Project car T34 Karmann Ghia a.k.a Rustbucket

Started by 80 Vert, January 28, 2012, 08:29:00 PM

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80 Vert

Well you know me, never do things the easy way  ;D
Purely novelty value, less than 5% of these cars were made with sunroofs so to find one these days is pretty rare.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

BB

Certainly you are a talent, with the skills, money and workshop. But mostly just so hard working and dedicated.
The end is nigh, but the end of what is the question?

spooln

77 CS1 Fiat Spider. 78 Mk1 Scirocco. 83 Mk1 GTI. 12 Abarth 595C Competizione. 18 Golf R. 20 Kodiaq vRS

80 Vert

Sandblasting has been a bust the last couple of weeks and on top of that I've had very little enthusiasm so the old rustbucket hasn't had much love lately.
Going in to winter has its downsides weather wise and the last 3 weekends have been raining with the exception of today, now normally I wouldn't come in to work ever on a Sunday but the weather was soo good I thought I'd better try and get er done.
After a late start only got the inside of the roof and roof panel done before running out of usefull light, once blasted I painted the whole area with Por15 since its a high moisture area.
Next on the list will be the drain box itself to blast and paint, once that is don't I'll start hacking on the car  ;D ;D
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

Well yesterday was the start of hacking the roof off, as we all know tearing something apart is easy........I cut the bulk of the roof skin away first exposing the side frames as well as the header frame around the windshield.
Just easier to work on peeling away the excess metal with the main roof out of the way.
I had the added complexity of replacing the rear upper window frame as well on mine, since the donor one was so nice I decided to leave it attached to the new roof and install all of it in one go which as I found out yesterday isn't all that easy.
Welded in a bar between the rear window pillars to keep them in the right distance apart, many many test fits and cutting a little at a time got the roof sitting down quite nicely.
Last thing for the day I painted the whole inner frame with por15, as to be expected it was rusty like the rest of the car  :roll:

Here the roof is sitting in place but I'm yet to trim back the rear frame to allow the roof to drop down in to place.
Once the roof is on for good I can then just drop the drain box out and deal with that as a seperate issue.
Main reason its there is to maintain the shape of the roof skin while it gets installed / welded in place.

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Angle

Wow! Very, very cool John. Thanks for putting all this work into my car.

ritmo

Such a nice overall shape. If its your car  Anglebox ..... I hope you are sitting down when the invoice for labour comes. :p

Angle

Quote from: ritmo on May 05, 2013, 01:11:02 PM
Such a nice overall shape. If its your car  Anglebox ..... I hope you are sitting down when the invoice for labour comes. :p

Ha, ha, ha - that would be the truth of it! This is clearly a labour of love by John; it's 100% his baby (his wife must be jealous)

80 Vert

Some decent progress made the last couple of nights, the front drains are done and installed.
Bit more trimming done on the roof panel and worked out one of the larger dents, few more dents to take care of once the roof skin is weded in place.
Also finished repairing the one and only rusty area of the roof, easy enough with it clamped in place.
Tiny bit more hammer work to do on it but pretty happy so far, won't be long now till it goes on for the final time.

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Fizz

Great work John, wow! I think u should design and build ur own car next. U have all the skills :D

80 Vert

I'm quite horrified just how badly made these things are, everything is soo weak and flimsy............just as if its made out of paper   ;D
All about styling in those days with little to no regard for safety  :P
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Fizz

Quote from: 80 Vert on May 07, 2013, 09:31:52 PM
I'm quite horrified just how badly made these things are, everything is soo weak and flimsy............just as if its made out of paper   ;D
All about styling in those days with little to no regard for safety  :P

So in other words a real drivers car   ;D

80 Vert

Haha yeah, funny I read a road test from the 60's the other day and they mentioned that it had a factory fitted cigarette lighter  ;D
Forget such trivial things like ABS, A/C etc, still.........it looks soo cool.
Hope to put a rolling chassis together this weekend to test fit the body and WHEELS!!! ;D
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Fizz

Awesome, think i need to pay u another visit soon  :)

80 Vert

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

#336
Bonded the roof on tonight, 3M 2 part panel bonding adhesive should do the trick for the sides / gutters and once this is dry I'll plug weld the front of the skin on as well as welding the back of the roof.
Can then remove the drain box again and finish taking out the rest of the dings before I weld the box back in for good.

Nearly have a rolling chassis together too, new rubber on the Fuchs ready to go.
Not sure about the tyre combo I have, not really a fan of the big / little look but may have no choice if I want more lows and big brakes.................ohh the sacrifices :P
Running 195/50/16 rear and 165/50/16 front on 16x6 Fuchs  ;D
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

coons

How were you suspending the roof in place before it was there for good? Did you use your hoist thing?

Looking good! How come such width differences on the tyres front and rear? Stretching the fronts so there's more space for turning the wheels?? ;)

80 Vert

The roof is really light, one person can lift it easily so one the fit was ok I just applied the glue and plopped it on, 20 pairs of vise grips hold it in place over night.

The wheels are only 6" wide so a 165 is actually about right width wise, really at the max width in front to fit under stock guards and even at that I'm not 100% that it will fit......................but I'll make it fit.  8)
May narrow the front end to fit a wider tyre under there.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration