NR4dRKZWxtTZ_jpBq1EIj3clNvrYxYyBqkyHF-_TDqYlHh-ZpptPeSfZNwsc3uznWNdQbI2O4LKL1I-4V-nlvDyAdZR6gpyMBbrZhQen8EFRBimlh/s1600/IMG-2241.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT9xnTeefMwmyFz2Emve7cokwwYH7NR4dRKZWxtTZ_jpBq1EIj3clNvrYxYyBqkyHF-_TDqYlHh-ZpptPeSfZNwsc3uznWNdQbI2O4LKL1I-4V-nlvDyAdZR6gpyMBbrZhQen8EFRBimlh/s640/IMG-2241.JPG" width="640" /></a></div>
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 14.04.18 all rights reserved.<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br />
<a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-39693880342385257282018-02-14T09:07:00.000-08:002018-02-14T09:07:18.715-08:009. Karmann Ghia Restoration - Bodywork Begins<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi380AHq5BMm2oU7DmTOUWp2t53Xc4BQnSUUHkuJ1wVN8DA1cGvL0BYZfDtZgKH9mupqcl9OYAPa9TPP860QE8mQZy_vr8CaNJSYbC6IDMYREnXFmpGus5qxZtRftBq-Wf-3R1nBw30FwmF/s1600/DSCF1364.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi380AHq5BMm2oU7DmTOUWp2t53Xc4BQnSUUHkuJ1wVN8DA1cGvL0BYZfDtZgKH9mupqcl9OYAPa9TPP860QE8mQZy_vr8CaNJSYbC6IDMYREnXFmpGus5qxZtRftBq-Wf-3R1nBw30FwmF/s320/DSCF1364.JPG" width="320" /></a></div>
I'm under no illusions how bad the bodywork is on my 1971 Karmann Ghia Convertible. It's Bad! I mentioned, in a previous blog, that the car has now been transported to my friends workshop (Unit Two Services at Ilkeston, Derbyshire), and we have at last started the slow and laborious work of trying to make a concours car out of a rusty wreck.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibscS_fa0fNNqsW0jtaa8uMp5HelGFxQXeV4rYYa5mHYHJrn29HLTNgvUcqRbJPT5bFUkepvbYeBVnKpD5tbYLDT15-62yvpSvZBGy3_J_SKD1EtS4ezN-6ZdtL_aY_Xyemtp7i96ePeLZ/s1600/IMG_2133.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibscS_fa0fNNqsW0jtaa8uMp5HelGFxQXeV4rYYa5mHYHJrn29HLTNgvUcqRbJPT5bFUkepvbYeBVnKpD5tbYLDT15-62yvpSvZBGy3_J_SKD1EtS4ezN-6ZdtL_aY_Xyemtp7i96ePeLZ/s320/IMG_2133.JPG" width="240" /></a> These, so far, are the new panels that I have bought. From the top:<br />
1. Bottom of wheel well<br />
2. Left headlamp surround<br />
3. Left headlamp bowl<br />
4. Right headlamp surround<br />
5. Right headlamp bowl<br />
6. Right front floor pan<br />
7. Left replacement sill<br />
8. Left Rear wing front lower section<br />
9. Right replacement sill<br />
10. Right Rear wing front lower section<br />
11. Left rear wheel arch<br />
12. Left Rear wing back lower section<br />
13. Engine tray left panel<br />
14. Engine tray right panel<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh48c4qKCFNkjVFXtuI0KxBVWO4V5vmtcD5KMee4GqdycIWmytWQDQ6IHpiXKiGtVcx2arXS78LWmO85Ob-QxM3W11-XNPEExEvuXI73o3AyykTmhYznkWJ0CNmBYPXcW6AYevt3vSuOIHE/s1600/IMG_2128.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh48c4qKCFNkjVFXtuI0KxBVWO4V5vmtcD5KMee4GqdycIWmytWQDQ6IHpiXKiGtVcx2arXS78LWmO85Ob-QxM3W11-XNPEExEvuXI73o3AyykTmhYznkWJ0CNmBYPXcW6AYevt3vSuOIHE/s320/IMG_2128.JPG" width="320" /></a>15. Engine tray rear panel<br />
16. Rear valance.<br />
<br />
As you can see it's quite a list and I think there will be more. The next job is to offer each new piece into place and mark around it with a felt tip pen. This shows where the body has got to be cut. It is then a case of sanding away all of the paint and filler (which is considerable) until bare metal is revealed. This is a very lengthy process and fills the workshop full of clouds of dust.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSwBB6_sXj5c27-pgnXJFlrtRi0ZfvtUXbAn608Q_cPKmX2UlI-aXOBlhdeDmYHD6azoQS39hTl3jrECTs4R3C1rmTiAIAcrApyjbO_gsM09bmbsTKZBsex3w6AVJrK2uuQOtnxKfyQIJl/s1600/IMG_2143.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSwBB6_sXj5c27-pgnXJFlrtRi0ZfvtUXbAn608Q_cPKmX2UlI-aXOBlhdeDmYHD6azoQS39hTl3jrECTs4R3C1rmTiAIAcrApyjbO_gsM09bmbsTKZBsex3w6AVJrK2uuQOtnxKfyQIJl/s320/IMG_2143.JPG" width="320" /></a>This sanding process has revealed the true extent of the accident damage that this car has received with a previous owner. If you look carefully at this picture of the left rear wing, you can see two rows of holes running along the body. This is where the bodywork has been pulled out with a slide hammer, to try and pull it back into place. Every one of these holes will need to be welded up, sanded and beaten back into place.<br />
<br />
You may also notice how high up the wing I have had to sand, a long way from the new panel felt tip lines. This is because of the amount of filler that was used in order to try and get this panel back into shape.If you look at the bottom left of the picture you can see the thick filler still on the part that's got to be cut out. <br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwUK5BowJR4DoD5LQkf1AATRK4L1CQMDoevAp7rOghp-LHpcT8_nNYNcUZDbVAkmilRCcDAbqb4hlfdmahd5XsEyuVz-Jid5B1CeYVbQ-6cF-NBhTPJlyA-HvPs2X2zPo_j4eUEk0c18ax/s1600/IMG_2146.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwUK5BowJR4DoD5LQkf1AATRK4L1CQMDoevAp7rOghp-LHpcT8_nNYNcUZDbVAkmilRCcDAbqb4hlfdmahd5XsEyuVz-Jid5B1CeYVbQ-6cF-NBhTPJlyA-HvPs2X2zPo_j4eUEk0c18ax/s320/IMG_2146.JPG" width="320" /></a></div>
<br />
The next job was to cut the headlight bowls out so that Colin could get his arm inside the front wing to start panel beating the dozens of dents that were hiding under the paint.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdvzB0VNHnhUWkW483yMsHE9EcvGTsAAxVn3wdgHhY7QmUkrKBtLjGhOlvv9e5Fy39_KH1zV9fEXWKJsGNtMtXGmARfROaWcUNPZYlz_yxfs2PNiW5x1nrqFfDuCp2PsR5gV4neQpdeoMr/s1600/IMG_2142.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdvzB0VNHnhUWkW483yMsHE9EcvGTsAAxVn3wdgHhY7QmUkrKBtLjGhOlvv9e5Fy39_KH1zV9fEXWKJsGNtMtXGmARfROaWcUNPZYlz_yxfs2PNiW5x1nrqFfDuCp2PsR5gV4neQpdeoMr/s320/IMG_2142.JPG" width="320" /></a></div>
So here is Colin hard at work panel beating the wing back to the shape it really should be.<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC1bE9Dv6p_ATAQFOzmbBKdyOfMOmpBg2F-V0CkwSKygUqcvHmzy37EXwyH9ezUtHrWWyIhPOQ9szLfKqEgQmT5lIs7gDMayVL_lgXpYDhr_45CKKRH8yiKZhJqFstpZ1hAtyrrKiPeRvh/s1600/IMG_2144.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC1bE9Dv6p_ATAQFOzmbBKdyOfMOmpBg2F-V0CkwSKygUqcvHmzy37EXwyH9ezUtHrWWyIhPOQ9szLfKqEgQmT5lIs7gDMayVL_lgXpYDhr_45CKKRH8yiKZhJqFstpZ1hAtyrrKiPeRvh/s320/IMG_2144.JPG" width="320" /></a></div>
<br />
And here is a good comparison. The right section of the wing is now beaten and the left front section is yet to be done. This takes a very long time and requires skills way above my level.<br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNY1BycEnAUxu9x_qzFMiTa4lpYrphtkI2s0T4SmM7DdpSCAmFOxTP3vMVfvibAlLynXGrZ_3vPFGAaOuspvpy1_EPuycQ7m7g7hVqzFTL7GLHdKZV4YxMxmTDtPlp4KmEZhfWRxX0aBNe/s1600/IMG_2152.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNY1BycEnAUxu9x_qzFMiTa4lpYrphtkI2s0T4SmM7DdpSCAmFOxTP3vMVfvibAlLynXGrZ_3vPFGAaOuspvpy1_EPuycQ7m7g7hVqzFTL7GLHdKZV4YxMxmTDtPlp4KmEZhfWRxX0aBNe/s320/IMG_2152.JPG" width="320" /></a><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihoae3jf8QMCQ7P-apRu-aAhARQq_OXIEhg3SJhvDNpEEc7NPNiB4LKrlL_e3KfK3wGN0dKpEe1SlReQdu5U73Xlhg9SLeMuN78kRpZfTUqOIn-brm-dZSmP9vs6BLf37KrGEKFmNALRpg/s1600/IMG-2164.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihoae3jf8QMCQ7P-apRu-aAhARQq_OXIEhg3SJhvDNpEEc7NPNiB4LKrlL_e3KfK3wGN0dKpEe1SlReQdu5U73Xlhg9SLeMuN78kRpZfTUqOIn-brm-dZSmP9vs6BLf37KrGEKFmNALRpg/s320/IMG-2164.jpg" width="320" /></a>The next and biggest problem is the sills. Because this car is a convertible, there is no strength provided by a steel roof. Consequently the sill have internal strengthening to stop the car sagging in the middle. On my car the sills are rotten so when I lift the car on the hoist the door jams widen and when I put it back on its wheels they close up again. Before we can cut the old sills away, the car must jacked up at different heights on all four corners until the door jams are perfect. The doors then had to be removed and bracing fitted to hold that position whilst we cut the rotten sills away. This was done by making steel plates to bolt onto the door hinge mountings and the seat belt mountings and then welding 6 heavy metal tubes to the plates in a criss-cross pattern.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRQIdqht9_UQBaDOhmt5Rn_lOHiPIZPSXdpRdUrw2RrNNrpOERirulHxKqtgQ0c9qUBGODJA41w70_lpmOeWvJ8F_tkELv5uZrSpN8q0kl-wMcLx4tQjxOIoq5GUxFCAVozo0toTNDQNEV/s1600/IMG-2165.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRQIdqht9_UQBaDOhmt5Rn_lOHiPIZPSXdpRdUrw2RrNNrpOERirulHxKqtgQ0c9qUBGODJA41w70_lpmOeWvJ8F_tkELv5uZrSpN8q0kl-wMcLx4tQjxOIoq5GUxFCAVozo0toTNDQNEV/s320/IMG-2165.jpg" width="320" /></a> Now, at last, we can cut away the sill and the bottom quarter panel and take a first look at the true extent of the damage. And it's not good. The long horizontal plate that you can see with holes along it is the strengthening plate, that should run from wheel arch to wheel arch. As you can see it has rotted away. Also virtually totally missing is the back of the heater tunnel box section, which also adds strength. All of this will have to be fabricated from new steel and welded in place before I attempt to remove the body from the chassis.<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkAthl5_WbMWm-b8Jll63nWVYB0Uzt_o95yJEqsxTyxbRsnlASJcWCNAP6FugY3RlfrPrZV2mbCn5vxPTuYFFEWa5fs6TMo4nssIXOhuryAwqPL8p8WSisaFw_TInd2Phv8lHsw9C8bmhh/s1600/IMG-2171.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkAthl5_WbMWm-b8Jll63nWVYB0Uzt_o95yJEqsxTyxbRsnlASJcWCNAP6FugY3RlfrPrZV2mbCn5vxPTuYFFEWa5fs6TMo4nssIXOhuryAwqPL8p8WSisaFw_TInd2Phv8lHsw9C8bmhh/s320/IMG-2171.JPG" width="240" /></a><br />
Finally, we were just looking at the back of the car and Colin noticed that the left rear light appeared to be on a slant, tucking in at the bottom. Investigation revealed that the accident had pushed the back of the car in and forward and this had pulled the bottom of the rear left wing inwards. To prove this we cut the rear engine tray and rear valance in half. It immediately sprung outward at the bottom and the rear light was now vertical. It's a good job that we are replacing those rear panels anyway.<br />
<br />
<br />
So that's where we are. The car is fully braced and the level of work required is still growing.<br />
<br />
More next time as the car goes under the cutter for major surgery.<br />
<br />
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 14.02.18 all rights reserved.<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br />
<a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a><br />
<br />
<br />
<br />
<br />
<br />
<br /></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-68677718442294309082018-01-01T02:40:00.001-08:002018-02-14T07:36:20.863-08:008. Karmann Ghia Restoration - Engine Rebuild Part 3<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYPly3V839LsCIKxoIlvwAsKKclxcSxDtiv8mOMKvBlfgYc5r719rmmSrA7OQ-UPqL3MltU4ChIDLd_51tpuJmBMOMxcdt0eVxrQcO77eq7j0qT_qTn59PMa7pcGLUkKKBAEjJG0xoL1wU/s1600/IMG-2120.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYPly3V839LsCIKxoIlvwAsKKclxcSxDtiv8mOMKvBlfgYc5r719rmmSrA7OQ-UPqL3MltU4ChIDLd_51tpuJmBMOMxcdt0eVxrQcO77eq7j0qT_qTn59PMa7pcGLUkKKBAEjJG0xoL1wU/s320/IMG-2120.jpg" width="320" /></a></div>
Well it's time for the final bits and bobs to go onto the engine for my 1971 Karmann Ghia convertible restoration. As I mentioned earlier in the blog, this is a "dry build", so quite a lot of the items fitted will have to come off again before the engine is fitted in the car. Consequently some things have been fitted without gaskets and in some cases not all of the fixings. Just sufficient to be sure that everything will fit when the time comes. This has turned out to be very wise, particularly with regard to the chrome engine tinware. I don't think that there has been a single panel that has not needed modification and I repeat my warning; "If you are considering fitting this replacement chrome tinware (and it's not chrome, it's thin polished stainless steel) which does look beautiful, then be prepared for lots of extra work.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv3A_s_XSkv3pE55s6WBILP3GvzfswHc0BF9ZssMr5WGlryOKwVBWCFszwtb-YY4dkhIVCQJ8XKnQSO3IDTHC41tHAx-WV2CyFyuRi-Usdx2_zCL7Vo8JM1WlyfbZ4iRtr1deymBfSsdYo/s1600/IMG-2095.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1199" data-original-width="1600" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv3A_s_XSkv3pE55s6WBILP3GvzfswHc0BF9ZssMr5WGlryOKwVBWCFszwtb-YY4dkhIVCQJ8XKnQSO3IDTHC41tHAx-WV2CyFyuRi-Usdx2_zCL7Vo8JM1WlyfbZ4iRtr1deymBfSsdYo/s320/IMG-2095.jpg" width="320" /></a></div>
So here's the next, and very typical, example. I decided to try fitting the rear engine tray. Everything lined up on the right hand side, but the left side overlapped the exhaust flange, as you can see in the picture. Now, as I am fitting twin carburettors, I don't actually need these inlet manifold flanges, but I do need to blank them off and I can't do that and make a gas tight seal with the tinware where it is.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdgaTLdbIfX9PA8wXbuEW2R4tofUesQ1vt2_x_vizfa_MQdEaI9Kq5yq9LYYCctG7DiF9VDVttpIvLX_PY7QGivGSlm0X4IkW-N47zpCRzKEFlvMOp81ZE68GvglHtrjqky090aTGLgtMb/s1600/IMG-2096.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdgaTLdbIfX9PA8wXbuEW2R4tofUesQ1vt2_x_vizfa_MQdEaI9Kq5yq9LYYCctG7DiF9VDVttpIvLX_PY7QGivGSlm0X4IkW-N47zpCRzKEFlvMOp81ZE68GvglHtrjqky090aTGLgtMb/s320/IMG-2096.jpg" width="320" /></a>So I marked the tray, with a chinagraph pencil, where it needed to be cut and removed the tray again and set about it with a small cutting disc on the Dremel. I also took a small amount off the right side too, just to give it a bit of clearance. I then had to finish and re-polish the edges, but it now fits and I could look at making some nice blanking plates for the flanges.<br />
<br />
So I made two cardboard templates, one for each side, and then found some thick aluminium to make the plates out of. These have to be quite thick in order that they don't distort when tightened down to make a gas tight seal.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioLHixIYnlue1-ZfNRAl8rKt0y06F_nLBGKsNo01G2AwFTvQBL7cgVBw0XpEU-IO1GYGJ89psM72niJREwtu1oCu1fGs5DJD_IE1gER41XgAbfvmZUOdaxGjJVb1NsGCDwRNZKY_fUtEJG/s1600/IMG-2097.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioLHixIYnlue1-ZfNRAl8rKt0y06F_nLBGKsNo01G2AwFTvQBL7cgVBw0XpEU-IO1GYGJ89psM72niJREwtu1oCu1fGs5DJD_IE1gER41XgAbfvmZUOdaxGjJVb1NsGCDwRNZKY_fUtEJG/s320/IMG-2097.jpg" width="320" /></a><br />
I then marked out the aluminium using the templates and cut them out. By placing the cardboard templates over the flanges, I could poke a spike through the templates to mark the correct position of the fixing holes. These positions could then be transferred to the blanking plates to allow them to be drilled, with a 6mm drill, for the fixing bolts.<br />
<br />
All that was left then was to polish the blanking plates and fix them in place using the normal VW gaskets underneath to make a good seal and tighten down the bolts nice and tight.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2d-0ltEo0ZXuF0PSLL-Lr_Uk7TfpZqnIHTFTxSHiMJKrA6Oa6esuBZMxN06E_Empxh5EsryNEJ93gESQqmEl9LBP7YUZTONLZ1OJX7sTTKKpfn0FH5H5HQxg3uk32tx1op7F5d86WgFoF/s1600/Pods.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="539" data-original-width="1600" height="107" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2d-0ltEo0ZXuF0PSLL-Lr_Uk7TfpZqnIHTFTxSHiMJKrA6Oa6esuBZMxN06E_Empxh5EsryNEJ93gESQqmEl9LBP7YUZTONLZ1OJX7sTTKKpfn0FH5H5HQxg3uk32tx1op7F5d86WgFoF/s320/Pods.jpg" width="320" /></a></div>
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsbuua-RzA9MgLJOFxYEGxLrPCmQiT0PK8rvmWSfoWSl4PreMy7gTYMnRXwTfPpwkxsjSgp_JUaeZeohJN876_kfbeRKd_B3WLkHSyhuXXstRiLMHTcg2nPcQmIA_mG-e53ZTeshP_g8qt/s1600/IMG-2101.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1201" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsbuua-RzA9MgLJOFxYEGxLrPCmQiT0PK8rvmWSfoWSl4PreMy7gTYMnRXwTfPpwkxsjSgp_JUaeZeohJN876_kfbeRKd_B3WLkHSyhuXXstRiLMHTcg2nPcQmIA_mG-e53ZTeshP_g8qt/s320/IMG-2101.jpg" width="240" /></a>So now it was time to take a look at the heater pipes. These are the two large flexible hoses that come from fan housing and pass down through the large holes in the rear engine tray and connect to the two heat exchange pods that are mounted on cylinder 2 and 4 exhaust pipes and these in turn connect to the heater boxes. Well they don't!!! Firstly the heat exchange pods are missing on the sports exhaust. So I thought that I could simply connect the hoses from the fan housing, down through the two holes in the rear engine tray and connect them directly to the heater boxes.<br />
<br />
So I stupidly set about making two adaptor tubes to fit in the heater boxes, for the hoses to fit on to. They fit into the heater boxes well, but I then discovered that there was no way that I could get a hose on to them as they are directly below the rear exhaust pipes. So they had to be scrapped. My next idea was to remove the pods from my original silencer and fit them around the new exhaust pipes. Getting them off the old exhaust wasn't too difficult, however when it came to offering them up to the new exhaust I found that the sports exhaust pipes are at severely different angles from the original exhaust and this stops the pods lining up with the heater box and the holes on the engine tray. Failure number two!!<br />
So finally I decided to give my friend, Colin, a call at "Unit Two Services" (Formally Gladex) in Ilkeston, Derbyshire. He came and had I look and said that what I need are "Dairy Tubes". I had no idea what he meant, but apparently they are tubes bent at right angles that can be cut and welded together to fit around difficult bends. He said he would order some for me and give me a call when he can fit them. So that part of the build is now on hold.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioQsHEPHch6-7okfxTvVIfbDDsJdn0OWTpsFf3eQF69DZmrYBfH63QPusc9rJ02QWvhr6MGuNifiu5PEp9C9K30QbrZPhloueNw54IK2wWFo-z8HwEzmNFl6umdWwNzXKc298cI_lDUx47/s1600/IMG-2100.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioQsHEPHch6-7okfxTvVIfbDDsJdn0OWTpsFf3eQF69DZmrYBfH63QPusc9rJ02QWvhr6MGuNifiu5PEp9C9K30QbrZPhloueNw54IK2wWFo-z8HwEzmNFl6umdWwNzXKc298cI_lDUx47/s320/IMG-2100.jpg" width="240" /></a></div>
I then turned my attention to the other end of the exhaust/heater system and decided to fit the heater levers. These open flaps inside the heater box and allow warm air to pass to the inside of the car. After greasing the pivot points I proceeded to fit the levers, not realising that there was a left and a right. I had looked at the levers and at first glance they looked identical, but I missed one small hole. That is the hole that the return spring fits through and must be to the flywheel side. Needless to say I didn't spot this until it came to fitting the springs and I had them the wrong way around. So they had to come off again and swap sides.<br />
<br />
The next bit is no surprise. I hooked the return spring onto the lever and then found that there was no hole in the tinware to hook the other end. I checked on the original tinware and found where the holes should be and then had to drill the new ones to suit. Not a big job but yet another missing detail on the replacement tinware.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-Lmaau95HzyZ5okHI-QK0UpS52wX8b1ad7xPc3lMUAgc8RHr7DZXbsVXUa3q-pONPgXC6yFpUmZJporQsbYtu7ElRFdab5UJpC7NOHlkzONhel47XLf2P4uUZ_4h8I6uWqibZPy7tyYBl/s1600/IMG-2098.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-Lmaau95HzyZ5okHI-QK0UpS52wX8b1ad7xPc3lMUAgc8RHr7DZXbsVXUa3q-pONPgXC6yFpUmZJporQsbYtu7ElRFdab5UJpC7NOHlkzONhel47XLf2P4uUZ_4h8I6uWqibZPy7tyYBl/s320/IMG-2098.jpg" width="320" /></a></div>
Now for an exciting bit. I decided to try dry fitting the twin carburettors. These fit remarkably easy, straight on top of the inlet manifolds with mounting plates on top to support the actuating bar that runs between the two. This bar was the only thing that needed modification and I had to shorten it by about 50mm (2") for it to fit nicely between the two carburettors. I must admit that they have made a huge difference to the look of the whole engine.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsd1vtfjJCPnT-oaKjA6WIG8_8R9n0DzCxPyCr1yErBoKQ4_zpsaTFxLFif1HNpgYfG8xNsj7IY8A1Q4h113x73krxFCZB9TywD3YrkLP4Rw7nKPMslodCVTIqNzwtaprE9qVYX5z1KZpt/s1600/IMG-2109.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsd1vtfjJCPnT-oaKjA6WIG8_8R9n0DzCxPyCr1yErBoKQ4_zpsaTFxLFif1HNpgYfG8xNsj7IY8A1Q4h113x73krxFCZB9TywD3YrkLP4Rw7nKPMslodCVTIqNzwtaprE9qVYX5z1KZpt/s320/IMG-2109.jpg" width="320" /></a>So now just some final bits. Time to fit the HT coil. Now normally the HT coil bolts to two captive nuts mounted on the fan housing behind the distributor. Well firstly it can't go quite as high as normal or it will hit the Carburettor actuating bar and secondly (you know what's coming) the new tinware has not got any captive nuts in it anyway. Obviously I could simply drill the fan housing and fix the HT coil in place with two self tapping screws. But I didn't think that self tappers were a good idea on a vibrating engine and felt that over time they may come loose. I needed captive nuts, but you can't get to the other side of the fan housing front plate to fix them. So once again I went to see my friend Colin and low and behold he had a special tool for fitting "Hank Bushes" These are like threaded "Pop Rivets" and can be inserted from one side of a piece of metal, just like a Pop Rivet, and then compressed with this tool to fix them in place. Well I borrowed it and it worked fantastic first time. So with two 6mm thread Hank Bushes in place I could now fit the HT coil.<br />
<br />
The old HT coil was in good working order but like everything else, pretty grotty. It had been hand painted with blue paint and the fixing bracket was rusty. Now I had already bought a polished stainless tubular trim plate to fit around the coil and a nice new chrome mounting bracket, but the coil itself posed a problem. As it mounts upside down, you would be able to see the old painted bottom sticking through the stainless sleeve. I've polished a few HT coils on motorbikes before and they have always been made of aluminium. But this one was steel and if I polish it, it will rust. So my first thought was to repaint it. But as I started to clean it another thought hit me. If I polish it to a mirror finish then I could spray it with clear lacquer and it would look like chrome. So that's what I did. The final bit was to fit the polished stainless tubular trim plate over the coil, but when I offered it in place it was too long and stuck out well beyond the coil body. So now I had to figure a way of cutting about 10mm off one end of this trim plate without distorting, squashing or damaging it. Well using any kind of tin snips or nibbling tool was bound to damage the shape of this tube as it is less than 1mm thick. So I marked it with a chinagraph pencil and then very carefully set about it with a miniature cutting disc on the Dremel. This was reasonably successful but did not leave a totally flat edge, but a few seconds on the belt linisher put that right, then a quick re-polish and on with it. And I think the result is really pleasing.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzDAGbHNQ582gQbr4ok8d-x0o0FFcos0BY9_Tj2TXGvcWvTGtvXWBR0fz6n5yrFcbNGW6AWn2DPWirKMxLNRvedi__-wM8kyYfx5R1Y3DlS7Gx94tghGQLmBXVx7kA1NA7RSKUSgHZwnSb/s1600/062.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzDAGbHNQ582gQbr4ok8d-x0o0FFcos0BY9_Tj2TXGvcWvTGtvXWBR0fz6n5yrFcbNGW6AWn2DPWirKMxLNRvedi__-wM8kyYfx5R1Y3DlS7Gx94tghGQLmBXVx7kA1NA7RSKUSgHZwnSb/s320/062.jpg" width="320" /></a><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaSPqK87452Qe1fki0GtBFUv0XQihd7BH8vDi2KI-sE7SZ_ueCZyjiltHHFzJNCzIMeaWwUtgGui2CVxovz_AOWWt5fy32zDLCHjESgl3uRk7w7i07n9VZqhVPwO2kMyqWy-b04J78Z64y/s1600/Breather.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1059" data-original-width="1600" height="211" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaSPqK87452Qe1fki0GtBFUv0XQihd7BH8vDi2KI-sE7SZ_ueCZyjiltHHFzJNCzIMeaWwUtgGui2CVxovz_AOWWt5fy32zDLCHjESgl3uRk7w7i07n9VZqhVPwO2kMyqWy-b04J78Z64y/s320/Breather.jpg" width="320" /></a>Now for the fuel pipes and the oil breather pipe. I was trying to figure out what to do with the oil breather pipe, which would normally go from at side of the filler cap to the old VW air filter. As I no longer have a standard air filter, where could I take it? My first thought was to make an oil "catcher" tank and fit it in the engine compartment, and then I came across this picture on the Internet and saw this brilliant solution. This person has taken the hose and dropped it into the top of the air filter directly above the number two cylinder venturi. I immediately thought that this is the answer.<br />
<br />
I also noticed that he had used braided hose and I've used this before on my motorcycles and really like the look. So I bought a selection of braided hose and found a suitable right angle connector for the top of the air filter from a local pneumatics store. and set about fitting them and what a nice result.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9Yh0bFlH7WulzqDru6_dLftgK-QyKBjyJVtccIGSgPXDQQxOGb30OLhXqYE0AuDUMar6P1iQjGxLn0mSK2Vjg-vcl4-rTR3zVOceOdq3aBqdUZMLMuKfRjenjC73n9FoTe0NrBa46ykGF/s1600/IMG-2123.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9Yh0bFlH7WulzqDru6_dLftgK-QyKBjyJVtccIGSgPXDQQxOGb30OLhXqYE0AuDUMar6P1iQjGxLn0mSK2Vjg-vcl4-rTR3zVOceOdq3aBqdUZMLMuKfRjenjC73n9FoTe0NrBa46ykGF/s320/IMG-2123.jpg" width="320" /></a></div>
Well the final thing to fit is the HT leads. I made the mistake of buying a set of blue leads (because the car is going to be blue when it's finished), before checking what they were made of and when they arrived I found that they were the "carbon" type. This basically means that there is no copper wire down the centre of the lead and relies upon some silk like material that has been carbonised. I remembered, from my days as a VW mechanic in the 1960's, that these leads work OK when they are new but create problems as they age. Furthermore I didn't like the "crimped on" plug caps. If one of those ever failed, I could not simply screw a standard plug cap into a carbon lead as the screw would just break up the carbon. So I scrapped them and ordered some proper copper leads which you can now see in the picture. So, cut to the right length and fitted all that was left was to push them into the new retaining clips that I had bought. But surprise, surprise, once again the new tinware had no holes to push the clips into. So once again I had to drill the fan housing. But there we are it's done. The tappets have been adjusted and the ignition timing done. So I am almost there.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDYr53fjqFpVHhhctelWE9yEhh5ehAzzpGeEgydl8qNKj5Qs6KgJwaKLPnQaO55avWAu6Nww-Qkf-V0TquU0YSOxCsaXAjJHZIJ0QAcnxmxgwro1fPe05YWqqR9eI3KuN9xEWcEjtwWZ3E/s1600/IMG-2121.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDYr53fjqFpVHhhctelWE9yEhh5ehAzzpGeEgydl8qNKj5Qs6KgJwaKLPnQaO55avWAu6Nww-Qkf-V0TquU0YSOxCsaXAjJHZIJ0QAcnxmxgwro1fPe05YWqqR9eI3KuN9xEWcEjtwWZ3E/s320/IMG-2121.jpg" width="320" /></a></div>
I'm just waiting for the heater pipe connectors before I can fasten down the rear engine tray and then once the engine is off the stand, I can fit the back plate, behind the fan housing and the oil cooler cover. Then all it needs is some oil.<br />
<br />
Hopefully by the next episode I will have started on the bodywork, provided my friend has time available in his workshop. If not I will start on the gearbox.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKMks5AzZW0k16OxTNEY15ssz9nVLGSK6N8Y4nNdrgqPSkDvXYE47H0svEsKFr5gOfGTD9mDpHiUaZg9BS9iekRrqaZuWcTFPf3zJtCJm-N0XHAtmI2bxRwmPzxXsOjlDhxflZyVWFG8v2/s1600/IMG-2122.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1550" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKMks5AzZW0k16OxTNEY15ssz9nVLGSK6N8Y4nNdrgqPSkDvXYE47H0svEsKFr5gOfGTD9mDpHiUaZg9BS9iekRrqaZuWcTFPf3zJtCJm-N0XHAtmI2bxRwmPzxXsOjlDhxflZyVWFG8v2/s320/IMG-2122.jpg" width="310" /></a></div>
