VASK Forum (VW Audi SportKlub of NZ)

VOLKSWAGEN => Other Volkswagen => Topic started by: 80 Vert on January 28, 2012, 08:29:00 pm

Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 28, 2012, 08:29:00 pm
Well, seeing as so many want me to post this up here goes.
Started pulling this car apart last week being carefull not to ruin any of the near impossible to get trim and moldings but this morning was time to brace the body before separating it from the chassis.

The bracing is more of a precaution as I'll be putting it in a rotisserie for all the rust repairs so I don't want anything weird to happen to the door gaps when big sections of the sills and pillars are cut away.
With the body hanging in a rotisserie from its bumper mounts all the stress would go into the roof and pillars, seeing as the rear pillars are pretty shot the bracing will stop any movement there.
Anyway rather than groveling on the ground I just lifted the front in the air to be able to work underneath unbolting the body from the floor, quite handy that overhead crane  ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0182.jpg)
Body unbolted and all other stuff disconnected it still wouldn't budge so another good look found 4 remaining bolts still attached  ::)
With those out it was a simple case of up up and away!  >:D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0183.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0184.jpg)
With the chassis rolled out from underneath I could start pulling that apart, pretty much removed everything off the chassis and pulled the motor out and front end off also.
Its nearly at its bare bones with only the rear subframe and gearbox left to come out.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0185.jpg)
These give an idea of where I'm heading, preffered option right now is the cream with black roof and red interior, the green I also like which is a 50's Beetle colour..........................
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/two15.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/Freddy_Files_Ninove_2011_081.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: bigbumper on January 28, 2012, 09:00:39 pm
Looking forward to seeing the progress on this one John

FWIW cream definitely gets my vote
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on January 28, 2012, 09:29:59 pm
Gona have the cement bag in the front? :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on January 28, 2012, 09:40:46 pm
Aircooled 1.8T??
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 28, 2012, 09:51:09 pm
Nah, probably a nice fuel injected stroker 2L
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on January 28, 2012, 09:53:37 pm
Nah, probably a nice fuel injected stroker 2L

;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: rambo_005 on January 28, 2012, 11:24:14 pm
Cream pic looks awesome... can't wait to see this progress - Type 34s are awesome! 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: M M on January 29, 2012, 06:37:30 pm
Looking forward to this, can't wait! :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Pinkmaggit on January 29, 2012, 08:34:28 pm
This is sure to be another standout car when it's finished. Can't wait to see what it'll look like in the end.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on January 29, 2012, 10:25:50 pm
Nice..... will follow.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 05, 2012, 03:26:31 pm
Thought I'd better start on making that rotisserie today as the body of the car has been in the way most of the week  ::)..............old rusty cars.............. ::)

Felt that the best and quickest way would be to use a couple of engine stands and seeing as I already had one I just bought a 2nd used one locally.
Started out making the mounts that bolt on the bumper mounts in the body, mainly tried to use scrap steel that we already had at work so it was a case of whatever works.
Figuring out where the center of gravity was on the body became a bit of a guessing game so after deciding how high to make the stands I cut up one of the engine stands and lengthened it by about 200mm and also widened it between the wheels to make it more stable.
That worked out pretty well and with the body hanging level in the gantry crane I could then measure up the back of the car and make the stand for that end.

With the 2nd stand done I dropped it down on the ground but it became evident pretty quickly I'd need to tie the stands together to stop them splaying out.
Some simple furniture tube bolted between the stands sorted that problem out pretty quick.
The great thing is that when this is done I can then use this stand for the Convertible and all I need to change is where it bolts to the body

Its certainly not going to win any awards but I didn't feel like spending all day making this thing so rough and ready it is!!
Balance is perfect, spins over very nice and at no time does it want to suddenly drop away from you so that's pretty cool.
Will be miles easier to work on the lower half of the body this way.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0186.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0187.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on February 05, 2012, 04:22:56 pm
GSB ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on February 05, 2012, 04:43:27 pm
with the glass out there's something very Lancia Fulvia about that roof!

(http://www.oldclassiccar.co.uk/classic-car-images/fulvia.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on February 06, 2012, 07:28:42 pm
Was thinking the same.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on February 06, 2012, 08:00:09 pm
I like the look of those Fulvias.
There is a brown one which trundles up and down my street from time to time
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: dubstar on February 06, 2012, 11:21:27 pm
Are you going to get it dipped or just cut out rust the old fashioned way?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 07, 2012, 07:47:18 am
I'm going to sandblast it myself in sections, cut the rust out- make any repairs then re blast and prime it.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 12, 2012, 12:08:36 pm
Been thinking all week where to start.................I guess it was a little overwhelming looking at the scale of repairs to be done!
In any case I thought replacing the panel above the transmission would be a decent place to start so in order to get at it properly the parcel shelf needed to come out so I got to work drilling spot welds out.

Ended up having to drill through all 3 skins to be able to release the parcel tray but after a few hours work it came away relatively cleanly.
That panel is in decent shape, just have to make a new box section that runs along the front of it as the ends have rusted off.

The little shelf below that was also heavily rusted so I took that out as well and will have to make a new one of those.
With both trays out of the way its easy enough to get at the main panel above the transmission so that will have to come out next, chipped off all the old sealer so I can find all the spotwelds.

Before that panel comes out I'll first get to work making a new panel, pretty much will have to be made in 2 pieces at least but I'll be able to join them somewhere.
Side panels also need quite a few repairs but these are also easy to get at now with the parcel tray out of the way.
All of this probably doesn't make much sense to most of you but this is what 50yo cars look like  ;D
Rust, rust and some more rust........... :( Rotisserie comes into its own here...
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0193.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0194.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on February 12, 2012, 01:29:08 pm
 :o looks like it was made in Turin...
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 12, 2012, 02:30:32 pm
I swear these were built from rusty steel  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 5-pot on February 14, 2012, 05:49:28 pm
Factory weight reduction?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on February 14, 2012, 06:24:56 pm
Oh man working with that rotisserie must be sooo sweet.
 You make it look easy John ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on February 17, 2012, 09:34:30 am
that C pillar doesn't look too healthy! 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 26, 2012, 09:55:41 pm
Wow a couple of weeks have gone by already, not much more has happened to the car but I have been busy organising my tools so that the serious work can begin so this update is more about that.
Got rid of a workbench that we don't use and brought the guilotine and folder over from the other shop so that they are more within reach.
Got a cheapo bead roller a while back so I set to work reinforcing the main frame and adding an electric drive to it, did that with a 30:1 worm / roller and a variable speed drill.
The drill I have isn't really powerfull enough at ultra low speed so I'm looking around for something with more punch.

