A pillar / Hinge repair and heater channel order

[Bschweg]

Can any one give me some clarification on what the order of assembly is for the:

- Lower hinge support and heater channel in relation to door gap?

IE do I fix the lower hinge support before attempting to fix a heater channel and rocker rust? If so when do I check door gaps or do I tack it all then set the gap with the rockers?

Do I jack up the car to stop the door from sagging then brace then tackle all this?

outer skin.

I thought the rocker was ok.. its fiberglass so more work to be done.

the missing lower hinge support

Thanks in advance for the help!

[kiwighia68]

A lot is going to depend on the extent of the damage to the area. In my case the door pillar itself needed to be replaced due to collision damage. I wrote the whole process up - repairs by an expert panelbeater - here:

https://www.thesamba.com/vw/forum/viewtopic.php?t=607279

It may not all be relevant or helpful to you, but I think it covers the dangers and best practice areas.

Good luck.
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Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015

[Sketchy_1]

Since the rockers are supported by the hinge pillar assembly you want to repair those first. Add your support braces to clean metal you don't intend to replace. Before cutting the hinge pillars out and the rocker where it attaches, I make easily removeable, clampable guide of where the hinge pillars current placement is. They clamp to the bracing. When you cut it out and begin installing the new one, it gets it close to it's original spot. It also doubles as an identifier of aftermarket quality. I use clecos and clamps extensively to position the parts where needed before welding. If mistakes or adjustments are needed they only produce a 1/8" hole.

This is all based on the hinge pillar being in the correct X,Y,Z position of the car. Hopefully one or both of your door hinge mounting plate areas have minimal rust, this will make the process easier. If not then you have to go with best fit. I'll put in the minimum amount of welds in place if clecos and clamps wont work due to space and access. Once the hinge pillar is in then you can hang the door to get the rocker aligned. I made braces that tied everything together and allowed the doors to be hung. This made installing the rockers easy and attain great gaps.
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69' Karmann Ghia Convertible AWD Project (FB Build) (STF Build)

[gorbur]

kiwighia68 thread is required reading. The pictures in particular give an insight on the whole hinge pillar assembly.
I would say if you're not altering upper and lower hinge plates and rebuilding the bottom of the pillar only, start there. Given the shape the pillar/rockers are in the front dogleg and rear extension are probably needing attention. Repair those. The idea being you will then have two solid anchor points for the HC/rockers. All of that work can be done body on the pan.
Following, (with body on pan) get the door gaps adjusted then brace. Very important and mandatory if a convertible. Be prepared and set up to lift the body a few times. Even with the bracing I didn't make any HC welds permanent until a few test fits with the body back on.
This is just a quick overview of the method I used. When you review the various threads, you will see variations that will work better for you.

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73 - Ghia Cabriolet, currently under resto
76 - Type1, 1776, full restomod

[Bschweg]

I will check all the builds out and thanks for all the great information and replies.

Its a coupe so I'll be bracing but not having to go crazy.

As for metal work I am going to have to buy some cleco clamps and cut some things open and find some clean metal.

I will keep this updated as I get more cuts done and metal replaced.

[jwilsman]

I'm looking for door braces for my Ghia project. Its a coupe but I need to replace the heater channels and want to keep the door openings stable. I know I've seen on this site that there is someone who makes some specifically for a Ghia. Its a link that was in a message on this forum. Does anyone know what person/company that was?
Thanks,
-Jeff
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1970 Kamann Ghia AutoStick
1970 Kamann Ghia 4spd
1967 Beetle