<br />
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 01.01.18 all rights reserved.<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br />
<a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a><br />
<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
</div>
<br /></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com1tag:blogger.com,1999:blog-738504069791591427.post-65828570448843909722017-11-04T09:21:00.003-07:002018-01-23T05:12:31.764-08:007. Karmann Ghia Restoration - Engine Rebuild Part 2.<div dir="ltr" style="text-align: left;" trbidi="on">
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpnr0DBwTJUBtTnlrjQhyphenhyphen-OtjIJwq-bw3Mes08w-CAuUCoqQKyggT9k6MPP_fXqG_gFUPfKc0wFMepAknyZAx-vHyFFae_6BYMkqWbiP5OgwLjawjI5s74-ilO32nRtcA8PzLR88oI5rXE/s1600/drybuild01.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpnr0DBwTJUBtTnlrjQhyphenhyphen-OtjIJwq-bw3Mes08w-CAuUCoqQKyggT9k6MPP_fXqG_gFUPfKc0wFMepAknyZAx-vHyFFae_6BYMkqWbiP5OgwLjawjI5s74-ilO32nRtcA8PzLR88oI5rXE/s320/drybuild01.jpg" width="320" /></a></div>
On the last blog, I had managed to get the crankcase halves together, so now it's time to look at the pistons, barrels and cylinder heads on my 1971 Karmann Ghia Convertible restoration.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfI0GbZ2EQ2Xwb0ZO4yx-DX9NPivk1vE6eFsOgMkS3lwAzrUkPzuhGLGBM3qmqib7lJ4ZiPXusbgRdJh9MnlD9x8so8QP6GXkoZGKtMLAqpnABLV5Y7GFFT7FqpJjYlzLzJanMFrnpuJ41/s1600/IMG_1956.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfI0GbZ2EQ2Xwb0ZO4yx-DX9NPivk1vE6eFsOgMkS3lwAzrUkPzuhGLGBM3qmqib7lJ4ZiPXusbgRdJh9MnlD9x8so8QP6GXkoZGKtMLAqpnABLV5Y7GFFT7FqpJjYlzLzJanMFrnpuJ41/s320/IMG_1956.JPG" width="320" /></a></div>
As I mentioned, when I stripped the engine, the internals are in very good condition (which was a surprise), so I decided to clean the original pistons and barrels, fit new piston rings, and the re-fit them. <br />
<br />
So I set about renovating each piston in turn being careful to keep the same piston with the same barrel. With the old piston rings removed, I could clean and polish the pistons and clean out any carbon from the piston ring grooves and then fit the new rings and clean and paint the barrels with "cylinder black".<br />
<br />
As you can see from the picture this process produced quite an improvement. What was unusual for me was the bottom piston ring. As I mentioned, I haven't built a VW engine since the 1960's and was expecting a normal "oil scraper" type bottom ring. This one was different. It has a thin bottom ring, about 1mm thick, then a concertina type metal spring and then another thin top ring, all fitting in the same bottom ring groove in the piston. These were not easy to assemble but with a little perseverance I succeeded.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3hRw4U-02POzSh1rZtRmvTgRcauoB3QHD28MQTsMeZtXw5KSdim0opVeeXGHxeVHx7OdyzvNSZU5pErvfnEV3zKHTpEGgCumPTT4lyaGMXU82ANg5M9tSmJbqp78ex-ZFCW9ozm1wT1Ka/s1600/IMG_1957.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3hRw4U-02POzSh1rZtRmvTgRcauoB3QHD28MQTsMeZtXw5KSdim0opVeeXGHxeVHx7OdyzvNSZU5pErvfnEV3zKHTpEGgCumPTT4lyaGMXU82ANg5M9tSmJbqp78ex-ZFCW9ozm1wT1Ka/s320/IMG_1957.JPG" width="320" /></a>Next was to fit the four renovated pistons onto the conrods on the engine. Just a simple matter of tapping the Gudeon pin through the little end bearing and fitting the two circlips. Then the hard bit, fitting the barrels. Now I have got a set of motorcycle piston ring clamps, so I thought that I would try one of those. Well that wasn't too successful, as the largest clamp was still a bit too small. So I now had the choice of either making a ring clamp or trying to do it the hard way. Don't ask me why, but I decided on the second option and slid the barrel over the top of the piston and then squeezed the rings together, one at a time with a screwdriver levered against the studs.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCcJPL0zURq9zaz3RTsdjQUHdjtEwYhjD9LtaehZnOuG6H_3SSdx0lH0Z3uqOXNgDIRN7ONRLv4lkzl3EyXiPt_cOk3ug9hbu-MbQErpxCziO9SuUf6IilePf848qxWqrmXQy0xmYD4SPO/s1600/Barrels+on.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCcJPL0zURq9zaz3RTsdjQUHdjtEwYhjD9LtaehZnOuG6H_3SSdx0lH0Z3uqOXNgDIRN7ONRLv4lkzl3EyXiPt_cOk3ug9hbu-MbQErpxCziO9SuUf6IilePf848qxWqrmXQy0xmYD4SPO/s320/Barrels+on.jpg" width="320" /></a>Well that worked OK until I got to the new oil ring. This ring, being in three parts would not squeeze together. So, and I don't recommend this, I decided to take advantage of the taper on the inside bottom of the barrel and try gently knocking the barrel over the bottom ring with a rubber hammer. To my total surprise it worked perfectly with no damage on all four pistons.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLHsK8Z7DP8J7KnKs392Ql3zDiCEE6oT_m1DT9RPH_8l6dU3j98GtNLTzedneAhu4Xc0i9J3HW4e17iBH_hz_sZiHHYZ0JR_Ttu-tyvw7hRAo_iMqDKNdGdsreS5DxNMN339jaNnYJc0dr/s1600/IMG_1964.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLHsK8Z7DP8J7KnKs392Ql3zDiCEE6oT_m1DT9RPH_8l6dU3j98GtNLTzedneAhu4Xc0i9J3HW4e17iBH_hz_sZiHHYZ0JR_Ttu-tyvw7hRAo_iMqDKNdGdsreS5DxNMN339jaNnYJc0dr/s320/IMG_1964.JPG" width="320" /></a>Now it's time to look at the cylinder heads. These have also been aqua-blasted and are beautifully clean. So it was just a case of cleaning up the old valves, which again show no sign of wear, and then the slow and laborious job of grinding them into the valve seats. I cleaned the carbon off the valves with a rotary wire brush and the ground each one into its seat carefully and with the exception of one valve, that took much longer than the others, they all seated beautifully. So then it was just a case of cleaning up the valve springs and rockers and the fitting the springs, caps and collets to the valve stems.<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhz9BvKP0VHnrTxEP3W9QM7TpYyXul81bWMWMXjioCzwtFOHmyws-8uIfQlyqnEnPr2aip40fWufR-TYpIentjtcoHghHOfLpwI-l6gSQpFta1hW5ntpQpnhUiJjoSsTk346eDAN8uthPV/s1600/IMG_1965.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhz9BvKP0VHnrTxEP3W9QM7TpYyXul81bWMWMXjioCzwtFOHmyws-8uIfQlyqnEnPr2aip40fWufR-TYpIentjtcoHghHOfLpwI-l6gSQpFta1hW5ntpQpnhUiJjoSsTk346eDAN8uthPV/s320/IMG_1965.JPG" width="240" /></a>So with the heads assembled I could now fit them. I looked in my box of new gaskets for the copper rings that I used to fit between the heads and the barrels and found none!. So I rang VW Heritage and was informed that later models have no cylinder head gaskets. Again my knowledge from the sixties was not up to date enough. So with that knowledge, I now carefully inspected the mating surfaces to ensure that they were clean and flat before offering the heads onto the barrels. Just before starting to fit the heads I remembered to fit the two heat deflector plates under the cylinder barrels. These just clip in, but must be fitted before the pushrod tubes.<br />
<br />
Fitting the heads is not quite as strait forward as it may seem, because at the same time you have to trap 4 pushrod tubes between the head and the crankcase. The way to achieve this is to slide the head onto the studs and then take 4 new pushrod tubes, fitted with new seals at both ends and trap them between the head and the crankcase by passing a push rod through the head and tube and into the cam follower in the crank case, so that the tube cannot drop out. I should mention that when I was building engines in the 1960's, it was always good practise to stretch the ends of the tubes a little before fitting them. This allowed the head to squash them up again as you tighten then head down, giving a better seal. <br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz7A5Da69nRzQSwsCBX_HYQKGsTARxjYKjKcAR7cdQO9q17H2qsmmdXTFuocka6ayH6LLN2UxdPQQkUaAUKHDBSdSVbsyZrS086JYbZoStYAlJHMEMgkUbRZz-DADT3zpLyllSiPCAGLVo/s1600/IMG_1963.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz7A5Da69nRzQSwsCBX_HYQKGsTARxjYKjKcAR7cdQO9q17H2qsmmdXTFuocka6ayH6LLN2UxdPQQkUaAUKHDBSdSVbsyZrS086JYbZoStYAlJHMEMgkUbRZz-DADT3zpLyllSiPCAGLVo/s320/IMG_1963.JPG" width="320" /></a>Now the heads could be tightened down, in a "criss-cross" pattern to the correct torque and they are on. Although I still must admit that I am uncomfortable with the knowledge that there are no cylinder head gaskets. Finally the rockers could be located onto the pushrods and the then, after fitting the new bottom pulley and the first bit of tinware behind it, I could rotate the engine with a socket on the pulley nut and see that all of the valves opened and closed correctly.<br />
<br />
<br />
You will notice that the first bit of tin-ware is chromed. I was originally going to renovate the old tin-ware and paint it. But it was in such a badly corroded condition and the cost cost of new chrome tin ware was so cheap, that I decided to replace it. I should say at this point, that if you are contemplating doing the same, then the new tin-ware needs considerable modification and it is not for the faint-hearted. As you will discover later in the blog.<br />
<br />
The next two things to look at were the fuel pump and distributor. The original fuel pump worked fine but looked terrible and needed renovation. So I set about stripping it and cleaning each part separately and the polishing each part. The difference was amazing. I then set about the distributor and cleaned and polished that too.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQi47ulrtX1k3gQ9aOpBUwt65csGryoTLI4kZfM83juqF9RJoc4o8iDY8t-MoG3GEtHnztvCuGySNzcn-lUChBNb3_MDPWu2KUQblrkze9DdUpNFZMgMlyhP_LTm9sP3q52NyfaXjN2wZC/s1600/IMG_1976.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQi47ulrtX1k3gQ9aOpBUwt65csGryoTLI4kZfM83juqF9RJoc4o8iDY8t-MoG3GEtHnztvCuGySNzcn-lUChBNb3_MDPWu2KUQblrkze9DdUpNFZMgMlyhP_LTm9sP3q52NyfaXjN2wZC/s320/IMG_1976.JPG" width="240" /></a>With both of them now fit for the engine I could attempt the fitting of them. The distributor first. This involves fitting the distributor drive gear shaft first. This is a "worm-gear" and fits down the hole that the distributor fits in, and mates with the brass gear on the crankshaft. First it is necessary to feed two steel thrust washers down the hole for the drive gear to sit on. If you don't do this then the gear will wear into the aluminium casing. So I opened my "bit draw" and took out the distributor drive and then looked for the two thrust washers. There was only one! Despite very lengthy searching, a second thrust washer was nowhere to be found. So I checked on the Internet to see if later engines only had one. But the answer came back every time "there must be two". So I got onto VW Heritage and they sold them in pairs (No surprise there) so I ordered two and now have a spare one.<br />
<br />
The trick now is to insert the two thrust washers without dropping them into the engine. This is achieved by putting a little grease on them and then sliding them down a long screwdriver into position. Once they were sitting safely on the shelf deep inside the engine, I could slide in the distributor drive shaft. This has a small "D" and a large "D" on the top and the small "D" must go towards the crankshaft pulley. So standing in front of the pulley, You offer the shaft slightly turned to the left so that as it engages with the gear on the crankshaft, the inter meshing gears turn the shaft until the small "D" is in the right position. A small spring then goes into a hole on the top of the distributor shaft and the newly polished distributor, with new points, rotor arm and cap pushes in on top of the spring.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv5cN1KqZgptGUaIObQrxR3uFsb30QqtTlJoyR6FN1MgbPhPb_jCmRbNeJfMan5ZshwmLsvFRmp1UrWrrmq-LNPFWSloOK3GYNqFb83srFPD3UqJnD_ky-b_Bh3FTJkXY0eBbhWlzrXLGd/s1600/IMG_2012.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv5cN1KqZgptGUaIObQrxR3uFsb30QqtTlJoyR6FN1MgbPhPb_jCmRbNeJfMan5ZshwmLsvFRmp1UrWrrmq-LNPFWSloOK3GYNqFb83srFPD3UqJnD_ky-b_Bh3FTJkXY0eBbhWlzrXLGd/s320/IMG_2012.JPG" width="320" /></a><br />
Now for the fuel pump. Firstly I cleaned up and fitted the Bakelite pump flange with new gaskets, top and bottom. Then the pump push rod can be dropped in the centre hole (point first). This engages onto a cam that is part of the distributor drive shaft. Then finally the nice clean fuel pump.<br />
<br />
The next two bits were easy. I popped on the new Oil Filler and breather pipe and pushed in the new Dip Stick. But I should have read the manual on the next bit.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbxkciPlev3HCSSqbFlNW2s1Keqt69Ze3bquxDqTckfA2xFhyJUIsKsUPK3hovb-TBpHfjAg58kwsRA4GONemQH1xBw5ikhlz0E8nHJwI3B4zjVpeSerp_07NUf-7lJNNdW7iKxkVjxRdp/s1600/IMG_2014.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbxkciPlev3HCSSqbFlNW2s1Keqt69Ze3bquxDqTckfA2xFhyJUIsKsUPK3hovb-TBpHfjAg58kwsRA4GONemQH1xBw5ikhlz0E8nHJwI3B4zjVpeSerp_07NUf-7lJNNdW7iKxkVjxRdp/s320/IMG_2014.JPG" width="240" /></a><br />
<br />
<br />
<br />
<br />
I decided it would be a good idea to fit the Oil Cooler Support casting. Not knowing that, if you do, you can't fit the oil cooler later. So, not knowing any better, I found the two rubber seals that fit under it and fastened the Oil Cooler support casting down with the three fixing nuts and washers.<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh56q1hq8L-PkUAYPqKAIZ_8blg4LbasC3NLruFG2hMHc165S70ZdXzlM68ZqpMG9GrqDJ-aDMN4wMVsJUvioX2brO-3FFiHnAsllUrPE72CsnRi_4kBwpqMdCviIryu7xfz4pAwA4Rp3PW/s1600/IMG_2023.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh56q1hq8L-PkUAYPqKAIZ_8blg4LbasC3NLruFG2hMHc165S70ZdXzlM68ZqpMG9GrqDJ-aDMN4wMVsJUvioX2brO-3FFiHnAsllUrPE72CsnRi_4kBwpqMdCviIryu7xfz4pAwA4Rp3PW/s320/IMG_2023.JPG" width="320" /></a>Once fitted, I turned my attention to the new tin-ware and decided to fit the two new cylinder top covers. These simply drop on and are fixed in place by two screws on each side that fix the cover to the cylinder head either side of the inlet ports.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOLpifLB5O61zTGRdF2-B-lcF_dDq6aharvO53QNgOCx1y8iTHxND7hWeoCbQkD2ozDuc8OODaBSHoNbgWIWFwFZvpgfsWbpIYa-Sz7mro7sBztAozck-Orzqu1uPUPTSB5XeN1obdCfsT/s1600/IMG_2021.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOLpifLB5O61zTGRdF2-B-lcF_dDq6aharvO53QNgOCx1y8iTHxND7hWeoCbQkD2ozDuc8OODaBSHoNbgWIWFwFZvpgfsWbpIYa-Sz7mro7sBztAozck-Orzqu1uPUPTSB5XeN1obdCfsT/s320/IMG_2021.JPG" width="240" /></a>It was now time to discover the first of many problems with the new tin-ware. I took a look at the new "Fan Housing" and compared it with the old one. The old one had thermostatically controlled flaps inside that control the flow of air over the cylinders. The new fan housing had nothing. Furthermore it had no provision for these flaps. I read on the Internet that these flaps are essential and so decided that I would have to fit the old ones into the new housing. This meant measuring exactly where they fit and then cutting slots in the new fan housing to accommodate the linkage that works the flaps.<br />
<br />
So first I had to find a way of positioning them in the new fan housing. This is difficult because they have an actuating lever that runs between the two sets, so they have to be exactly the correct distance apart and they also have to be positioned so that the rod that drops through the 1&2 cylinder head lines up so that it can connect to the thermostat and with no straight edges to measure from, this required the making of cardboard templates so that I could drill the fixing holes in exactly the correct position.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJRJ2LeTRsOCe77Dj5xw9DptTXKEQNg2CNGEKjXnTyMbM_AJ9y3nrjo-0lvwAlP1TiWTY90g89tvuStFOD5YJsl6heuMtD-v61GqFd2J6rjI3dV1CZUCp3fwNCHemSEeeNDX0ijuURplbG/s1600/Flaps-2.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="989" data-original-width="1320" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJRJ2LeTRsOCe77Dj5xw9DptTXKEQNg2CNGEKjXnTyMbM_AJ9y3nrjo-0lvwAlP1TiWTY90g89tvuStFOD5YJsl6heuMtD-v61GqFd2J6rjI3dV1CZUCp3fwNCHemSEeeNDX0ijuURplbG/s320/Flaps-2.jpg" width="320" /></a></div>
The flaps over cylinders 3&4 had the additional problem that the internal baffles in the fan housing, reached into the area that the flaps had to occupy. So I also had to cut away some of the internal metalwork to accommodate them.<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjy2jTws5Mt6GUdeZedFAPSuVS-OBePJoToixflCS0TzknpViE3ske8Ws-N6ilsBWnKKJV0SGwd5O7Dpud4N5X993_IkEGzZjefMu91G648ifSxGl4wVqKOjKWHcDWtxXYAdaATuRHHzgHJ/s1600/Flaps-1.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="979" data-original-width="1306" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjy2jTws5Mt6GUdeZedFAPSuVS-OBePJoToixflCS0TzknpViE3ske8Ws-N6ilsBWnKKJV0SGwd5O7Dpud4N5X993_IkEGzZjefMu91G648ifSxGl4wVqKOjKWHcDWtxXYAdaATuRHHzgHJ/s320/Flaps-1.jpg" width="320" /></a>Once I had managed to mount the two sets of flaps and checked that the external actuating rod still reached between them, I then had to renovate the flaps and all their working parts. This picture shows the 3&4 cylinder flaps done and the 1&2 cylinder flaps awaiting attention. You can also spot the actuating rod on the 1&2 flaps that drops through the fins of the cylinder head and connects to the thermostat.<br />
<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNEZYBQ09G00UvNTm-1HPxSn10IBGtUHt0FyzJa-8xSDEuPEskRQ_ghqy-yDR_TW2E4Vmp2Y6vSVUBwof5sW17LZI98Mdyq7WE-lS-6vLALGypyrw2W5jVSZobvuH8V-QbAOjg7uLiHq_Q/s1600/IMG_2037.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNEZYBQ09G00UvNTm-1HPxSn10IBGtUHt0FyzJa-8xSDEuPEskRQ_ghqy-yDR_TW2E4Vmp2Y6vSVUBwof5sW17LZI98Mdyq7WE-lS-6vLALGypyrw2W5jVSZobvuH8V-QbAOjg7uLiHq_Q/s320/IMG_2037.JPG" width="320" /></a></div>
Well, with the flaps now mounted I tried the fan housing in place and everything seemed to fit OK. But there's more trouble to come.<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggxi63_yzvljDW_OS-91grg3wgmSBhOYVoRoys6HAI5lZ3KVL0ZJfZaP4S9-fQugjCaOvRUF-fhz8Uoj2t09SB-AST5eKXFcLeHL5b_yeVxeYr2cl_ehUROELqgkz8HA9ljPAunD2lIedk/s1600/IMG_2031.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggxi63_yzvljDW_OS-91grg3wgmSBhOYVoRoys6HAI5lZ3KVL0ZJfZaP4S9-fQugjCaOvRUF-fhz8Uoj2t09SB-AST5eKXFcLeHL5b_yeVxeYr2cl_ehUROELqgkz8HA9ljPAunD2lIedk/s320/IMG_2031.JPG" width="320" /></a>So now I could look at the generator and fan and like almost everything on this engine, they were in good working order but filthy. So I stripped off the old tin-ware and renovated everything except the outer fan plate, which I replaced with a new chrome one.<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdPamtN34j1tbk37gQ0tgXU2KE6IT0I2jZpWKWps3SgBiaGq5kP9SDmQYAyd7-lg4NG4tqWVv1dVC4XEB9RVrPoycOA7eKI16g8ipDhjxPNp2mGPI-orET2Hq1umOOnMM5k_o2BlRsC4rX/s1600/IMG_2035.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdPamtN34j1tbk37gQ0tgXU2KE6IT0I2jZpWKWps3SgBiaGq5kP9SDmQYAyd7-lg4NG4tqWVv1dVC4XEB9RVrPoycOA7eKI16g8ipDhjxPNp2mGPI-orET2Hq1umOOnMM5k_o2BlRsC4rX/s320/IMG_2035.JPG" width="240" /></a><br />
<br />
<br />
<br />
<br />
<br />
<br />
The fan was particularly difficult to clean and I worked my way thought about 10 small rotary wire brushes for my Dremel before I was happy with it.<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjI3LMKIEtQKDgBF0lzVs1MzSGQInLVcV1Z8X9ri6kA-gPDsI06fYctZqUXWQd3aAUxqn2U_MxnHaYfhF_r4FjsFduTB-JFkTupecKec-ImOIJ0pVcjHCpGd9jLBhYPBxE4LQTZYeadnvtt/s1600/IMG_2059.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjI3LMKIEtQKDgBF0lzVs1MzSGQInLVcV1Z8X9ri6kA-gPDsI06fYctZqUXWQd3aAUxqn2U_MxnHaYfhF_r4FjsFduTB-JFkTupecKec-ImOIJ0pVcjHCpGd9jLBhYPBxE4LQTZYeadnvtt/s320/IMG_2059.JPG" width="320" /></a><br />
So now with the fan and generator reassembled I could fit them in the fan housing and try them in place.<br />
<br />
Two more problems soon became apparent. Firstly, the cylinder covers seemed to stand away from the fan housing by about 5mm on each side. Secondly, I happened to be looking at the old cylinder covers and noticed some air deflector vanes inside the old covers just between the spark plug holes. A quick search on the Internet revealed that these were additions added to later engines to stop overheating in this area. I didn't remember seeing them on the new covers. There was only one thing to do, strip it again. Sure enough there were no such vanes in the new tin-ware. Obviously, I couldn't just buy the vanes as they are a welded on part of the cylinder covers. So there was only one thing I could do, I used a small cutting disc on the Dremel and slowly ground away the spot welds on the old covers and then drilled and pop-riveted them back onto the new covers. Then, of course I had to rebuild it again.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi57CJtHV2vxsRAs1ueIOb_xD48fpZpWItQNzhxwbEAfnT2I_Vl9A8_7COTSvCCCxXEWJmfRHGAvPUGhDeDW37IBysUFZPScp43jIHqRt56zopoV5K4qI31_SHRtT-wdXihhXUnLoCvLmj6/s1600/IMG_2061.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi57CJtHV2vxsRAs1ueIOb_xD48fpZpWItQNzhxwbEAfnT2I_Vl9A8_7COTSvCCCxXEWJmfRHGAvPUGhDeDW37IBysUFZPScp43jIHqRt56zopoV5K4qI31_SHRtT-wdXihhXUnLoCvLmj6/s320/IMG_2061.JPG" width="320" /></a>Just before rebuilding it I decided to fit the oil cooler, except it will not go on as there is insufficient space between the back of the crankcase and the mounting studs to get it in. I should have fitted it to the oil cooler mount casting before fitting the casting to the crankcase. I didn't want to remove the casting again because I didn't want to disturb the rubber seals so I removed the studs instead, passed them through the oil cooler and then put them back in and it worked a treat. So here you can see the back of the fan housing showing the connecting linkage on the thermostat flaps in place and the fan housing now covering the oil cooler.<br />
<br />
I was reading about the oil cooler on the Internet and discovered that there was a small metal plate that fits around the base of the oil cooler to stop air escaping before it passes through it. I'd missed that and had to find the offending plate in a draw, strip it down again, fit the plate and then put it all back together again.<br />
<br />
Finally the old heat exchange boxes were inspected and found to be unserviceable. So I ordered new ones and a new sports exhaust. So I decided to do a "dry build" and slip them in place to see how they fit. No surprise, they didn't! Once again the new tin-ware stopped them fitting and I had to remove everything again and cut 4mm off the cylinder covers where they touch the crankcase, to enable them to slide on further and allow the exhaust flanges to line up. One final adjustment. As I was, by now, very nervous or anything that touches the new tin-ware, I decided to try the two inlet manifolds, for my new twin carburettors, in place. As expected they didn't fit and I had to linish the sides of the manifolds to get them to fit through the hole provided in the tin-ware.<br />
<br />
But there it is. Much more to do yet but it is beginning to look like an engine. <br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgp88-paHSJk6AsonOveaybkGVSqEKoU4m_7w9yAzCxWa-7pR6Cf07eOx5-nltMMa2XMcOvY-_7TjPdA1mvERV8KRrYMnPrA7fVkVu1du4VRCwq_NenvVJrwwfIq_BgpafK0wzioW7OapTp/s1600/IMG_2062.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgp88-paHSJk6AsonOveaybkGVSqEKoU4m_7w9yAzCxWa-7pR6Cf07eOx5-nltMMa2XMcOvY-_7TjPdA1mvERV8KRrYMnPrA7fVkVu1du4VRCwq_NenvVJrwwfIq_BgpafK0wzioW7OapTp/s320/IMG_2062.JPG" width="320" /></a></div>
One final thing, the car left my workshop last week and has gone to my friends place to start on the bodywork. So more on that to come.<br />
<br />
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 05.11.17 all rights reserved.<br />
<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a><br /></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-13558287416858260722017-10-04T06:54:00.000-07:002018-01-23T05:11:57.407-08:006. Karmann Ghia Restoration - Engine rebuild commences<div dir="ltr" style="text-align: left;" trbidi="on">
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV_rtErxPBmKn4sSvXLXYHUDQzM1gx6HsjdPkh-5JrDdPqo0OIQ7lfe9K2d6gCcC5v59asWYxK_UmoUlikb8_r0zp8hTfhAePbTZvU6g4_MrKjhh2Pdbuul0SjYhiys-6hlruigGGS08Cg/s1600/IMG_1849.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV_rtErxPBmKn4sSvXLXYHUDQzM1gx6HsjdPkh-5JrDdPqo0OIQ7lfe9K2d6gCcC5v59asWYxK_UmoUlikb8_r0zp8hTfhAePbTZvU6g4_MrKjhh2Pdbuul0SjYhiys-6hlruigGGS08Cg/s320/IMG_1849.JPG" width="320" /></a></div>
<br />
<br />
<br />
<br />
<br />
The crankcase halves, cylinder heads etc. have all come back from the aqua-blasters and they are now lovely and clean, so I can commence rebuilding the engine for my 1971 Karmann Ghia Convertible.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieAD3nQv1574YpGJdlYekL8Sw45JYFr_5up-qkHGoVJKpDNYixOxbd7oflj4W4l9gjDFE2R7MqyI0NyCfObwqhdWZpfq29fjUak3HsyqCUilYILrhllAMByAGKYiY9gb3QKsroRkl-eivH/s1600/IMG_1821.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieAD3nQv1574YpGJdlYekL8Sw45JYFr_5up-qkHGoVJKpDNYixOxbd7oflj4W4l9gjDFE2R7MqyI0NyCfObwqhdWZpfq29fjUak3HsyqCUilYILrhllAMByAGKYiY9gb3QKsroRkl-eivH/s320/IMG_1821.JPG" width="320" /></a></div>
So the first stage is to fit all new big end bearings. I have checked the old bearings for wear and the journals on the crankshaft and surprisingly they are all in excellent condition. So really I have only replaced the bearings because with the engine stripped, it seems a sensible thing to do. I carefully replaced each big end, one at a time, and then refitted the con rod to the crankshaft in the same orientation before doing the next one. As you can see from the picture, the old bearings, on the bench, show next to no sign of wear and the con rod in the picture shows the nice new bearings in place.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjux2XmdZmWQTsChYZ7MoPcCRSTYoTyzVCPssdfWrbXhxBE7TB3pe5kszyjaDz8TR5l66Aj9bv111BmH6nx4WQAmANGqIZENdJfrauLJ0HrSWBvGcgiXEFHe9qH7bdnMGMw9RFWDHNB0vBg/s1600/IMG_1822.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjux2XmdZmWQTsChYZ7MoPcCRSTYoTyzVCPssdfWrbXhxBE7TB3pe5kszyjaDz8TR5l66Aj9bv111BmH6nx4WQAmANGqIZENdJfrauLJ0HrSWBvGcgiXEFHe9qH7bdnMGMw9RFWDHNB0vBg/s320/IMG_1822.JPG" width="320" /></a></div>
The next stage is to rebuild the crankshaft on the camshaft drive end. Firstly I put the new main bearing on the crankshaft, ensuring that the small hole, that locates on a dowel pin in the crankcase was towards the flywheel end of the crankshaft. Next was the camshaft drive gear woodruff key, which simply taps into a groove in the crankshaft. Then it was the turn of the camshaft gear. This required heating up with a blow-lamp, to expand it, to enable it to slide over the mounting surface. You need some thick leather gloves to handle this whilst sliding it on and you also have to ensure that the chamfer on the inside of the gear goes towards the flywheel end of the crankshaft.<br />
<br />
Next up is a spacer, that simply slides on and then the brass distributor drive gear. This also needs heating up before sliding on. Now with all those in place it was time to fit the retaining circlip. You need some really strong circlip pliers to open this heavyweight clip and once in place it's a good idea to tap the circlip down into the groove to ensure that it is seated properly.<br />
<br />
Now the small main bearing can be slipped on, again ensuring that the dowel pin hole is towards the flywheel end and finally the oil thrower and the final woodruff key for the fan belt pulley.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgMyTe9AWriJJHZoy_gt5i4YhgS7_qU659rodVgRB8_7D6r9A6xYxVw5eAC89RHyGKHg37flolwLABJFc00P8z2MDkPqLNQUg9Nv8p6Zk58yWEcNLQLfJR6AcEJnoEBZtR5ddar9NFEL2Y/s1600/IMG_1823.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgMyTe9AWriJJHZoy_gt5i4YhgS7_qU659rodVgRB8_7D6r9A6xYxVw5eAC89RHyGKHg37flolwLABJFc00P8z2MDkPqLNQUg9Nv8p6Zk58yWEcNLQLfJR6AcEJnoEBZtR5ddar9NFEL2Y/s320/IMG_1823.JPG" width="240" /></a>I must admit at this point I was feeling pretty confident and that usually comes before a fall! Time to offer the crankshaft into the crankcase. So with the split centre main bearing in place and the flywheel main bearing slid over the end of the crankshaft, I carefully lowered the crankshaft into place. Now came the delicate task of rotating the three, non-split, bearings until they locate with the dowel pins in the crankcase.The flywheel bearing rotated and clicked onto the dowel beautifully, as did the small back bearing, but the one next to the camshaft gear was more difficult as the "click" was really difficult to feel and it was a long time before I was happy that it was it place. Now I could fit the camshaft bearings and the four cam followers that sit under the camshaft. Then the camshaft could be fitted. There are two teeth on the crankshaft gear that are marked with a centre-pop mark and one tooth on the camshaft that is marked with a circle. To get the valve timing correct, the circle must sit between the two centre-popped teeth. That done, I was almost ready to put the top half of the crankcase on. All I needed was the core plug that fits at the flywheel end of the camshaft. But no matter where I looked, I couldn't find it. I searched everywhere I and finally decided that I must have left it stuck in one half of the crankcase when I sent it for blasting and they've come back without it. Apart from the delay, I didn't see a problem and ordered a new one from VW Heritage at 70p. When it arrived it was exactly as I expected, a small metal cap, with a protruding ridge around it, just as I remembered from the 1960's.<br />
<br />
You will remember that I said "confidence usually comes before a fall", well from here onwards everything starts to go wrong.<br />
<br />
I took the new core plug into the workshop and offered it up to the crankcase. I then realised that my crankcase has no corresponding groove for the core plug to fit into. Internet investigation revealed that Brazilian engines were fitted with a "rubber" core plug. I rang VW Heritage and they didn't have one. So I tried e-mailing dozens of VW based businesses world wide and eventually someone replied who had one and a week later it arrived. Cost £8.90.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie6FoOGE5JtnToy1oObSZUct2PPDxl0vBoX7y325GY8WX6VIp48x5baCkQEKFryeKZfsENFL3aG8Lni2wg3YDdz3pb78oqYG9p9syL15vx1b-CydC6PIAfGmoCmDio3XvHjukVGMAGhxXQ/s1600/IMG_1850.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie6FoOGE5JtnToy1oObSZUct2PPDxl0vBoX7y325GY8WX6VIp48x5baCkQEKFryeKZfsENFL3aG8Lni2wg3YDdz3pb78oqYG9p9syL15vx1b-CydC6PIAfGmoCmDio3XvHjukVGMAGhxXQ/s320/IMG_1850.JPG" width="320" /></a>So at last I could put the two crankcase halves together. But first I had to figure out how to hold the other four cam followers, in the top half of the crankcase, in place whilst I held it upside down. The answer came from a wire coat hanger, wound around a broom handle to create two spring clips. I carefully put a thin layer of blue gasket sealant around the edge of the case and lowered it into place. Then with a torque wrench I tightened the six 12mm nuts down and then all of the 8mm fixings around the edge of the case.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXhMCwnO_zjAfF2AHQcznC2Cs00aNb1LNXGzYHjzagtFI_2k3kjSRtqgNirPw_NIn5JEA85tZqmlkxSWtvh-gukwtTUlvDAYYt0dSv2dQTsJCm7bk2fvLXkO_qeZWYOao9Yb74P6TdPdFg/s1600/IMG_1846.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXhMCwnO_zjAfF2AHQcznC2Cs00aNb1LNXGzYHjzagtFI_2k3kjSRtqgNirPw_NIn5JEA85tZqmlkxSWtvh-gukwtTUlvDAYYt0dSv2dQTsJCm7bk2fvLXkO_qeZWYOao9Yb74P6TdPdFg/s320/IMG_1846.JPG" width="320" /></a>One final check, to ensure that the crankshaft is still free to turn and it wasn't!!! The crankshaft was locked solid and the only thing I could do was strip the whole thing down again. And it got worse.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhp8VanLtUNby-_JP3DbWEKsqfqJQvyIg7cLv5SSY5sVendQLK_iLOtH6VhFRwzW2E7HgQpbn34h99z0i-gU2PurBlrj2xk762eYOhpMHgItslFvEAVAA4lPbM5HgFn2Hw0Tezi2FmvQY3s/s1600/IMG_1848.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhp8VanLtUNby-_JP3DbWEKsqfqJQvyIg7cLv5SSY5sVendQLK_iLOtH6VhFRwzW2E7HgQpbn34h99z0i-gU2PurBlrj2xk762eYOhpMHgItslFvEAVAA4lPbM5HgFn2Hw0Tezi2FmvQY3s/s320/IMG_1848.JPG" width="320" /></a>Inspection of the main bearing next to the camshaft gear showed had not been seated on the dowel, as I thought, and the tightening down process had indented the bearing and pressed it right through onto the inner surface, rendering the bearing useless. Furthermore I found that you could not buy just one bearing and had to buy a full set. What's more I had to heat up and strip all of the gears off the end of the crankshaft again to remove the bearing and doing so damaged the brass distributor gear with the puller.<br />
<br />
I was not a happy bunny and the replacement parts cost me another £65. Careful examination of the crankcase revealed that the dowel for this bearing sat lower than all of the other dowels, making it impossible to feel when locating the bearing.<br />
<br />
When the new ones arrived I decided to take a different approach. This time I mounted all of the bearings in the crankcase before fitting them to the crankshaft. With the bearings in place and located on their dowels, I took a felt tip pen and marked both sides of the bearing where it lined up with the crankcase. Now when the crankshaft is lowered into place, if I can see all of the black lines, then the dowel holes are directly downwards. I then had to go through the whole procedure again, heating up gears, rebuilding the crankshaft, refitting the camshaft etc. But this time it bolted down and the crankshaft still turned freely. Lesson learnt.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqz5WhBxnWt_2ztxaruIvLk9_vBKyvW9E6JncRLs8Wtmv-v_79qtUU5badgvZyzPPrddmkfQB8A_CpJexnFqjyLdfSWRYJrGuP3LHzZQiciphloSeVrKpGzgOqPYl0HizM0F6ACkGMuhW-/s1600/IMG_1849.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqz5WhBxnWt_2ztxaruIvLk9_vBKyvW9E6JncRLs8Wtmv-v_79qtUU5badgvZyzPPrddmkfQB8A_CpJexnFqjyLdfSWRYJrGuP3LHzZQiciphloSeVrKpGzgOqPYl0HizM0F6ACkGMuhW-/s320/IMG_1849.JPG" width="320" /></a><br />
Now with the crankcase together I could look at continuing the rebuild and I felt that the oil pump would be a good place to start. So I found the appropriate gaskets and put the one, that fits between the oil pump and the crankcase, on top of the engine so that I wouldn't forget it whilst I prepared the pump itself. The pump was in excellent condition but filthy and not fit to put on my nice clean crankcase. So into the parts washer bath along with the steel plate cover and then a good scrub and then a trip into the polishing shed to clean up the aluminium edge on the pump. That done I put a nice thin coat of blue sealant onto the crankcase and knocked the pump in, onto its four studs with a soft faced hammer. I was just thinking how nice it looked, when I noticed the gasket still sitting on the top of the engine. "Oh bother" I said (or something like that).<br />
<br />
Knocking the oil pump in is one thing, but getting it out again is quite another. I consulted the manual and it was very specific. "<i>Do not try to lever the oil pump out of the crank case, this will irrecoverably damage the mating surfaces".</i> Apparently there are only two ways of removing the pump.<br />
1. Split the crankcase again.<br />
2. Use the special VW oil pump extractor.<br />
<br />
After all the trouble I had, there was no way, I was going to split the crankcase again. So that left the special tool, that I don't have! <i> </i><br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcozshhW3L5NGG2BbRGu1qlrYmERBk9hQWSj69NWmxl2DeYIBodVaVkNHgZLEKownwP7ftZ9yDrh1Dz5-9DwPeC3Hkxd675Z3wjO62ivMUfFMAso-27snyIbquWDzj4mb1aJ09LFGITwj3/s1600/IMG_1854.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcozshhW3L5NGG2BbRGu1qlrYmERBk9hQWSj69NWmxl2DeYIBodVaVkNHgZLEKownwP7ftZ9yDrh1Dz5-9DwPeC3Hkxd675Z3wjO62ivMUfFMAso-27snyIbquWDzj4mb1aJ09LFGITwj3/s320/IMG_1854.JPG" width="240" /></a>I decided to take a look at the pump and see if I could figure out how this special tool could work. The only thing that I could see that a tool could get hold of was the two oil ways, left and right, which are basically two holes in the sides of the pump body about 8mm in diameter. I decided that a metal rod between these two holes that I could pull on was the answer. So I found an 8mm bolt and cut the head off. I then put the bolt in the lathe and turned it down until it fit inside the two holes. This also involved filing a curve out of the centre of the bolt to clear the shaft that supports the idler gear in the pump. Now how to pull on the rod? I found a piece of 10mm threaded rod and welded it to the centre of the turned down bolt. I could now slide the bolt into one oil way and then slide the whole thing across to locate in the hole on the other side. Now all I needed was a "U" shaped piece of metal to fit either side of the pump and I could pull it out. At last a little luck, instead of having to make one, I found a Lambretta clutch compressor that suited the job perfectly. So with the centre bolt removed from the compressor and my threaded rod inserted, all I had to do was tighten the nut and the oil pump pulled out perfectly.<br />
<br />
Now I could fit the offending gasket, refit the pump, add the outer gasket and bolt down the metal cover plate. Not the best day I have ever had but at least it ended well. Next will be the pistons, cylinders and heads. Fingers crossed I don't make any more silly mistakes.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfccpZSlIgn2ZQxYCP0XlaVM-RuPeJyJgcO30KYs_jEOTV7Qh4Yx64ZkgvePbGwprjKmcDXBhNO2W1uNix9d5rfY3__hFOWQlkS0ORTSzOtZ9nqCpJG4YAKCZLU5A-wc5UzqwWzUgln6_j/s1600/IMG_1851.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfccpZSlIgn2ZQxYCP0XlaVM-RuPeJyJgcO30KYs_jEOTV7Qh4Yx64ZkgvePbGwprjKmcDXBhNO2W1uNix9d5rfY3__hFOWQlkS0ORTSzOtZ9nqCpJG4YAKCZLU5A-wc5UzqwWzUgln6_j/s320/IMG_1851.JPG" width="240" /></a></div>
<br />
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 04.10.17 all rights reserved.<br />
<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" target="_blank">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-74329206896035521512017-07-06T03:48:00.003-07:002018-01-23T05:11:30.317-08:005. Karmann Ghia Restoration - Engine Strip<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxkyv_AF09Oy3xH3qIW1K2-hn2k48pvqxbwRqQbLODsNf_32FfP670Y6EX8pEaKFBSHKGGDp5wxs8tg8KB9-Rxij-37UaafTOvLRARqfEwrJBqKugDBZydfDbrN1BhQGDdXaXuMh05SJuR/s1600/IMG_1624.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxkyv_AF09Oy3xH3qIW1K2-hn2k48pvqxbwRqQbLODsNf_32FfP670Y6EX8pEaKFBSHKGGDp5wxs8tg8KB9-Rxij-37UaafTOvLRARqfEwrJBqKugDBZydfDbrN1BhQGDdXaXuMh05SJuR/s320/IMG_1624.JPG" width="320" /></a></div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8pJCT_RYIFQesChGuBOe7xq89TytMTrv-SlRMw-zqITlbXJUIBtrHv9difbdyd0GVFsKTX8UrW6Nh8Rd2RMc_BvLtyIgyIy_rJmdgaIUPt4vXGWDw4HoupK8cWXlXmJda7Sc-dz612vXj/s1600/IMG_1623.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8pJCT_RYIFQesChGuBOe7xq89TytMTrv-SlRMw-zqITlbXJUIBtrHv9difbdyd0GVFsKTX8UrW6Nh8Rd2RMc_BvLtyIgyIy_rJmdgaIUPt4vXGWDw4HoupK8cWXlXmJda7Sc-dz612vXj/s320/IMG_1623.JPG" width="320" /></a>In the absence of progress on the bodywork on my 1971 Karmann Ghia Convertible (My friend has an American car stuck on his car lift so can't do the welding yet), I decided to take a look at the engine. My wife bought me a VW engine cradle at Christmas and now is the time to try using it. I decided to use my motorcycle lift as a base for the stand and secured the swivel socket to the lift with 10mm bolts and wing nuts. This makes it easy to remove when I want to put a bike back on the stand. I then bolted the cradle to the engine and with a jack under the engine, slid the cradle into the socket and tightened the clamp and with a couple of the car's wheels on the other end of the lift, as a counterbalance, I was ready to start stripping the engine.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyAIKsLxoNPpShox6_8qkLR0Wy6bt_JV1FUhlMEu3LETYC-H7bscp3rau-kGkbY0ap7Op8jFR65nUGfVPzrpHSbBht8l3ZWyjSqijwfYvuawvZyVINtWtIyQyRciwFH25PzXTIbmRtSmUZ/s1600/IMG_1625.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyAIKsLxoNPpShox6_8qkLR0Wy6bt_JV1FUhlMEu3LETYC-H7bscp3rau-kGkbY0ap7Op8jFR65nUGfVPzrpHSbBht8l3ZWyjSqijwfYvuawvZyVINtWtIyQyRciwFH25PzXTIbmRtSmUZ/s320/IMG_1625.JPG" width="320" /></a>So the first thing was the exhaust, which to my surprise unbolted with very few problems and with the exception of the clamp bolts, where the exhaust connects to the heater boxes, which snapped, all other nuts bolts and screws came out OK. I have no intention of refitting this exhaust, but I never throw anything away until a project is completed. So right now, it's under the bench. The heater boxes were next and again they came off reasonably easily. These are in quite good condition and will just need cleaning up and painting.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_H01I9rTrSHzQoscNQrtbQLDIBificqr5efCud_VLEyk01Afn9foPHq-Kx-DW1aIgWrP8ZSS6xiYE2ikStFQhdUcWBi4jhOzSklC-Qrd01QWAkKMxBrfurXAb_p-nMVU4kaCzAg9yeHa4/s1600/IMG_1626.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_H01I9rTrSHzQoscNQrtbQLDIBificqr5efCud_VLEyk01Afn9foPHq-Kx-DW1aIgWrP8ZSS6xiYE2ikStFQhdUcWBi4jhOzSklC-Qrd01QWAkKMxBrfurXAb_p-nMVU4kaCzAg9yeHa4/s320/IMG_1626.JPG" width="320" /></a><br />
With the exhaust and heater boxes off, I could now tackle the tin-ware and the fan housing was my next target. As I mentioned in my earlier blog, I haven't stripped a VW engine since the late 1960's and things have changed a little and removing the fan housing is one of them. I now discovered that you can't remove the side screws until the inlet manifolds have been removed and also there is an interesting shutter system on the back of the fan housing that also needs disconnecting. Well the manifolds came off by releasing the jubilee clips joining them to a rubber hose which in turn connects to the rest of the inlet manifold that goes up to the carburettor. So two clips and two nuts on each side and they were off. I could now reach the side screws on the fan housing and remove them and with the fan belt removed and the alternator clip released, the fan housing should lift off. Well it lifted about 30mm and then stopped. I had forgotten that the shutter arrangement in the fan housing is connected to the thermostat under the right hand cylinder barrels by a thin metal rod and this also needs disconnecting before the fan housing will lift off. So thermostat removed, off it came.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYjGFIyMWH386ROpHLhy6S2gdfispBq3F1SooDSrCjtInalYEALKNMg_-EZanlzJu3bIFIuf59yWa_c9GvIKhdBGO4xPthjReWGPpWjBpCsjFLWp9N_n7VD-jlKxQjO2GjcY1rdy2mRp5S/s1600/IMG_1628.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYjGFIyMWH386ROpHLhy6S2gdfispBq3F1SooDSrCjtInalYEALKNMg_-EZanlzJu3bIFIuf59yWa_c9GvIKhdBGO4xPthjReWGPpWjBpCsjFLWp9N_n7VD-jlKxQjO2GjcY1rdy2mRp5S/s320/IMG_1628.JPG" width="320" /></a>I could then remove the inlet manifold and carburettor and the petrol pump and distributor. You will note from the picture, that I have not attempted to remove the Bakelite fuel pump flange as I remembered that they usually snap the long stem that goes deep inside the engine block , that is on underside of this flange, when you try to get them out. So I decided to leave this until later. Removing the fan housing also properly revealed the oil cooler making it easy for this to be removed,<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggXZL9i2irTLD_K77s37aSWF_7AkRmd5PzFo7Fuk9W0gn7H462tYN9m25lLABYdGtN021p46QFpsKI9LbZ6qk7k60pi04_-QDvfz7pizUfFb8QqRQflToa8EOscTTYFUGO0huiM1x1woWs/s1600/IMG_1632.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggXZL9i2irTLD_K77s37aSWF_7AkRmd5PzFo7Fuk9W0gn7H462tYN9m25lLABYdGtN021p46QFpsKI9LbZ6qk7k60pi04_-QDvfz7pizUfFb8QqRQflToa8EOscTTYFUGO0huiM1x1woWs/s320/IMG_1632.JPG" width="320" /></a>So now I could remove the final bits of tinware and expose the cylinder heads and barrels.I felt that this was a good time to remove the clutch and flywheel and see what condition they were in. Well the pressure plate was excellent but the centre plate and flywheel were not so good. It looks as though the clutch has been recently replaced but the flywheel was not. This seemed like a very odd thing to do, as the flywheel is so bad that it has ruined one side of the centre plate.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkPjKg8vJ2Y22J88jyRHFa9_BgSqQI5pXvQLmj-R_4UcFgfZZNHPYIgP4UBPP48DXiW1M7W_1VTkziANNOQdKgjoMRqdQGiH_J5PfG7fz5V7XL0Rk4frr0ygQtXuKiE9gRTkJAkkid2bp9/s1600/IMG_1644.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkPjKg8vJ2Y22J88jyRHFa9_BgSqQI5pXvQLmj-R_4UcFgfZZNHPYIgP4UBPP48DXiW1M7W_1VTkziANNOQdKgjoMRqdQGiH_J5PfG7fz5V7XL0Rk4frr0ygQtXuKiE9gRTkJAkkid2bp9/s320/IMG_1644.JPG" width="240" /></a><br />
It took a while to discover why the flywheel had not been replaced. Then answer is simple, whoever did the clutch replacement could not get the flywheel off the engine and so left in on. I approached removing the flywheel with great confidence. I inserted my flywheel stop, put a 36mm socket on the flywheel nut and using a long power bar attempted to undo the nut. It did not move. So I slipped a long six foot tube over the power bar and tried again. This managed to lift the bike lift up on to two wheels but still didn't move the nut. So I got a man to press down with all his weight on the left side of the engine whilst I tried again with even more effort. This time there was a bang and the bar moved. Unfortunately it was not the nut coming undone. It was the teeth breaking off my flywheel stop. This nut is really on tight! So now I had to make a bar to fit across the pressure plate fixing bolts and extend outwards and lock into the engine cradle. I then took the engine off the stand and sat it on the floor, I then got a man to stand on the cylinder heads while I got a ten foot tube over the power bar and tried again. The power bar was bending, the man was loosing his balance as the engine tipped and then suddenly it moved and the nut was loose. No wonder the person who changed the clutch did not change the flywheel.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvHeZMKXdcYUx4-UbiIWsHRU4qB_HQP3FMY6No9YKziLqdzsb82KmIq9SQZb4gmNbI04QRvSHlDotA7hpwui0lnO0GfO_ho2iVMBhNwPAAbYzVemTHbvEylHrinxORNBee5evZrcc2OzNq/s1600/IMG_1633.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvHeZMKXdcYUx4-UbiIWsHRU4qB_HQP3FMY6No9YKziLqdzsb82KmIq9SQZb4gmNbI04QRvSHlDotA7hpwui0lnO0GfO_ho2iVMBhNwPAAbYzVemTHbvEylHrinxORNBee5evZrcc2OzNq/s320/IMG_1633.JPG" width="320" /></a>The next stage was to drain the oil, which was black, and then remove the cylinder heads and the cylinders.The heads came off quite easily, although No1 cylinder came off with the head and was well stuck in the head. To my surprise the heads, valves and cylinders are in remarkable condition. No sign of scoring in the barrels or on the pistons and all the valves look good. It is my intention to have hardened valve seats fitted in the heads anyway but it's still nice to find good news for a change.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3yNQCcVLe05EQj3VakKySr4aHgdlxzQ85uehGZ_s6ogQVS9Hcv2vxm5SyGBF3VIafkSd46fBK0QYKtg__q5vby-UAlaMSubH08duLd7A2MMHTQVVP37RkTph4Qv3K7YVlf2ZJkbpw7J1p/s1600/IMG_1634.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3yNQCcVLe05EQj3VakKySr4aHgdlxzQ85uehGZ_s6ogQVS9Hcv2vxm5SyGBF3VIafkSd46fBK0QYKtg__q5vby-UAlaMSubH08duLd7A2MMHTQVVP37RkTph4Qv3K7YVlf2ZJkbpw7J1p/s320/IMG_1634.JPG" width="320" /></a><br />
So how to remove the No1 cylinder<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1sspjzOkAp8PCJKFufLBZPsiZfthwKLuWYX2cmsM8rGWr3RrFoTJtrq2WyAq31GNEsx0H2oh5z5A8h77m0C-KDU0JQZSTnT7uZng6Aawc1wIhYUsrKI7cmvp05RqbklmfALsgS-RhLoCy/s1600/IMG_1639.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1sspjzOkAp8PCJKFufLBZPsiZfthwKLuWYX2cmsM8rGWr3RrFoTJtrq2WyAq31GNEsx0H2oh5z5A8h77m0C-KDU0JQZSTnT7uZng6Aawc1wIhYUsrKI7cmvp05RqbklmfALsgS-RhLoCy/s320/IMG_1639.JPG" width="320" /></a> from the head.I thought that maybe I could just give the barrel a gentle tap with a rubber hammer to loosen it, but that didn't work. So I then tried a rubber belt wrench rapped around the cylinder and tried to turn it. That didn't work either. So I settled for soaking the joint in penetrating oil and leaving it for a two days. That didn't work either. I was running out of ideas, when I decided to try another approach. Aluminium expands at a greater rate than cast iron, so I thought I would try heating up the cylinder head with a blow-lamp and see if that would beak the seal with the barrel. Success, it did and the barrel could then be removed from the head.<br />
<br />
Now I could strip the heads and take a look at the mating surfaces on the valves. More good news, the valves are all good. Although I will probably fit new ones when I rebuild the engine anyway. It seems quite odd that the car is in such bad condition and the outside of the engine is so filthy and yet the inside of the engine is looking so good. Perhaps when I split the crank case the story will change!<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAU7_vYVs4_BVC3BMlQAYcF3-CYNkC59hxGQQMYiWFfyozEF88zfVozCwZhttTZRUJTOJyhpnwsIUMmzab3kfQWx3jmcF5AAUYX0t9qY-GjvAA2JKYAFhJOJfSjsoi4k0qt-X6PvLqP3FA/s1600/IMG_1641.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAU7_vYVs4_BVC3BMlQAYcF3-CYNkC59hxGQQMYiWFfyozEF88zfVozCwZhttTZRUJTOJyhpnwsIUMmzab3kfQWx3jmcF5AAUYX0t9qY-GjvAA2JKYAFhJOJfSjsoi4k0qt-X6PvLqP3FA/s320/IMG_1641.JPG" width="320" /></a></div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOFcKzChjbjDTLLPLFM2Wj_MXjw0L7U0tiGsvLOwimlzHU24AIhtKwYOsYYOfCnYCSNZohUFjZg-QUoU4tap71IPl_520BUVxSXjYnmX7cWeINxoLKGbDXDzEjoc0wIcQhfx6qbVZ8vZs9/s1600/IMG_1642.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOFcKzChjbjDTLLPLFM2Wj_MXjw0L7U0tiGsvLOwimlzHU24AIhtKwYOsYYOfCnYCSNZohUFjZg-QUoU4tap71IPl_520BUVxSXjYnmX7cWeINxoLKGbDXDzEjoc0wIcQhfx6qbVZ8vZs9/s320/IMG_1642.JPG" width="320" /></a>So now it's time to delve deep inside and split the crank case. So I removed the four nuts on the oil pump and all of the fixings holding the crank case together. Then with a gentle tap, with a fibre hammer, on the casing I loosened the two halves just enough to release the pressure on the oil pump housing so that it could easily be removed.<br />
<br />
Now a few more gentle taps and a little pulling and the two halves of the crank casing separated and revealed a really nice clean engine. The main bearings showed some slight scratches where grit had passed around them but no real signs of wear and the cam followers are completely unmarked. More importantly there is no sludge or metal deposits in the bottom of the crank case. Wow!!<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxGPdol7aXNLUk_VKGWIl2cER_g08TXA0utm1YMCLz2FQ3xnxadWlYifATAdiML2bL-RYdckXOSBpU-AjSJPCjtKSe-EDnmr6293VcAZfoos5avTBppx5ipxHdMTlVdK9sOBac01jEpMig/s1600/IMG_1640.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxGPdol7aXNLUk_VKGWIl2cER_g08TXA0utm1YMCLz2FQ3xnxadWlYifATAdiML2bL-RYdckXOSBpU-AjSJPCjtKSe-EDnmr6293VcAZfoos5avTBppx5ipxHdMTlVdK9sOBac01jEpMig/s320/IMG_1640.JPG" width="320" /></a>The other thing that I noticed was quite a surprise. In my ignorance I had assumed that this car and its engine had been made in Germany. However under the grime on the side of the crank casing it clearly says "Brazil".<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivxz4xG8YI9XMFf3gKZ9QFBPT2nPGMP3G8xXgncsd-siqWBadlDKW8mzEeYTLRAqST_ofWv4xgmOw_zjMhyHoJeQE9HbIDgvmjQBed3wnjrFZtl8aCaxh3HMj5-dzJ0xjWK3FsAkK9fQbX/s1600/IMG_1643.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivxz4xG8YI9XMFf3gKZ9QFBPT2nPGMP3G8xXgncsd-siqWBadlDKW8mzEeYTLRAqST_ofWv4xgmOw_zjMhyHoJeQE9HbIDgvmjQBed3wnjrFZtl8aCaxh3HMj5-dzJ0xjWK3FsAkK9fQbX/s320/IMG_1643.JPG" width="320" /></a>Well now for the final bit of the engine strip. The crank shaft.I decided, at this point, only to remove one con-rod and take a look at the big ends. True to form they are beautiful. It almost seems a shame to replace them, when they are so good. But when you are so deep into an engine I feel that I should fit new bearings just to be on the safe side.<br />
<br />
So the only bit left to look at now is the back main bearing and to do that I've got to remove the oil thrower, the distributor drive and the camshaft drive and this requires the use of some more heat and the use of a puller.<br />
<br />
As you can see, I've laid out the parts in the order that they were removed and photographed them so that, when I start the rebuild, I have a record of the correct order of assembly.<br />
<br />
As anticipated, the main bearing is beautiful. Unfortunately the puller had chipped a tooth on both the distributor drive and the camshaft drive. I suppose I could simply chamfer the chipped teeth and re-fit them but, knowing me, I will probably replace them when it comes to the rebuild.<br />
<br />
Well that's the end of the engine strip. I'm still having trouble locating two of the nylon bushes for the soft top.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB9g8-HJ2CJkqsZ6iMNwHk9WgqoMO-iFjO0Ai31Pf_oQLuD_T6_Zm2sWH-IgTTSKGb7nvYsdbuZCj9xK8OcGrbOfLhj9dAekX8W1mDD9EFM5x6gpKbH01JtJg1u6EdOIPy3Zr7hXHVLPG4/s1600/Hood+Bush.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1205" data-original-width="1600" height="241" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB9g8-HJ2CJkqsZ6iMNwHk9WgqoMO-iFjO0Ai31Pf_oQLuD_T6_Zm2sWH-IgTTSKGb7nvYsdbuZCj9xK8OcGrbOfLhj9dAekX8W1mDD9EFM5x6gpKbH01JtJg1u6EdOIPy3Zr7hXHVLPG4/s320/Hood+Bush.jpg" width="320" /></a></div>
<br />
If anyone has any idea where I might get two of these bushes, please let me know.<br />
<br />
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 07.06.17 all rights reserved.<br />
<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" target="_blank">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a><br />
<br />
<br />
<br /></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-90014724417845904602017-06-07T09:22:00.000-07:002018-01-23T05:10:58.255-08:004. Karmann Ghia Restoration - Engine out & more<div dir="ltr" style="text-align: left;" trbidi="on">
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVPND4JELmu9iSldkPGqpBGr1TvOcQFxVFKRFoSxQ_NY4-WijQQEsKjUdORZ-cWIAw41VgpxM9LbKEFJdVcQvGiqXL5WqgO559o_nxNuRJZ4sJKC3VIygKJs3UsOBVmjdnOK4VJYR59iWv/s1600/IMG_1357.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVPND4JELmu9iSldkPGqpBGr1TvOcQFxVFKRFoSxQ_NY4-WijQQEsKjUdORZ-cWIAw41VgpxM9LbKEFJdVcQvGiqXL5WqgO559o_nxNuRJZ4sJKC3VIygKJs3UsOBVmjdnOK4VJYR59iWv/s320/IMG_1357.JPG" width="320" /></a></div>
<br />