The concept works extremely well but the drill is the weak part, begins to get a tad hot and smoking  ;D
Also cut down a trolley I had to mount the bead roller and english wheel on, keeps things tidy and stops them walking around the floor.
Last thing Saturday I started making the roller profiles to be able to roll the ridges for the new panel above the transmission.
Hopefully in the coming weeks I'll be fabricating some panels!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0226.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0227.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on February 28, 2012, 10:09:25 pm
Now that is awesome..... flag Auckland move to Wellington. ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 04, 2012, 11:12:00 am
What a great day working on the Ghia!
Sorted out the bead roller problem with an 1100watt Ryobi grunter from Bunnings, seems to handle things quite nicely.
Time had come to start on making the replacement panel for under the rear seat.
Last week I made the appropriate shape dies in the lathe for the deep grooves that are in that panel, after running a couple of test pieces I soon realized it distorts the rest of the panel quite badly when bead rolling such a wide deep groove.

The solution turned out to be quite easy, by pre stretching the area where the groove goes in the english wheel it raises / stretches the metal thus keeping the sheet more flat when rolling the groove.
Unfortunately the throat on my cheapo bead roller isn't deep enough to make the panel in one piece so I decided to make it in 3 pieces, started out with the center panel and marked out the center groove and once this was rolled I pressed the ends with a press tool I made to final shape the ends of the rolled groove.
Worked outwards from there and to finish off folded the front and rear lips to end up with the below
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0230.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0231.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0234.jpg)
Once that was made I set to work making the new legs to support it, those were easy enough in the press brake.

The end pieces were quite challenging also and kinda glad I made the separate as it also allows me to fine tune the total length of the finished panel.
Some templates of the wheelhouses helped a lot as the old panel was soo badly rusted that I couldn't copy them.
Few trial fits with the cardboard I marked it out on sheetmetal, rolled the groove, bent up the edges and offered it up in the car which looks pretty good so far and seems to fit really nice.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0232.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0233.jpg)
Last job for the day was to punch the holes of the body bolts to go through and attach on of the side pieces after some careful measuring in the car.
I'm super stoked how this came out considering I've never used a bead roller, possibilities seem endless  :P
Next will be the big panel above the gearbox, I can already see that will be a big headache and most probably will be done in 3 sections also.
Its funny how you quickly reach the limitations of machines you buy..............never quite big enough  ;D

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on March 04, 2012, 08:56:50 pm
Looks factory!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: mark2 golf on March 04, 2012, 09:40:40 pm
very nice john
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 11, 2012, 09:35:27 am
The big panel is beginning to take shape but man is it a lot of work!
Been trying to do an hour or so after work each day and started out by making a couple of test pieces as shown before which went well so filled with confidence I started marking out the main panel and rolling the beads 
Where the bead stops and starts it just distorts the panel like crazy but all that went away once I pressed the radiused parts, lucky that the whole panel fits in the press otherwise that would be another thing to figure out  ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0237.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0238.jpg)
With one radius done I'll be able to hopefully press the other side on Friday, the top part of the panel near the engine bay has these oblong holes for the body bolts to go through which also have a stepped edge as well so again a simple press tool for that looks like it will work going by the test piece I did earlier.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0239.jpg)
Managed to finish off pressing the other side of the beads on Friday night which helped to straighten out the lower portion of the panel.
Made steady progress on the car yesterday chipping away at the trans panel, got the oblong holes pressed first and then started to cut out the old trans panel which seemed to take forever  :(
Maybe I was just too eager to get the new one fitted haha!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0240.jpg)
With the old one gone and left with a big hole where everything was I cleaned up all the flanges where the new one is going to live.
Looking at it further I figured it would be much easier if the rear bulkhead came out too and since it was already unpicked from the lower rear windshield edge and also from the trans panel it just left the sides to drill off so I just did that and removed it.
The other bonus is that I can sandblast and prime it before it goes back in.

Now for the tricky part, folding the weld edges up on the new panel!  8) 
Took some measurements in a few places and made a cardboard template which was transfered and marked out, measured again to double check and started to fold the lip with a hammer & dolly.

Dropped the panel in and was surprised how well it fitted, secured it in place with a bunch of screws for now.
Finished the day with this...................will take it out again to final trim to size and hopefully sandblast the whole area next weekend
Once everything is sandblasted and epoxied the new stuff can begin to be welded in place for good.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0241.jpg)

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: sifty on March 11, 2012, 09:42:23 am
s**tballs dude... I'm so impressed.  :o What is your 'day job'?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 11, 2012, 09:45:01 am
Fixing waterblasters LOL  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on March 11, 2012, 09:48:40 am
That's pretty good work there John for a water blaster repair man ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on March 11, 2012, 11:03:06 am
Wow!!!!

Ps ever thought of making a 24v v6 waterblaster?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on March 11, 2012, 12:53:33 pm
I commend you for your patience John, I'd have thrown a lot of spanners before getting to that stage, probably cut myself on the metal edges and hit the panel with a hammer!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 11, 2012, 02:55:57 pm
Ohh don't you worry about cuts!! have plenty of those..................surprisingly though I haven't sworn once so far making these panels which isn't like me at all  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on March 11, 2012, 04:45:35 pm
Ohh don't you worry about cuts!! have plenty of those..................surprisingly though I haven't sworn once so far making these panels which isn't like me at all  ;D

Nice work

are you using the same machine for Folding?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: kiwihigh on March 11, 2012, 04:55:59 pm
Top work! look forward to watching this thread mature  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 11, 2012, 05:20:30 pm
Nice work

are you using the same machine for Folding?

Thats the plan once I make the dies but for now I use a folder where I can and a hammer & dolly where I can't.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on March 13, 2012, 10:40:05 pm
as a guy that love to work with metal ......i got all squidgy in my pants looking at those peices being formed........nice one buddy! that Vdub is going to be better than new when you are done with it!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on March 14, 2012, 09:42:25 am
Ohh don't you worry about cuts!! have plenty of those..................surprisingly though I haven't sworn once so far making these panels which isn't like me at all  ;D

 That's nice to hear I'm not the only one who dissolves into cursing around cars sometimes >:D
 I'm way better than I was when I was younger tho.
 My mate put his tool through a few windscreens but I never did.
 I threw a coil spring once tho and it nearly hit my brother in the head :-[
 That pretty much cured the worst of it, the look on his face.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: dubstar on March 14, 2012, 03:29:17 pm
My mate put his tool through a few windscreens but I never did.

