Bring out your dead - Kman 71 vert build

[Basketcase]

you're doing a great job.
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'72 Karmann Ghia Coupe (the Boss's)

[kman]

It was tempting to drill a new hole in the dash for this but prudence dictated that I put the auxiliary power outlet in a less prominent place. I used some leftover PVC pipe and a bracket and put it under the dash; still reachable and useable.

Up close

From the drivers view.

[c21darrel]

That looks good!
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GhiaBuild
http://www.thesamba.com/vw/forum/viewtopic.php?t=481184
1967 DC build
https://www.thesamba.com/vw/forum/viewtopic.php?t=693583&highlight=67+dc
Stop dead photo links! Post your photos to The Samba Gallery!

[NOVA Airhead]

Great idea! Looks good!
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Ghia Owner Emeritus

[kman]

Thanks to NOVA Airhead I got enough side trim material to finish my side trim. I used an extra door piece to fashion a lower left rear quarter trim piece. I used my Oxyacetylene torch to shape and weld the point into it. I came out OK, not great just OK.

The middle bow was very easy to make. I used 5/4 stock poplar. Maybe $10 worth.

The front bow is another animal. I glued up and added more material to what I had and shaped it with a rotary buffer and 50 grit sandpaper. I nee both guide pins to finish shaping it as I only have one. They are on order with my top.

Speaking of which I hope that gets here pretty soon.

[c21darrel]

Nice work on the side trim!!
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GhiaBuild
http://www.thesamba.com/vw/forum/viewtopic.php?t=481184
1967 DC build
https://www.thesamba.com/vw/forum/viewtopic.php?t=693583&highlight=67+dc
Stop dead photo links! Post your photos to The Samba Gallery!

[NOVA Airhead]

kman:

That side trim looks great in the photos. Glad you could use it.

Your work on the bows really looks great as well.

Nova
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Ghia Owner Emeritus

[kman]

I finished the convertible top. Even with great instructions on this site a very difficult DIY job for a 1st timer.

1st I shaped the wood bows a bit more to match all the pictures I could find online.

It took me about 30 hours to put it in. really nice quality canvas from Convertible Specialties. Too frustrated to stop and take pictures. I was very motivated.

Next is to rebuild a 2nd engine I have. This is the candidate.

This is my solution for mounting it to the stand.

[CiderGuy]

Convertible top looks fantastic.

I bought a VW bench mounted engine stand and cut off the top of a hf stand and welded the bench mounted one on.
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Cars Currently Owned:

1970 Karmann Ghia Coupe
1973 Karmann Ghia Coupe - Project car for sale
1970 Karmann Ghia Convertible (Body off restoration)

Timing is everything

[kman]

Good idea. I'm too cheap for that 3, 3 1/4 pieces of thick wall gas pipe and some 3/16 inch flat stock scrap I had lying around. Welded to the stock supports.

[kman]

So. The engine is an AH. Bone stock. Nothing had been machined or replaced. The crank is still good. Cam and lifters worn. Most everything still within specs. I hate to replace genuine VW parts with aftermarket crap which is all I can really afford so my plan is hone cylinders, polish crank, new rings, lifters, bearings, valves, rebuilt carb and fuel pump. We will call it refreshed.

[kman]

Engine is mostly back together. Went through every part, cleaned and or replaced what was worn. New lifters, bearings, camshaft, rings, valves, seals, etc, crosshatched the cylinders, plugged the outlet on the oil pump and set it up for a full flow oil filter. Fit of all the parts was good. I replaced with german, except for the camshaft.

Started to rob the other engine for its parts. I still need to rebuild a carberator. The one I had on the working engine leaked. And the other is unknown.

[kman]

I sourced and installed a working thermostat. Between the two engines I had a full set of tins. I had to repair some of it, including the "Hoover" bit that goes on the oil cooler.

Yesterday I pulled the engine out and found that my throw out bearing was chewed up. Not sure what I did wrong there.

[kman]

Problem fixed... Here is a picture of my chewed up throw out bearing. It still spins but wouldn't have lasted much longer. I don't want this to happen again. I noticed my clutch cable had a bit of play and maybe it stretched on the few short drives I did. Will a new clutch kit solve this. What am I missing?

[kman]

After looking at some pictures of new clutch kits I may have answered my own question. It appears the pressure plate I have been using is missing the center disc.

[kman]

An engine is finally back in and running. So far it is a success. Time will tell. I tried to keep it as original in function as possible with exception to the full flow filter setup. I removed the EGR?? valve because I don't have the right exhaust to connect it to. I rebuilt the carburetor. I had to replace the fuel pump even though when I hand tested it it worked fine, it still didn't bring fuel from the tank to the engine. That is important when you want to start the car. I want to replace the nasty looking coil eventually and I need to clean the wiring up a little.

As a bonus it's upgraded with a 50 amp alternator and the thermostat has proven to work well. Oh and a brand new Sachs clutch kit.

[PeteSC]

Nice Ghia, and hat's off on the metal fab. Nice job all around....great looking car!

[kman]

Thank you.

I am getting really close to a finished product it's definitely usable as is. There are many mistakes. Many things I did over (door seals for one). A few things I would like to do.

I learned some lessons.

Buy more than enough color. I now have a slightly mismatched Left rear quarter and door. Its just the way it's going to have to be.

Though It worked to make my own panels, I won't do that again unless the cost is significantly more.

Make better lists. Many times I had to undo something to get something done.

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I still need to make a cover for the staples on the underside of the front bow and maybe a couple of pull handles. I need to straighten the angle of the rear bumper. Need to make a trunk liner. I would like a new dash, my repair looks pretty bad. There is still some polishing and fine tuning to do.

I'm not sure if I want sun visors. They look kind of dumb on a convertible.

Here are some pictures. I took it out today.

[Basketcase]

beautiful!
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'72 Karmann Ghia Coupe (the Boss's)

[kman]

Thanks. Probably going to the Ypsi show May 22. hopefully.

Wasn't sure I was coming back from this.