Well my 1971 Karmann Ghia Convertible has been measured up for its tow bar, which was cleverly done by bending mild steel rods into the correct shape and lengths. These can then be used as templates to make the proper square tubing parts for the tow bar. So now I can commence further stripping and that starts with the engine.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4WXHgG_hI9GIifqmhgO2O3a8tTID86yOim-CgML5nL7LiCtqZiCvQbCQY857sx0Oykd5oKFMkXUr7qbhZW3BvJgifedYMoDoYcK_51Ba0IsmcAUDUhMPyIm8_QGeFd_ymICJdlZlWznLh/s1600/IMG_1598.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4WXHgG_hI9GIifqmhgO2O3a8tTID86yOim-CgML5nL7LiCtqZiCvQbCQY857sx0Oykd5oKFMkXUr7qbhZW3BvJgifedYMoDoYcK_51Ba0IsmcAUDUhMPyIm8_QGeFd_ymICJdlZlWznLh/s320/IMG_1598.JPG" width="320" /></a>My experience of removing VW engines is quite good, although the last time I removed one was about 1969, however the bolts are still in the same places although some things have changed. The main one being the position of the oil cooler, which is now on the back of the fan housing and stops you reaching the top left bolt. I discovered that to combat this VW introduced a hank bush in that position and the bolt now has to be removed from over the top of the gearbox and that's pretty awkward.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCvGwLr6vmc7lGwMUSvLSlBVeyxknr_SbxvC7tnHoD_QJGNBzlYxRuCxHIuf878MBJDGAJy199mzGWKfiKY5lfJH_bAREmWr1Co6NSV2hTi3id_qXFgaFkVz6cedF44zPo1s5ETjKe70CQ/s1600/IMG_1599.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCvGwLr6vmc7lGwMUSvLSlBVeyxknr_SbxvC7tnHoD_QJGNBzlYxRuCxHIuf878MBJDGAJy199mzGWKfiKY5lfJH_bAREmWr1Co6NSV2hTi3id_qXFgaFkVz6cedF44zPo1s5ETjKe70CQ/s320/IMG_1599.JPG" width="320" /></a>Anyway with the front tray removed, all wiring, the throttle cable, heater cables and heater pipes removed, I could now undo all four fixings on the bell housing and remove the engine. Easier said than done. It was stuck and required a fair bit of levering and pulling and adjusting of the jack under the engine, before it finally pulled backwards and could be dropped out from underneath the car. Although this engine runs, it is my intention to completely strip and overhaul it, but not yet. My main priority at this point is the bodywork.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjW0QiaUFsb6q-98T57n6tMy9pNc5zCOTfLw4MQ3MANsgD_tdx58bylqo_a5HO9287CAJzT-I-EOZUzw_yd-zmL7FhyphenhyphenKgHsftI0wXzpuNbs_MDp3J8OO4rKqQ1pCCMt8IqmneaPC6I_9owZ/s1600/IMG_1601.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjW0QiaUFsb6q-98T57n6tMy9pNc5zCOTfLw4MQ3MANsgD_tdx58bylqo_a5HO9287CAJzT-I-EOZUzw_yd-zmL7FhyphenhyphenKgHsftI0wXzpuNbs_MDp3J8OO4rKqQ1pCCMt8IqmneaPC6I_9owZ/s320/IMG_1601.JPG" width="320" /></a>My friend, who has offered to do the welding for me (He's much better at it than I am) has said that he wants to transport the car up to his workshop to do it, so I am limited what I can do before he collects it. So I thought I would look at the areas that need replacement panels first and the Near Side Rear needs it the most.<br />
<br />
I have received quite a few of the replacement panels, so I offered them up to the car and drew around them with a black felt tip pen. My next task was to find solid metal where the black lines are to have something to weld to. Well the more I sanded with my DS orbital sander, the more filler I found. In fact it was so thick that it measured 10mm thick in some places, and my sander was just eating sanding discs. So I decided to use the angle grinder fitted with a heavy duty sanding disc. This cut through the filler and I did find good metal but filled the workshop with clouds of dust. So I have now ordered a dust extractor to fit my angle grinder before I do any more.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-CL7yMAV3HSS0HTm9K9lfAIQTnKLJ3O7zKPCS-zCCYsFRGnuZqvC4o2fgCrtJfkbhbJYpW5PbebWjsRnHesXJeYeipy36aagfX7a8WMwWQREcbpOAmTEFQw17hzA0x1PiHLqFDeFYM1ps/s1600/IMG_1591.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-CL7yMAV3HSS0HTm9K9lfAIQTnKLJ3O7zKPCS-zCCYsFRGnuZqvC4o2fgCrtJfkbhbJYpW5PbebWjsRnHesXJeYeipy36aagfX7a8WMwWQREcbpOAmTEFQw17hzA0x1PiHLqFDeFYM1ps/s320/IMG_1591.JPG" width="320" /></a><br />
So that left me with the question "what else can I get on with?" So I decided to turn my attention to the soft top. More bad news. Now I already knew that the car would need a new hood and headlining, but now I discover that the front wooden bow is completely rotten and needs replacing and the price quoted for that is very high. One of the metal cones that passes through this wood and located the hood onto the top of the windscreen frame snapped off.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd8uwds0fFIjIoD91qbMHCLNgBf03g_38lJgA4qx78N_74IAj3IkJm7RrvnpeZkZN-cMpnGm2A90mz6LFWKLSZm5z2AR5GHsK2q4mohoVYF_Xa6qCVwa6HC6-oNRIZKi7SKQy-JLM7yofu/s1600/Window+sealing+rubbers.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd8uwds0fFIjIoD91qbMHCLNgBf03g_38lJgA4qx78N_74IAj3IkJm7RrvnpeZkZN-cMpnGm2A90mz6LFWKLSZm5z2AR5GHsK2q4mohoVYF_Xa6qCVwa6HC6-oNRIZKi7SKQy-JLM7yofu/s320/Window+sealing+rubbers.jpg" width="320" /></a><br />
So I turned my attention to the rubber seals that are connected to the hood and fit around the windows. These are perished and need replacing. So far the quote I have for these seals is over £100. I can't believe the cost for 4 bits of rubber.<br />
<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAkPcjhs8It5Y1NYS1v8Kmw6TswTXGA2S_IIM7BNl4L3M4YMD7-k95lcDarHGd4iOGAi7as-RF1BPtGi7SXrXOV_dGQAXJ-qyq-8YbW2xrdy8zYkySsuCSHDNu0KZNwbI0GQyqV9uVwokn/s1600/Hood+Bush.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="1205" data-original-width="1600" height="241" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAkPcjhs8It5Y1NYS1v8Kmw6TswTXGA2S_IIM7BNl4L3M4YMD7-k95lcDarHGd4iOGAi7as-RF1BPtGi7SXrXOV_dGQAXJ-qyq-8YbW2xrdy8zYkySsuCSHDNu0KZNwbI0GQyqV9uVwokn/s320/Hood+Bush.jpg" width="320" /></a><br />
<br />
So now I decided to take a look at the hood frame itself. This will need to be shot blasted and powder coated before the new hood is fitted. But first there are two nylon bushes that need replacing and no one seems to have any or have any idea where I can get them from. If you know where I can get them please get in touch with me. This is not just a straight bush as the inside hole is concave to house a round pivot ball.<br />
<br />
<br />
Finally I need a new rear window catch, as the old one has a broken lever on it. Again, if you know where I can get one, please let me know. If not, I think that I can make this part and possible fix the old one.<br />
<br />
I also managed to buy a complete second hand interior for the car, seats, carpets and door cards all in the right colours, although they will need some attention before they will be ready to fit. But at least that may have saved me some money. <br />
<br />
Well that's it for now, I have no idea what the next stage will be so keep a look out for the next blog.<br />
<br />
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 07.06.17 all rights reserved.<br />
<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" target="_blank">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-80812279205112628382017-04-04T08:19:00.001-07:002018-01-23T05:10:30.254-08:003. Karmann Ghia Retoration - Hood off and more<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhY0V6zu54vKA4w_vHgvLcXtQx-BuOXlYEZYHM9q8hMXFL4YmcKHoI3NPVkLkfnAooILUiqTpLBd3qK03ILof785oxicVmfXT1gPYEz7yFWNU9o3-yjfUz2QhjcJizLaJE2I8fZRU_L12EP/s1600/DSCF1384.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhY0V6zu54vKA4w_vHgvLcXtQx-BuOXlYEZYHM9q8hMXFL4YmcKHoI3NPVkLkfnAooILUiqTpLBd3qK03ILof785oxicVmfXT1gPYEz7yFWNU9o3-yjfUz2QhjcJizLaJE2I8fZRU_L12EP/s320/DSCF1384.JPG" width="320" /></a></div>
Time to look at removing convertible hood off my 1971 Karmann Ghia and at first glance it doesn't look too difficult. There appears to be three large 10mm bolts holding it in place on each side of the rear quarter. However closer inspection revealed what looks like a wire rope passing around the bottom edge of the hood and terminating on each side, near the fixing bolts I mentioned, with a threaded adjuster. So I traced the path of the wire rope and found that its job is to pull the back of the hood into a groove around the body, holding the hood in place.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwRNyXpqj_AEOZpmU3gaJ5yoxLkWVRvXPO5SEZXF_kXfA49kml4mFvoS_uciNg_6G4KvyqrF_Cm9kmkdLhakSPrAgqc97KajItoo3pB5Qba9j_SEp5FXyIM4v_QMIp0y7pbnXhS7Xe1_kt/s1600/DSCF1377.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwRNyXpqj_AEOZpmU3gaJ5yoxLkWVRvXPO5SEZXF_kXfA49kml4mFvoS_uciNg_6G4KvyqrF_Cm9kmkdLhakSPrAgqc97KajItoo3pB5Qba9j_SEp5FXyIM4v_QMIp0y7pbnXhS7Xe1_kt/s320/DSCF1377.JPG" width="320" /></a></div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguKmhLqw2fjezzgMcmgejFPsPHerdBxy7hgHHh5tMCHBYjYJYEMlbFFvQpOtyfm_2ORE9rETFH7lWwgbcLkLudDTnw_AJWRE8UtvZ_vPkOqIRHp1oIlDABmuf3Fb950LaNAieepKZK80f9/s1600/DSCF1379.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguKmhLqw2fjezzgMcmgejFPsPHerdBxy7hgHHh5tMCHBYjYJYEMlbFFvQpOtyfm_2ORE9rETFH7lWwgbcLkLudDTnw_AJWRE8UtvZ_vPkOqIRHp1oIlDABmuf3Fb950LaNAieepKZK80f9/s320/DSCF1379.JPG" width="320" /></a><br />
So I released the wire rope at both ends, expecting the back of the hood to fall out of the groove at the back of the car and allow me to lift the whole back of the hood up. Wrong! Firstly nothing moved. So I used a screwdriver and prised the edge of the hood out of the groove, only to discover that the wire rope had corroded in the middle and snapped long ago and that the hood was only held in place by rust and old age. But the hood still would not lift. So now I lifted the rear corner of the hood and found a webbing strap and some horse hair all held in place with a curved metal strip screwed to the body.<br />
<br />
So I set about undoing what I thought were pozi headed self tappers. As you can see, I couldn't move them and after trying cutting slots in them, I finally decided to cut the heads off. To my surprise this revealed a second metal strip with more screws in it and these wouldn't move either. So I cut those off too.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzplovpnInxiJLgYdbvZXxTHCFA8m7kAq-rppnoo9pW9UpXYbYK9TnzHhKWYk_VlxLnvJfh2t4FNOaOqByXma3HDsogEZyUg_1PqwbH7h_pyEBOFn1Kmyychw4Mty-Li9fwaScL0nxx4PH/s1600/DSCF1380.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzplovpnInxiJLgYdbvZXxTHCFA8m7kAq-rppnoo9pW9UpXYbYK9TnzHhKWYk_VlxLnvJfh2t4FNOaOqByXma3HDsogEZyUg_1PqwbH7h_pyEBOFn1Kmyychw4Mty-Li9fwaScL0nxx4PH/s320/DSCF1380.JPG" width="320" /></a> Now with both metal strips off both sides of the hood I was sure that the rear of the hood would now be free. It wasn't! So time to look inside the car and I found that the headlining was glued to the inside bodywork and trapped under the hinges for the opening rear window.<br />
<br />
Well once I had removed the headlining and the hinges, I could now see why the screws in the corners wouldn't come out. Under the headlining were hiding the remains of 14 nuts and bolts that I had cut, thinking they were self tapping screws.<br />
<br />
So at last the rear of the hood is free and I can attempt to remove it.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinP8xo8VvAtU4RApsqW9Wc7MX62oJwIHCk_3rmdfgvqTSd6Zfuaw5kaFp8hEjRuwA4A_cn4-J3xHfBay5xDm0MDuliyk7tgrXo0WZYMUqIlZ82ibdzBe939w4Gae4Fds3khdCXiR1FzFTW/s1600/DSCF1383.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinP8xo8VvAtU4RApsqW9Wc7MX62oJwIHCk_3rmdfgvqTSd6Zfuaw5kaFp8hEjRuwA4A_cn4-J3xHfBay5xDm0MDuliyk7tgrXo0WZYMUqIlZ82ibdzBe939w4Gae4Fds3khdCXiR1FzFTW/s320/DSCF1383.JPG" width="320" /></a></div>
<br />
<br />
<br />
All that is left that is left is the six large 10mm bolts holding the hood to the bodywork. These came out quite easily and I now needed help to lift the hood off the car.<br />
<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwpOCBlqrN1_bYj1b7sBm4Fbcuzwg__-EsST2wTzKKvWBJrV77UUh9kKPnACPcrkF7s-kgBs66oM7L2vkeG4W0YoiOqPX70ySoWKhIkInolJW0DDQFN1kjlhyphenhyphen5HdXC73_2B6FWJxDn4VBm/s1600/DSCF1392.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwpOCBlqrN1_bYj1b7sBm4Fbcuzwg__-EsST2wTzKKvWBJrV77UUh9kKPnACPcrkF7s-kgBs66oM7L2vkeG4W0YoiOqPX70ySoWKhIkInolJW0DDQFN1kjlhyphenhyphen5HdXC73_2B6FWJxDn4VBm/s320/DSCF1392.JPG" width="320" /></a></div>
And here it is. Close inspection shows one disconnected strut and a main pivot point, that looks as though it should have a rubber bush in it, that has completely collapsed. This leaves me with a small dilemma. I will need to repair the frame before it is re-trimmed but I wanted to leave it in one piece so that the trimmers could see how it goes together. I think the answer may be to call the trimmers and see what they say.<br />
<br />
<br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC87E1mtT8ksMq5mrq7i0RgX9AXjdA8bi6JxIoDWklMjdA2zxPIRBOUJwaf12B2_ftZXhZmewHRIusQMHFAyF0rwm4BA7zBJ3g2noyh66N4ltuwgWFyV_36c10GMeVF9fcEAf-4ql-lYLo/s1600/DSCF1386.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC87E1mtT8ksMq5mrq7i0RgX9AXjdA8bi6JxIoDWklMjdA2zxPIRBOUJwaf12B2_ftZXhZmewHRIusQMHFAyF0rwm4BA7zBJ3g2noyh66N4ltuwgWFyV_36c10GMeVF9fcEAf-4ql-lYLo/s320/DSCF1386.JPG" width="320" /></a>So no I am back at the front of the car and can completely strip the dashboard and wiring. At first I thought that I would label each wire so that I know where it goes when it comes to putting it together again. But it soon became apparent that there was so much none standard wiring that it was pointless and so I decided to just strip it out and try and figure it out when the time comes to rewire. I did however notice that the windscreen demister tubes were completely missing so I will have to source them and try and figure out how they fit.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidtuPmnzELjnUL0GwjKZ8fPYF1FQ4sZFdrDp6lDYiynA9o3mLr9YEmJfXdND33pXPifp6LkMXh-XXQItNVY5-V7Wobtr3SImkohyZGyIOTrVo819Q_Mt7ioXIvPavjTXw8ubpyJzNPCmnF/s1600/DSCF1393.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidtuPmnzELjnUL0GwjKZ8fPYF1FQ4sZFdrDp6lDYiynA9o3mLr9YEmJfXdND33pXPifp6LkMXh-XXQItNVY5-V7Wobtr3SImkohyZGyIOTrVo819Q_Mt7ioXIvPavjTXw8ubpyJzNPCmnF/s320/DSCF1393.JPG" width="320" /></a><br />
Right one last job. I removed the front under wing cover plates to enable me to remove the radio aerial and take a look at the petrol filler cap. Well the aerial was easy and came out with no trouble. But the petrol filler was a different story. This picture shows under the wing and no matter how I tried, I could not see how this filler tube is held in place and it would not move. So I scoured the Internet for help and found none. So after cutting the rubber breather pipe on the side and a lot of pulling, poking and prodding, I jammed a screwdriver down the side of the pipe between it and the large rubber grommets at each end and squirted lots of WD40 in. I then pulled down and pushed in on the pipe trying to force it through the grommets.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgskAPgNpZoTMBOhpFzGDcDwdEh9uSKWjp6XmNdlChJXP_fytuiKoQQrNcIgBkM5gEdlT7774YJf8WDZVuDVS8ZJHOc6-tUZfwnNqo5ijAUFoXfYzLeE8su_B_6TM4CgbpaME8PvloO_h2i/s1600/DSCF1398.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgskAPgNpZoTMBOhpFzGDcDwdEh9uSKWjp6XmNdlChJXP_fytuiKoQQrNcIgBkM5gEdlT7774YJf8WDZVuDVS8ZJHOc6-tUZfwnNqo5ijAUFoXfYzLeE8su_B_6TM4CgbpaME8PvloO_h2i/s320/DSCF1398.JPG" width="320" /></a></div>