Was he still able to have kids after?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on March 14, 2012, 05:53:00 pm
Awesome work John. What sort of folder do you use?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 14, 2012, 08:56:24 pm
Just an industrial folder, bit limited because of the blade set up so for a lot of the small folds I use a vise or do it by hand with hammer & dolly or on the edge of a bench.
The big folder is really only any good for folding longer lenghts of flat sheet, I made this patch panel tonight mainly by hand and used the bead roller with a set of step dies for the step in the sheet.
Once I get a chance I'll make a set of tipping dies for the bead roller which will allow that to also bend to 90 degrees.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0246.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 5-pot on March 16, 2012, 01:41:48 pm
John,  I've come to the conclusion that you do this purely because you're just so f*ckin good at it.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on March 16, 2012, 03:05:09 pm
This has become my favorite thread, great to see this standard of restoration
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 16, 2012, 04:14:05 pm
Its a funny thing, for me its not even about the car so much....
Sure I like them, always have but with this one as any project I've done its more about the journey rather than the destination. (most normal people are the other way round   ;D)
Metal work like this has always facinated me and something I've wanted to learn / experiment with, the Jetta had a little of it but nothing like making entire replacement panels.

With these Karmann Ghias there's very very little available in repair panels so in all reality there's not much option but to bodge it or make panels and fix it properly.
Plus there's probably less than 10 in NZ and mine is the oldest one here, may have also found an uber rare factory sunroof clip for it so that may see its way over here too.  ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on March 16, 2012, 04:44:41 pm
Respect mate! Couldn't agree more about the journey - it must be very satisfying to finish something but the buzz of seeing it all come together is the real deal.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on March 16, 2012, 08:47:30 pm
Ooooooh sunroof....that is going to be amazing!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 16, 2012, 08:52:31 pm
Not only that, electric sunroof!  Very very rare option back in the 60's...............we'll see if I can secure it first before I get too excited  :P
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on March 16, 2012, 08:56:11 pm
s**t!.......wow electric....get it cause I'm seriously excited.....that will be awesome.....rarerity....woohoo!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on March 16, 2012, 09:20:44 pm
Its a funny thing, for me its not even about the car so much....
Sure I like them, always have

Hah!

"Good for nothing piece of ...."

No further comments  :P
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 17, 2012, 07:43:26 pm
Got up this morning to see a wet driveway and thought OH GREAT here goes a week of prep down the toilet, not much good sandblasting outside when its raining!
Anyways headed off to work and finished making the other side C pillar panel which has sorted another big hole.
Also final fit / trimmed the big panel so thats ready to be welded in now.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0247.jpg)
By lunchtime I looked outside to see the sun and pretty clear skies so looks like sandblasting is back on the program!  ;D
Pushed the body outside and layed out a big tarp to make recycling the sand a bit easier as it seems to catch 80% of it.
Spent quite a few hours blasting the rear area where I've been making stuff for, quite nice to see some of the rust vaporised  >:D
Plan was to blast the whole area then epoxy prime it but as per usual NZ weather threw a spanner in that plan and started spitting as I was finishing blasting so the mad rush was on to get the bare metal back inside.  >:( >:( >:( F*cking weather!!!!!!!!!!!!!! ::)
Not much point priming it after getting a little wet so I ended up acid washing the whole area, next week I can clean the acid off and prime it.
After all of that its actually not a dumb idea to acid wash it as in some places the metal is very pitted and chances are some rust will remain but the acid should take care of that.
Other areas look like swiss cheese, more metal to be replaced  ::) Maybe the badge on the front should be Fiat............... ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0250.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0249.jpg)
All in all a mixed bag today made better in part by the arrival of the new shoes in the way of 16x6 Porsche Fuchs for the car courtesy of Badhabit! Cheers!!
Don't need them yet but as Filx and Veedub will tell you, You can never have too many wheels!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0248.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 20, 2012, 09:01:13 pm
Managed a good solid couple of hours on the rustbucket tonight, started welding the trans panel back in after doing quite a big repair to one of the wheelhouses which looked like swiss cheese after blasting ;D
The nice thing about new clean unrusted steel is how nicely it welds, just great to work on!
Thats one of the reasons I rather replace bigger sections as the chance of hitting thin steel is greatly reduced.

The sandblasting from the weekend looks like its a bust too, the acid wash became a bit of a gluggy mess so once the trans panel is in I'll re blast and prime the whole lot in one go.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RevHappy on March 20, 2012, 09:28:18 pm
awesome mate!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 25, 2012, 10:55:40 am
Finaly feel like I've turned the corner with this rear area since the welding has begun, no longer does it feel like I'm just tearing stuff apart anymore.
Got all the holes pre drilled in the new panels and also epoxy primed inside the rear chassis legs before welding the new stuff in.
Finished final fit on the smaller shelf which will get welded in next, just have it located with a bunch of screws right now.
Idealy I wanted to re blast the area I did last week but watching the weather it said there would be rain so I flagged that and did a bunch of other rust repairs instead.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0262.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0263.jpg)
Repaired both lower corners of the body where it meets the pan, finished off the rear wheel house and also around one of the heater outlets, funny thing was that as I finished up for the day the sun was still out so could have done blasting anyway!  You can never tell..................
The plan now is to completely finish all the rust holes and any remaining metal work in this area then blast and prime the whole lot so in some ways its kinda better its worked out this way.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0266.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0264.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0265.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on March 25, 2012, 11:17:20 am
One day you will start with nothing and build yourself an entire car! :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on March 25, 2012, 08:20:09 pm
One day you will start with nothing and build yourself an entire car! :)


Now there's a plan!.........THE VERT- MOBILE"......hehehe
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 31, 2012, 07:24:21 pm
Bit of an update from this last week with the welding, got the rear bulkhead / firewall back in the right spot and also welded in the new panels below the C pillar.
When I removed the parcel shelf I found the ends of the box section under it to be quite rusty so rather than patch them I folded up a new one.
Got to say I'm really loving this work and how its coming together, an hour or so each night makes a huge difference rather than just doing a Saturday on it.

With the side panels in place I could finally measure the length it needed to be and finish that piece.
Trial fitted the parcel shelf held in with some bolts giving me the exact place to weld in the new box section.
Also finished and installed the small lower back seat shelf as well.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0270.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0269.jpg)
The small corner pieces at the C pillar were completely rusted through so new ones had to be fabbed up.
I used one of the old ones to make some cuts so that I could squash it flat to be able to make a card pattern.
With that done I traced it on to metal. cut it out and folded it.
Bit of extra hammer / dolly work to get the rounds and curves in it like the original.
Welded up the cut lines and ground up it looks just like the original, now to make a reverse one for the other side!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0263-1.jpg)
This morning I started on one of the C pillars, best way forward was just to make a new one and replace the whole thing.
Again a card template to give the rough shape did the trick and with a combination of hammer / dolly and the bead roller we have this...........almost ready to weld in
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0264-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0265-1.jpg)
Seeing as the weather was playing ball this afternoon I decided to re blast the interior rear area plus all my welded bits and prime them.
Since it was just the remainder of the gluggy acid that was left it came off in a big hurry so I kept going and also did the top of the rear compartment as well as the water drain area right at the back and inside the C pillar while its cut apart (well whats left of it anyway............)
All epoxied it sure looks a whole lot different now than that rusty mess I had before.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0266-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0267-1.jpg)


Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: blackbetty on April 02, 2012, 12:08:33 pm
Looking great!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on April 02, 2012, 07:38:11 pm
That is fukin amazing work 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Pinkmaggit on April 13, 2012, 09:43:52 pm
Wow, this is amazing. Your fabrication skills are superb!  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on April 13, 2012, 10:18:50 pm
Wow, this is amazing. Your fabrication skills are superb!  ;D

x1
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 16, 2012, 10:19:16 pm
Just a little update, not a whole lot has changed lately but the rear parcel tray is back in for good along with both rear pillars just about completely replaced.
Next I'll start stripping all the underseal off the rear wheel tubs so that I can sandblast / prime the rear underside of the body.............hopefully this Sat weather permitting.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 19, 2012, 08:52:10 pm
Been chipping away at the underseal the last couple of nights doing one wheel arch each night, I started out with the propane torch but that set the underseal alight so in the end a heat gun set at 300 C and a gasket scraper did the job very well.
Didn't end up taking as long as first thought so both arches are ready for blasting, they look to be in pretty decent shape which is a nice surprise!
Looks like Saturday is going to be a cracker weather wise so I'm going to make the most of it.
Here's a couple of pics of the finished pillars too, not much to look at I know but its all progesss............
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/ghia1jpg.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/ghiajpg.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0234-1.jpg)
 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 5-pot on April 20, 2012, 12:20:00 am
some people recommend getting some dry ice, laying it on the underseal for a couple of minutes and giving it a good whack with a hammer to shatter a majority of it off.  Still need the heat gun and scraper to get the rest though.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on April 21, 2012, 05:22:08 pm
This will be a very valuble car when you have finished,and it won't be one of those checkbook restorations like guys in the states do,top work ,cheers
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 21, 2012, 08:53:23 pm
Got given some paint stripper dics for a grinder a while back so I put one of them to use yesterday, quite a violent affair as it just rips off multiple layers of paint in one go right down to bare metal.
Pretty quick too, did a whole rear quarter in 30-35 mins. Unfortunately I uncovered a bodgy American repair in the process, they just love drilling holes and using a dent puller then bogging over it without welding up the holes!  ::) YAY another thing for me to straighten out and fix properly...........
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0219.jpg)
Started beating on it with a dolly and slap stick but the panel has streched when repaired so there's an "oil can" there now so I used some heat to try and shrink it back with limited success, Its already 100% better but still needs more time spent to get it to a point where it will need little to no filler.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0220.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0221.jpg)
So that brings me to today, really bit off more than I could chew.................... :-[
Started blasting at 11 and worked right through to 3 pm at which time I epoxied everything I'd blasted which wasn't so bad....................but then the clean up.................. :(
Our yard out back looked like a beach  ;D which all had to be swept up  :(
That took another 2 hours after which I was about to pass out from exhaustion! so the lesson learnt is to do smaller areas next time.
Still, LOTS got done  >:D
NO MORE RUST!!! Rust holes yes  ;D >:D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0222.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Filx on April 22, 2012, 09:52:01 am
I got a chance to see the progress yesterday and whoa - sorry to roll out a tired old cliche but words and pics don't do justice to the amount of work and skill in this thin already. She's going to be soooooo smooth and clean when she's finished.

But yes I didn't realise Henderson had a beach until I saw the results of the blasting outside the shop! hahahhaa
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on April 22, 2012, 04:59:30 pm
Progress is looking pretty fast paced for a sideline project! This car is going to be hella cool  8)

Any further thoughts on colour? How about yellow?  ;)

What about wheels?

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 22, 2012, 05:05:26 pm
Hahaaahaaaa yellow, thats funny!
There is actually a very pale yellow with black roof that these came out in which looks pretty cool but my mind is fairly set on cream with black roof, going with 16x6 Fuchs all round  ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on April 22, 2012, 07:49:57 pm
Looks like a new one.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on April 22, 2012, 09:30:26 pm
Hahaaahaaaa yellow, thats funny!
There is actually a very pale yellow with black roof that these came out in which looks pretty cool but my mind is fairly set on cream with black roof, going with 16x6 Fuchs all round  ;)

Hahaha, nah I think cream is the right choice  8)

Glad I'm not the only one who turned your shop into a beach too  ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 27, 2012, 08:51:45 pm
Cut a big hole in the bottom of the guard, will start making the needed panels tomorow to hopefully fix that area.
With a big gaping hole there it also allows me to sandblast the inside of the rear 1/4 panel and prime it, will still be tricky to get at but easier than through the taillight hole!  ;D
Same story on the other side but haven't cut that away yet...................
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0223.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on April 28, 2012, 10:02:54 am
Hmm it certainly shows that you can do all you like to the outside of a car but unless you deal to the inside it will still rust away quite fast at an age like this car is.
 I use a product called ripo which I spray though a parts wash gun.
 But it is only really as good as how much you can spray directly onto the surface and even though it "mists" it is not fail safe.
 Sometimes you can unbolt stuff and spray though the bolt holes etc for coverage but Vert is doing it right eh :)