After about 20 minutes of this and a movement of about 5mm the WD40 started to melt the under seal and revealed a thin jubilee clip around the bottom grommet. Obviously it would not unfasten, but a quick cut with the Dremel and off it came. Once this clip had been removed, the pipe simply pulled down and then out. It's simple when you know how!!<br />
<br />
The final part of this job is to remove the petrol flap lock mechanism. This had completely seized and despite all my attempts finally broke its aluminium casting whilst trying to remove it. So I'll have to find a new one of those.<br />
<br />
Well that's it for this episode, I'm not sure whether the next one will be tow bar in or engine out but we will see.<br />
<br />
<br />
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 04.04.17 all rights reserved.<br />
<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html" target="_blank">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a><br />
<br />
<br />
<br /></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com0tag:blogger.com,1999:blog-738504069791591427.post-46232090630270737612017-03-29T13:27:00.003-07:002018-01-23T05:09:26.060-08:002. Karmann Ghia Retoration - The strip begins<div dir="ltr" style="text-align: left;" trbidi="on">
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsEmIf3th4g36lRymbeTiUUfZ2doJyLpkugzNaXZN9RMmsTehz5KC05E1v5eDBO6gqhR8eKNrPo6RPBREoW0LN3ZebBqETg8DgGKqrw3pPUkng8S8xkSoP4cSa8C5iS_OUCN2xYqX1v6NS/s1600/DSCF1365.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsEmIf3th4g36lRymbeTiUUfZ2doJyLpkugzNaXZN9RMmsTehz5KC05E1v5eDBO6gqhR8eKNrPo6RPBREoW0LN3ZebBqETg8DgGKqrw3pPUkng8S8xkSoP4cSa8C5iS_OUCN2xYqX1v6NS/s320/DSCF1365.JPG" width="320" /></a></div>
Well the stripping has begun on my 1971 VW Karmann Ghia convertible and the more I uncover the worse it gets, although that is no surprise. On every restoration that I have done, when I've started to pull them apart they have always revealed hidden disasters.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibIWDjQ836IHKnvZHAQPzKHIHmcocY3yIL2c8Ucmm42vHE8J-NQ5jPmlI2OhduTL6eQaqgBzUsSkwtAd7sRK00_6WUOE7ylpy8D8gbqo9f_5hxcusYE0fsgsnA2DFsW3svzZ0KqsdoHXVT/s1600/DSCF1328.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibIWDjQ836IHKnvZHAQPzKHIHmcocY3yIL2c8Ucmm42vHE8J-NQ5jPmlI2OhduTL6eQaqgBzUsSkwtAd7sRK00_6WUOE7ylpy8D8gbqo9f_5hxcusYE0fsgsnA2DFsW3svzZ0KqsdoHXVT/s320/DSCF1328.JPG" width="320" /></a>As mentioned in my previous blog, I had decided to do the tow bar first. Well as usual, that didn't work out and although the car has now been measured for the tow bar, there is no further progress in that direction. So I decided to get on with the rest of the project.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgczEnd7_pdh-Q3sv_0HdTdUuFje9QWobqggQl3ZJctnKxjiR3e3N8vW9ng4cwvJkob3Rp-DbVbP6Nba_ZVxWigOetgLuo4C1PZoHQnjBD-224TBsH2p5xGqPvODg5BcvSS_YmJiruG38Nw/s1600/DSCF1327.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgczEnd7_pdh-Q3sv_0HdTdUuFje9QWobqggQl3ZJctnKxjiR3e3N8vW9ng4cwvJkob3Rp-DbVbP6Nba_ZVxWigOetgLuo4C1PZoHQnjBD-224TBsH2p5xGqPvODg5BcvSS_YmJiruG38Nw/s320/DSCF1327.JPG" width="320" /></a>The first thing was to try and find out how far the rust has spread under the paint. So I set about the car with a very heavy duty wire wheel mounted on my angle grinder and wherever I saw signs of rust I attacked it with the wire wheel. This disclosed holes around the headlights and around the front air intakes. Obviously both sills have gone and, now the bumpers are removed I can see considerable rust on the rear panel.<br />
<br />
Of course the other problem with stripping a car that is this old, is that many of the screws and bolts you try to remove simply snap. Even the bigger nuts and bolts were seized solid. Fortunately some of my special tools came in handy, particularly my air wrench and some special sockets, that I was given for Christmas, that have a conical cutting inner shape and dig into old rounded off bolt heads. Many of the tiny pozi headed self tapping screws, holding in the interior trim just would not move and I had to resort to cutting a slot in them with the Dremel and then using a straight cut screwdriver.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjI_DlgJaE-LCESuQwJaszwCc_0wUxSTJBG0yFSTXP33NUAvzLfTHx3rqWL7jjun7lEBGZIiQNZ1FRHHKA58fYvH9OP80eQi6vCtNpq3rbgMCV74lfUQEX_LHvqFhxTs2EBKVExFsIQGNHd/s1600/DSCF1360.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjI_DlgJaE-LCESuQwJaszwCc_0wUxSTJBG0yFSTXP33NUAvzLfTHx3rqWL7jjun7lEBGZIiQNZ1FRHHKA58fYvH9OP80eQi6vCtNpq3rbgMCV74lfUQEX_LHvqFhxTs2EBKVExFsIQGNHd/s320/DSCF1360.JPG" width="320" /></a></div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggHrZtG-0-ScoGK9COwvn79jXDuD1y81WTjqMQYIOJEpNF0f4Wv9xXij5MyiXRflUEggOpzLiO6NP-PtAJWTrS4Gx_LCljgbPjWIQgS8Wh1H-Gakc0KqzX0NJ8csA9z1paUggA_jRsAni0/s1600/DSCF1329.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggHrZtG-0-ScoGK9COwvn79jXDuD1y81WTjqMQYIOJEpNF0f4Wv9xXij5MyiXRflUEggOpzLiO6NP-PtAJWTrS4Gx_LCljgbPjWIQgS8Wh1H-Gakc0KqzX0NJ8csA9z1paUggA_jRsAni0/s320/DSCF1329.JPG" width="320" /></a><br />
<br />
The next stage, after removing the bumpers, was to take off the bonnet and boot lids and strip all of the furniture off them. This was quite easy compared to items that had to withstand the weather on their fixings. However, removing the battery from the engine compartment revealed the inside of the near side wing and this was a surprise. There were three rows of small holes drilled the length of the inner wing about 60 holes in all and these all had small amounts of filler poking through the holes.These holes combined with the huge amount of filler that I found on the outside of the rear wing has convinced me that this car had had a near side accident at some time and that these holes were used to pull out the wing as best they could. If you click on this picture of the outer wing, you can see just how deep the filler is on this side.<br />
<br />
Well, with all of the outer trim, lights, badges etc. removed, it's time to look at the interior.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwFdvkZPqlQePXHbi-ogYWiBde05sp46L9RLIv9A9tE_MJoZI2RkRV3DiC3KgHwauNf8pE4J7grFtSj4Bs-wadPa0m5MAo_BAMMgt-3soQXOTtbXIZwPTHVBHjdLttwcgLudFgtxG6OnwX/s1600/IMG_1356.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwFdvkZPqlQePXHbi-ogYWiBde05sp46L9RLIv9A9tE_MJoZI2RkRV3DiC3KgHwauNf8pE4J7grFtSj4Bs-wadPa0m5MAo_BAMMgt-3soQXOTtbXIZwPTHVBHjdLttwcgLudFgtxG6OnwX/s320/IMG_1356.JPG" width="320" /></a>So "out with the seats" - mistake!!!, I'll explain that in a minute. The drivers seat slid out easily and, apart from needing a new foam base, revealed that it had a seat heater fitted in it (not standard). The passenger seat was not so easy and required a friend to pull it whilst I pushed with both feet from the rear, but as you can see, it did come out eventually. Now the carpets and door sill trims can be removed and reveal just how bad things are underneath. Well the front of the floor pan is OK and the off side rear section is too, but the near side rear floor pan is only held together with the sound deadening material stuck to it.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRabVsxxE5dLeKyqHzFK58ETf6MxDE1sNwT_rjTvFsQLnNlXZryNj6pzUHkQ-lzNJTO4xt26rYkgD0tI-oTrw8lnp68YwpsFjEDU8t1SlYT8dX7m6qzB6bB32onCPcU3YKGwR71NQLgg30/s1600/DSCF1363.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRabVsxxE5dLeKyqHzFK58ETf6MxDE1sNwT_rjTvFsQLnNlXZryNj6pzUHkQ-lzNJTO4xt26rYkgD0tI-oTrw8lnp68YwpsFjEDU8t1SlYT8dX7m6qzB6bB32onCPcU3YKGwR71NQLgg30/s320/DSCF1363.JPG" width="320" /></a><br />
I now decided that this was a good time to remove the windscreen, but first I felt that it would be easier if I took the steering wheel and column out first. Not too difficult but someone has already replaced the ignition switch before and all of the wires have butt crimp connectors on them and will not withdraw through the hole in the dashboard. So I've had to cut them. That done and with the steering coupling removed, it all came off quite easily. As did the padded top on the dashboard, which is only held on with plastic nuts and will have to be replaced.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3jTfJaN6nkVSE3fBLL4Pgod4a9M3rW0mCdn2jXQTP146_xOWrqsOZI_PinW4nkl11dfmzkf0o7elkhlhqbY6HfWuy9bpAGE1uosT4eMzWXuow5tNJP33HBr-csnv4JDzWXo8vgmdkEodJ/s1600/DSCF1359.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3jTfJaN6nkVSE3fBLL4Pgod4a9M3rW0mCdn2jXQTP146_xOWrqsOZI_PinW4nkl11dfmzkf0o7elkhlhqbY6HfWuy9bpAGE1uosT4eMzWXuow5tNJP33HBr-csnv4JDzWXo8vgmdkEodJ/s320/DSCF1359.JPG" width="320" /></a>Now to reveal why taking the seats out was a mistake. It's time to remove the windscreen! I know the correct way to do this. You sit on the seat, put your feet on the glass and gently push it out forwards with someone to catch it on the other side. But I had already removed the seats!!! So I decided to try a different approach, as the screen rubber seemed quite soft and I had no one here to help me. So I tried gently levering the rubber out from the front. I should have known better and you know what's coming. Yes I broke the windscreen. !!!**** Idiot. The surprising news is that I found you can still buy one, but I could have done without the expense. Another look at the floor pan revealed that the heater channels will also need repairing.<br />
<br />
I don't know if you've seen the episode of Wheeler Dealers on TV, where they renovate a Karmann Ghia? But if you did, you will recall that Edd had to repair a large strange hole under the dashboard that he informed us once held an auxiliary heater for the USA. Well mine has got the same hole (neatly covered with masking tape), so this will also need to be repaired.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMu66IMOelFhydmhWMd-xUYDOH7M4HvcPVCs97vaT2qrxX-DeapxVS0-92QG62vCMa7ZidNtLe3VpLWFQtLykD9RatPWMxGOZz8wt9s0QW0v14lZHKk2hd1Bi1jwx0TDmZp_7U_VQ3ejlN/s1600/DSCF1367.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMu66IMOelFhydmhWMd-xUYDOH7M4HvcPVCs97vaT2qrxX-DeapxVS0-92QG62vCMa7ZidNtLe3VpLWFQtLykD9RatPWMxGOZz8wt9s0QW0v14lZHKk2hd1Bi1jwx0TDmZp_7U_VQ3ejlN/s320/DSCF1367.JPG" width="320" /></a></div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2qgIPceUSKP0Dpz5Yq8KnxMIjkeYEqobEN5Wk4fsiPCa0lNAp8r-CASr-7M5RsnnH77rTjp-3erOs0wpauec9l0nqXMuXAZXBNhHI9mC225jh6dsrYoh_kQcHUIQ3jo_HQUpEcFxABN9G/s1600/DSCF1371.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2qgIPceUSKP0Dpz5Yq8KnxMIjkeYEqobEN5Wk4fsiPCa0lNAp8r-CASr-7M5RsnnH77rTjp-3erOs0wpauec9l0nqXMuXAZXBNhHI9mC225jh6dsrYoh_kQcHUIQ3jo_HQUpEcFxABN9G/s320/DSCF1371.JPG" width="320" /></a>Now for the doors. Removing the handles and the door card is easy, just a couple of philips screws on the handles and then unclip the card and lift and off it comes. But getting the window glass out is a different matter.<br />
<br />
To remove the window on a VW beetle, you simply unbolt everything and draw the glass out through the bottom of the door aperture inside the car. Not so with a Karmann Ghia. I downloaded a manual extract to tell me how to do it. First you have to remove the chrome and rubber strip on the top edge of the door. Then, looking down the hole, you can see two rubber buffers. These also have to be removed. Neither of these jobs are easy as you are literally working down the slot. But the next bit is worse. You then remove the window mechanism (that's easy) and that leaves the window with the metal plate fixed to the bottom of it. The manual then says remove the window upwards through the slot. This is almost impossible. I suppose that when the car was new and things hadn't rusted then the window and plate might have fit through the slot. But now, with age, it is a nightmare trying to lever the rusty metal plate through a slot that has now distorted with age and now has wavy internal edges. I was certain that I was going to break the windows, but by some miracle I didn't. However the thought of getting them back in again, when the doors have nice new and soft paintwork is somewhat worrying.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvOReLIemPUizRDPYFAmOWJdQGh8c2uiBLXFQc3owj3sELXVLFP33pmy_A1eRdeCHstjFW4CC5OEsHwkgJIEoX1I_bk1MZ9U2NwFMsRS7-7o4k7WTk3AkOzikG5L_Cx0HyAtCMXWTa3-iA/s1600/DSCF1366.JPG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvOReLIemPUizRDPYFAmOWJdQGh8c2uiBLXFQc3owj3sELXVLFP33pmy_A1eRdeCHstjFW4CC5OEsHwkgJIEoX1I_bk1MZ9U2NwFMsRS7-7o4k7WTk3AkOzikG5L_Cx0HyAtCMXWTa3-iA/s320/DSCF1366.JPG" width="320" /></a>My next task will be removing the convertible hood. I've already taken the rear window out, which was just a couple of bolts and so I suppose the next thing to do is unbolt it and see what happens. I would like to remove it in one piece so that the trimmers can see how it should be when I take it to them. But I can also see that there are some repairs necessary on the frame too.<br />
<br />
But more of that next time.<br />
<br />
<br />
<br />
You can contact me on hopcroftscoot@gmail.com<br />
<br />
Copyright 29.03.17 all rights reserved.<br />
<br />
<br />
My Other Blogs:<br />
<b>1961 BSA A10 Super Rocket Motorcycle:</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2012/07/before.html</a><br />
<br />
<b>1961 Ariel Arrow Super Sport Motorcycle :</b><br />
<a href="http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html" target="_blank">http://60sclassicmotorbikes.blogspot.co.uk/2014/01/1961-aerial-golden-arrow-restoration.html</a><br />
<br />
<b>Miniature Land Rover Defender:</b><br />
<a href="http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide" target="_blank">http://miniaturelandrover.blogspot.co.uk/2016/02/1-miniature-land-rover-defender-idea.html?view=timeslide</a><br />
<br />
<b>Motorcycle Trailers / Caravans:</b><br /><a href="http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html">http://motorcycletrailersandcaravans.blogspot.co.uk/2018/01/1-motorcycle-trailers-problem.html</a><br /><br />
<br /></div>
Kevin Hopcrofthttp://www.blogger.com/profile/12923059532044113512noreply@blogger.com1