  I once repaired a Holden Ute by cutting the whole rear side off and hammering it out and welding the same bit back on, wasn't to Verts standards of course but it was good job for the money paid ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 29, 2012, 10:36:14 am
With the weather a bit iffy this morning and not really suitable for blasting I carried on repairing the rear lower corner of the body, started with making the new section for the inner fender and its not hard to see why these darn things rust
Perfect dirt / water trap between the 2 skins with no way out, I'll make a nice little drain gully in the new panels to avoid this problem in future.
Next up is the lower inner panel which I still need to cut a hole in for the drain pipe coming from the rear tray, starting to look a whole lot better.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0232-1.jpg)
couple of these panels have some pretty complex shapes, easy enough to make in a dirty big old press but by hand not so much.
Struggled quite a bit with the outer skin but here its roughed in and starting to take the correct shape.
Didn't help either that the other 2 panels I made are not yet welded so everything tends to move around a little.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0233-1.jpg)
Formed the wheel arch a little better, cut to size and trimming little by little got it to fit pretty nice.
Its all just held with weld clamps and vise grips right now and once primed inside the 1/4 I'll begin welding them in.
What is surprising is that I've gone through 2/3 of a 2400x1200 sheet of electrogalv already and the rear half isn't even finished yet ::)
All in all a great day to be in the shop working on the car!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0234-2.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0235-1.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on April 29, 2012, 08:25:21 pm
Very nice work as always vert..... out of curosity what gauge electro galv?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 29, 2012, 08:35:30 pm
Most of the car seems to be 0.8mm and then some inner panels are thinner so I'm just using 0.8 for everything.
Have always prefered to use electro galv for its resistance to rusting especially on the inside once welded as a lot of those areas you can't get to afterwards.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on April 29, 2012, 09:11:11 pm
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0233-1.jpg)

Are you putting that bonus vice grip that came with the car into use?

Looking good
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on April 29, 2012, 09:39:07 pm
Most of the car seems to be 0.8mm and then some inner panels are thinner so I'm just using 0.8 for everything.
Have always prefered to use electro galv for its resistance to rusting especially on the inside once welded as a lot of those areas you can't get to afterwards.

nice thanks.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 29, 2012, 09:46:36 pm

Are you putting that bonus vice grip that came with the car into use?

Looking good

Hahaaaa yeah I am, its in the picture!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on April 30, 2012, 04:33:47 pm
Most of the car seems to be 0.8mm and then some inner panels are thinner so I'm just using 0.8 for everything.
Have always prefered to use electro galv for its resistance to rusting especially on the inside once welded as a lot of those areas you can't get to afterwards.

 Yes it is a toatl drag that even tho you are going to be able to paint all in there, after you weld it all up you will burn the paint away where you weld and will have to just try to spray more paint etc in there to get to the welded areas.
 
 You have done really well with that outer panel, bloody hard to do.
 Are those wing nut things the weld clamps?
 How do they work? Are they magnets?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: schattenblau on April 30, 2012, 04:39:25 pm
Celeb owner (the Fringe guy) pushes his own car after it breaks down

(http://cdn03.cdn.justjared.com/wp-content/uploads/2012/04/jackson-airport-rush/jackson-airport-rush-05.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on April 30, 2012, 04:54:58 pm
Celeb owner (the Fringe guy) pushes his own car after it breaks down

(http://cdn03.cdn.justjared.com/wp-content/uploads/2012/04/jackson-airport-rush/jackson-airport-rush-05.JPG)

look at the top of the windscreen, is it a cut-down coupe?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 30, 2012, 05:27:02 pm
Nope, genuine Type 1 convertible Ghia.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 05, 2012, 09:09:58 pm
Ze german who made zis car vent crazy vis ze spotwelding gun  ::) drilled out 117 spotwelds just on the lower edge of the sill, its true what they say..........cars rust from the inside out!
Sill looked not too bad from the outside but in reality is rotten as a pear, tried to take it off as complete as possible so that I can copy it when I make a new one.
At the A pillar is where the real horrors are, everything pretty much rusted through, including the pipe for the heaters that goes up to the windscreen (for those that don't know, aircooled cars have heat exchangers on the exhaust for interior heating)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0248-1.jpg)
Kept picking away at the front pillar trying to remove pieces layer by layer to understand how it all goes together once new panels are made.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0249-1.jpg)
All of that took me up to lunchtime so with the weather looking good I did some more blasting, mainly inside the rear 1/4 panel and also at the rear air intake which had some serious rust at the bottom of it.
Problem with blasting the inside of the rear 1/4 is that you can't see anything at all so its pure guesswork, sand and dust just blows out of every orifice making it impossible to see anything.
Got there in the end and primed it, also managed to blast / prime the inside of the sill as well which was a bonus for today.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0253.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0254.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0251.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on May 06, 2012, 09:26:35 am
I'm doing my Fiat at the mo :P
 Man rust suxs.
 You just keep on finding it.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on May 06, 2012, 11:41:17 am
Saw this thing again yesterday. What can I say, it's rusty  :-X

You've gotta have some balls to dive into a project like this!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 09, 2012, 10:23:09 pm
Did some more work on the old girl tonight, my shrinking disc arived from the States yesterday so I put that to use.
The rear 1/4 panel that had previously been repaired poorly was of course wobbly as under all the poo they smeared over the repair, with it all ground out the panel itself had waves big enough to sail a yacht on!  ;D
The shrinking disc is just a stainless disc for a grinder which you can use to shrink metal back to its original shape, have read about it many times and now finaly bought one.............WOW, just amazing how well it works!
Not often I'm impressed with tools I buy but this thing is amazing, in just a few hours I have the rear 1/4 just about finished, 95% of dents / waves gone..............no bog needed  >:D 8)
Pictures just don't show how good it came out, can see this getting a lot of use on this car......
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RevHappy on May 09, 2012, 10:32:32 pm
at work we have a spot welder that doubles as a dent puller and also has a attachment to shrink panels. AMAZING. much better than the old acetylene torch and a wet rag.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on May 10, 2012, 09:16:09 am
How does the disc work Vert? Sounds good.
 You do such great work.
 I am just trying to stop my Fiat rusting away rather than rebuilding it.
 Ive not got the skills or patients do do what you do.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 10, 2012, 11:28:34 am
This explains it fairly well.
http://www.youtube.com/watch?v=X8cruauERmI
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on May 10, 2012, 02:42:33 pm
Nice :)
 Obviously works best on nice solid old steel, but you could do any if you were careful, is its the stainless making the sparks as a sacrificial thing? Could you grind a hole if you went to rough?
 Does the disc wear out?
 You are really showing some pro metal skills and really I bet you enjoy doing the more technical bits rather than making beaches with a sand blaster :P
 I just wish I had a good sandblaster at the, I may buy a spot type one that you get with the over head hopper. Have you ever tried one?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on May 12, 2012, 06:24:23 pm
Nice. Have seen the discs used with great results....but never in the flesh.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 13, 2012, 09:52:35 am
Here's a bit more explanation on how removing dents works, you sand to reveal all the low spots and then use a marker pen to mark out all your lows meaning you can then go and deal to each dent on its own.
Using a dolly and slap stick you raise each dent up to the level of the main panel, still leaves the surface somewhat wavy so thats where the shrinking disc comes in.
With the discs large surface it generates heat just on all the high spots and when rapidly cooled with water it tightens up the whole area taking the highs out.
Also really good when welding patch panels in like I did on the guard bottom, welding it on distorted the metal pretty bad but after a little effort with the dolly and disc it only needs a minute amount of filler
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0227-1.jpg)
Carried on yesterday welding in the lower part of the rear guard and installing the rear water drain pipe, took me ages to get the little drain pipe in the right place...............was a lot more difficult then what I thought and not really looking forward to doing the other side!  :(
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0229.jpg)
With that out of the way I could carry on and start looking at repairing the rotten A pillar, thtas the first area that needs to be repaired before I can make a new outer sill.
The outer sill covers pretty much all of the A pillar and the outer guards front and rear go over sections of the sill, rust trap? you betcha but hey its survived 50 years so far  ;D
First job is to deal with the rusted through heater pipe and its support plate, the plate was easy enough to make but the heater pipe not so much.
Got there in the end and welded it to the plate, primed it ready for welding to the body.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0232-2.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0231-1.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on May 13, 2012, 10:51:43 am
As much as i liked your other projects...... i am enjoying this one sooo much more. People who don't do metal work or seen it in person  will have no idea how much time it takes.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 13, 2012, 10:58:55 am
Thanks! I'm really enjoying it and learning new skills along the way.
I have  a lot of respect for guys who can do these kinds of repairs and use no filler what so ever..........takes a lot of skill and they make it look so easy  :(
You're right though and even I'm forgetting how far its come already, when you see it most days you think man its going quite slowly but looking back through this thread one can see just how much has been replaced already...................and thats just in the back half  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on May 13, 2012, 02:21:48 pm
Im really enjoying the metal work as well.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on May 14, 2012, 10:09:41 am
Me too.
 Top notch job.
 When I first saw the body I did not think it was as bad as it was.
 Thankfully my Fiat is not as bad in the hidden places as that was.
 
 It is hard and often horrible work doing grinding, metal cutting an shaping and then hot spattering welding, but having it on that rotisserie must be just magic.  And also having it all sand blasted back properly too. Not so much foul fumes burning off as you concentrate on welding breathing it all in :P
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on May 18, 2012, 05:51:23 pm
1:20

http://www.youtube.com/watch?v=yFIDY97UFQw&feature=related


Slightly different model, still damn cool though. Is it a later model?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 18, 2012, 07:32:25 pm
Thats the more common Type 1 Ghia, there's a cut away of the 2 different types of Karmann Ghia.
T34 or Type 3 Ghia top, Type 1 Ghia below.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 18, 2012, 07:44:56 pm
Been doin werk every night this week and the rust situation has improved quite a lot, started making the RH outer sill and after some trial an error we have a RESULT!
Which I'm very happy with by the way, had a lot of difficulty putting the step in both ends for the outer guards to go over but with a little thought and the shrinking disc all came right.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0233-2.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0234-3.jpg)
Pitty my sheet of electro galv isn't wide enough to do the whole sill in one length but in some ways making it in 2 sections is a little more managable.
Made the rear section and welded it on to the front bit, still some fitting / trimming to do and drill the trim holes too before I weld it on tomorow.
Figuring out what things are supposed to look like is the tough part, eveything is soooo rusty you don't really have any idea.
I'm changing one part of it as its just a huge rust trap and sonce its not seen it doesn't matter if it differs from original.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0235-2.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on May 19, 2012, 10:44:41 am
I used to get Galbraiths to fold me up sills. I have done many on old Holdens and some Hillmans.
 Used to quite enjoy doing them. I felt quite pro 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 20, 2012, 10:04:22 am
With all that effort gone into making a new sill, yesterday was the payoff with welding it on the body.
Quite a big step forward again in the fight against rust, a couple of days ago I painted the inside of the heater chanel with some tough chassis black and at the same time painted the inside of the new sill panel so hopefully it should last longer than the original.
Started out this morning trimming the new panel to size and annoyingly cut off too much at the rear  :(
With it sitting where I wanted it and carefull measurements taken front and rear I began welding it on, really slow process welding a panel this long having to let it cool right down to keep distortion at a minimum.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0236-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0239-2.jpg)
The temptation is just to go for it but that will bite you in the ass with severe warping due to the heat and since I can't get to the inside after wards I just took my time, the welding came out ACE!
Little to no distortion so no bog will be required here!   :P
Once the welds were ground up I moved on to capping the end of the heater channel at the A pillar, new section fabbed up that was pretty easy to weld on.
The factory has a real rust trap here with a gully of sorts at the end of the heater channel that fills up with dirt and water so I eliminated that and did it my way which should be a lot better.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0237-1.jpg)
By now it was around 2pm and the day had been fantastic so far so I just carried on and started to make the final piece of the front wheelhouse / A pillar.
Bit of messing around trying to get the shape I wanted but it came out really good and pretty much just like it was when new.
Still have some rust treatment to do there so didn't weld this piece in yet.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0240-2.jpg)
Final piece for the day was the inner guard at the rear where the torsion cover is, also rusted through so new piece made and fitting pretty good.
Will continue here next week by cutting the hole and final trimming it to size and probably start looking at making the outer guard panel which will nearly complete one whole lower side of the car!! YAY  ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0241-1.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Filx on May 20, 2012, 10:41:47 am
All that's left to do is everything!  >:D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: John Stone on May 20, 2012, 06:18:39 pm
Like all before me have said John....amazing skill and clarity of vision.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 20, 2012, 09:21:21 pm
Thanks, Haha I use my day at work to think about what I'm going to do next and how  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SOFTLAD on May 20, 2012, 10:15:51 pm
Knowing you over the last few years, you're having a ball at the moment with this eh?
The write up as always is fantastic, looking forward to the next installment :) :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 21, 2012, 10:05:22 am
Sure am enjoying this one Paul, new challenges are always nice!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on May 21, 2012, 10:28:56 am
Craft work like this is always very satisfying.
 More so really than bolting up engine parts etc.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 25, 2012, 09:07:41 pm
Just about ready to weld the next piece on, finished up the rear lower guard tonight.
Been working on this piece every night this week, bit harder to make as its a thicker gauge steel.
Started out cutting a rough shape of what I wanted and then rolled the lower edge to match the new sill, made a good cock up folding the edge which I hadn't realised tapered off towards the back of the car so had to flatten it back out and re do it  >:(
At this stage its being trimmed to fit the hole...................quite a big hole too  >:D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0063.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0064.jpg)
Happy with the fit I cut the 1/4 panel further above the swage line so that once welded I can work on the weld from both sides.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0065.jpg)
Next job was the torsion housing cover plate, the old panel has a recess for the cover plate and if I attempted that by hand you'd make a meal out of it so I made a really simple press tool to do the job for me.
Just a lump of steel with the right size step machined in to it and a male plug for the other side all located with a pin in the center.
First test piece was a little deep for my liking so after a couple of adustments I got what I wanted and was ready for the big moment!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0074.jpg)
You only really get one shot at this sort of thing hence the test piece!
With everything lined up and double checking the step was going inwards not outwards the press did the rest, easy peasy.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0075.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0077.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0076.jpg)
Everything is primed now ready for welding tomorow so with a little luck that will complete the whole rear guard area.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on May 25, 2012, 10:15:50 pm
Wow!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: M M on May 26, 2012, 11:50:26 am
This is amazing work!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 26, 2012, 09:07:59 pm
Spent most of the day welding on my rustbucket, couple of visitors during the day made a nice break too.
Anywhoo the repair section is on for good and looks awesome, took ages to weld it but still distorted a fair bit so with both sides ground flat I used the slap stick and dolly to straighten it out some.
Found that this thicker material needed to be smacked a bit harder so I quickly made another slapper (no smart arse comments please!  ;D) out of a bigger heavier file which worked a treat and soon beat it in to shape.
Plug welded the wheel arch and filed it to shape by hand completing that side of the body...................for now...................... :P
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0078.jpg)
Last job for the day I took the rear part of the rotisserie off to gain access to the rust hole in the rear apron, bare metaled the whole thing first get a better idea of what I'm dealing with.
Few wobbles in the lower part of it too which will need attention at the same time.
Its interesting how much wear there is in the rotating part of the rotisserie from all the sand that's got in there, thankfully its not a critical part  :o
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0079.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 02, 2012, 06:18:41 pm
Dealt to the section of rot in the rear apron this morning, pretty easy spot to make a patch for and weld in.
Also fixed up the bottom edge of the apron as thats seen a lot of abuse over the years making it pretty wobbly, was then able to put the rear section of the rotisserie back on to get the body mobile again as its a right PITA having it sitting right in the middle of the shop.
Felt like having a short day today so to finish up I stripped all the paint off the rear cowl, left rear 1/4 panel etc completing the paint stripping for the rear half of the body YAY  :laugh: ::).
Found some more filler and some damage to the lower part of the wheel arch so that will be my start point next week for the rust work on the left side.
Since the weather is a bit colder now I did an acid wash on the bare metal and epoxy primed the whole area before calling it a day  :)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0084.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0085.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0061.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0060.jpg)

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on June 02, 2012, 09:43:06 pm
Rocco flat angles easy compare to this. Inspiring work there vert.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on June 26, 2012, 09:57:50 pm
Any progress Vert?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 27, 2012, 08:44:44 pm
No not lately I'm afraid, been busy with a mini project (not a Mini as such  ;D) so the Ghia got pushed aside while that is going on.
Soon to be completed / revealed and to be honest I'm quite keen to get back to the Ghia and start on the left side of the body.
When I started this I swore I wouldn't set any goals and only work on it when I felt like it but I'm already heading towards wanting all the repairs done by the end of the year  :-X
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on June 29, 2012, 12:59:41 pm
Sounds good.... yip i have seen many a car go from hobby to chore.....good luck with it
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on June 29, 2012, 07:25:27 pm
I think Vert likes results more than it becoming a chore!
 He has the right combination needed to get things done.
 The most being hard work.
 Which I myself am a little shy on....
 Early to bed late to rise is my motto :P Well for winter :laugh:
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 07, 2012, 09:15:58 pm
With the mini project almost complete I had a few spare hours left in the day for the rustbucket, the next logical step is the left side sill and guard bottoms which is pretty much repeating what I've already done so not as exciting I'm afraid but I'll try to take some pictures of the different steps needed to make these panels.
The good part of this is that once done the rust repairs will be about 75% done on the body  ;D :-X

Since its been about a month since I last drilled out spot welds and to be honest its easy to forget as it really isn't a lot of fun however its got to be done!
Started out on the rear guard behind the door and split that apart from the body so the outer skin could come off followed by the lower piece on the front guard leaving the complete sill exposed which will be cut off next.
Nice previous repair uncovered which was just a generous dollop of poo to "fix" that rust hole  ::) ::)
I'm actualy amazed I haven't uncovered a bunch of these types of repairs which just goes to show that the car hasn't been molested too much in its lifetime.
I'll get the sill cut off next week so then no doubt more blasting will be required, same rust holes as the other side and pretty much as bad if not worse.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0095.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0096.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0097.jpg)

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on July 08, 2012, 11:09:33 am
Its so much rustier than I thought it was when I first saw it :P
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 15, 2012, 05:52:10 pm
Yeeeeeaap it is BB and the rust saga continues, cut off the other sill yesterday and this side has the wiring tube running through it to the rear in some parts its worse and others not as bad as the other side but overall it will still need everything replaced.
Once the outer panel was off it was a matter of cutting all the other bits off around the A pillar and I quickly realised that it would be better to pull the wiring out as well but the problem with that was the plastic conduit had gone as hard as concrete over the years so where it bent 90 deg upwards you just couldn't pull it through the tube so I decided to remove the tube all together to make repairs and blasting a lot easier at the same time the wiring could be pulled out.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0104.jpg)
Later on I'll replace all of the flexible conduit over the wiring making installation easy again once the body is painted, the tube it runs though is ok but again easier to bend up a new one rather than sandblast and paint this one.
The weather is whats going to hold me up now since this whole side needs blasting and priming but I'll make a start on the new panels for now and see where that takes me.
Less interesting doing stuff I've already done but at least it will be easier and in theory quicker this time round.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0102.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0103.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SOFTLAD on July 15, 2012, 07:34:10 pm
I saw this on Saturday morning, it is a fantastic project to see what John has already done and to see the large amount still to do.
The bare lines of the body shell shows you how boring modern cars have become.
Look forward to the next installment
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on July 19, 2012, 10:33:50 am
Insane amount of spot welds holding the sill on!
 Would it not be better to just run the rear wiring along the floor on the inside so you can always just get to it again?
 It seems a bit crazy to have it inside the sill?
 Must be only a few wires?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on July 19, 2012, 03:53:16 pm
Was this living in a dry part of the US, or not?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 19, 2012, 04:18:06 pm
Northern California, imagine how bad a European or UK one is  >:D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 21, 2012, 09:05:39 pm
Went and got another sheet of electrogalv last week, still find it hard to believe there's an entire 1200x2400 sheet in that bodyshell already  :o.....................but there is  ;D
Even the guy at the sheetmetal place said.......wow it must be a rusty car  >:D, yes mate Karmann built the best rustbuckets in the business!

Started making the outer sill panel last week so this morning that was the logical place to carry on, faffed around quite a bit shaping the step on the die I made so once happy with that I used the shrinking disc to shrink the excess metal back flush again.
Tried this new technique on this side hoping it would be quicker but it turned out to take just as long however its probably come out a little nicer than the other side.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0109.jpg)
Done with that the day was rolling on so I got a little more serious and started folding the lower lip with the tipping dies in the bead roller.
This beadroller has really been one of the best tools one can have for sheetmetal fab, some of the stuff I've made just wouldn't have come out half as nice otherwise.
Placed the skin on and held in place with vise grips.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0110.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0111.jpg)
Before I could carry on with the 2nd section of the sill I'd first have to repair the completely rotten rear inner guard corner as the sill welds to it at that point.
Cut the rusted sections away there really wasn't much left to look at or to get an idea of what its supposed to look like so I did the best I could looking at the repaired side for measurements.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0112.jpg)
Surprisingly this piece took ages to make, most of the afternoon infact and its mainly due to its fairly complex shape with metal curving in a few directions.
Probably would have been loads easier making it out of 2-3 pieces but that's no fun is it  >:D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0113.jpg)
Last job of the day I made the rear part of the sill, walk in the park compared to the rear corner and whipped that up in 20 min.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0114.jpg)
Weather is still too iffy for blasting so I'll move on to making the required pieces for the front corner next.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on July 21, 2012, 11:08:07 pm
You should have just made a chain link steering wheel, pull out the springs and turn it into a rat rod, would have been waaay easier  :P

Seriously though this thing's going to be damn cool, I hope it goes properly low!  ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 04, 2012, 08:54:14 pm
Back on the Ghia this morning, the wet weather has really slowed me down (dunno why as there's HEAPS of other stuff to do  :() I tend to get bogged down wanting to finish the one particular thing I'm working on but since the rain hasn't really let up I had to reluctantly move on.
Pretty much have all the pieces made for the left side sill which has to be blasted and primed now before I can weld it back together.

Decided that tackling the major rust in the nose was the next most difficult area to repair so after carefully assesing what to do I marked the lines to be cut, problem being I had to pretty much take it apart layer by layer (even though its all rotten) so that I have at least something left to measure and copy as well as figure out what it looked like when new.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0110-1.jpg)
Its amazing how 2 bits of metal rotten as a pear stay firmly together by a spotweld even tough everything around it is rusty.
With the outer skin off the inner frame is revealed, at least whats left of it.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0111-1.jpg)
I supported the body up side down on jack stands to take the weight off the bumper mounts because I don't want anything weird happening when I cut more metal away around that area.
Pretty much all of the weight hangs from the bumper mounts when the body is in the rotisserie.
Again trying to save what was left all took time but with that out of the way I cut off the bottom of the lower wheel houses and made new sections for those areas to be welded in place.
At this point the spare wheel well (also rusty and dented  ::)) was bolted back in to make sure that everything fits nice and lines up.
Finished up welding in the left lower panels at this point, quite awkward place to get at with a grinder and air saw but it looks pretty good now.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0113-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0112-1.jpg)
Other side was quite a bit quicker and a little less rusty so that got finished up before the end of the day, next job will be making a new support rail for the bottom of the tyre well and then a new lower outer skin to finish off with.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0114-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0115.jpg)
Sometimes I do look at it and laugh thinking WHY am I fixing this old piece of crap but take one look at the lines of the body it all makes sense again...........and because I can  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on August 05, 2012, 12:20:56 pm
They are a sensational looking car Vert and after you have finished I think this car will be worth at least 35k which is about what it will have cost you to do it :P
 But who else will have such a minter?
 Maybe it will be worth more if you sold it in America or something?
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on August 05, 2012, 02:52:20 pm
Are there many (if any) mint restored ones in NZ?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 05, 2012, 03:07:33 pm
Are there many (if any) mint restored ones in NZ?

There are about 10 in NZ, all pretty average from what I know.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on August 05, 2012, 07:13:11 pm
Better than new is always a good target.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on August 05, 2012, 10:45:54 pm
Well we know that this is going to be by far the best in NZ then, unless there is some crazy low milage minter.
 Do you have mods you are going to do or will you keep it standard?
 Or have you already said at the start :P
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 11, 2012, 08:31:29 pm
Manly stock "looking" BB ;)
Carried on with repairing the lower nose this morning which is probably the last really "difficult" area to repair on the body, finishing this will complete all the major rust with just small patches to do here, there and everywhere  :laugh:
The lower support rail for the spare wheel pan is a reasonably complicated thing to make, I suppose there's other ways to do it by taking short cuts but I'm not really interested in doing that after all I'm learning how to do metalwork and the different techniques it takes.
Started out folding some sheetmetal in to a U shape and using the stretcher to form a curve in the channel that follows the wheel tub.
With that done the ends need to go the other way so swapped the jaws over to shrinkers and used those to pull the ends around, found I had to fold to a 75 deg angle instead of a 90 otherwise it wouldn't fit in the jaws.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0109-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0110-2.jpg)
Drilled the holes for the captive nuts and bolted it on the wheel well..............after a lot of fiddling  ;D
With it sitting pretty good it needed an extra angled strip for the seal to be held captive so again a strip of sheetmetal folded to a 90 curved to the right shape in the shrinker and welded it on.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0115-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0114-2.jpg)
Now the tricky part, figuring out what curvature this panel had originally as its got to match the lower nose skin.....................which is rusted / cut away.
A guy from Germany had emailed me some pictures and measurements from his car which proved to be handy, after a bit of contemplation and guesswork I came up with something that looked to be OK so trimmed the panel down and folded the edges over.
Most of it came out pretty good with a couple of areas that needed to be adjusted, welded it on the body at this point which made me feel pretty good knowing another major part was done.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0117.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0116.jpg)
Seeing as I was on a bit of a roll and things were going well  ;D I thought I'd have a go at making the lower nose skin but the one piece of 1.0mm steel I had was too short, not wanting to quit now I just welded another bit on!
The lower part of the nose curves both ways and has sort of a trough in the centre, the english wheel really is the only way to make this part of it so wheeling a curve into the panel you quickly begin to see it taking shape but as with everything the last 10% takes 90% of the time.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0118.jpg)
Its really starting to take shape at this point and also rolled the swage lines in.
After several more hours of fine tuning it was getting pretty late in the day but I'm 95% there with the skin and it seems to fit really nice so far.
Finished the day fitting it in place properly with panel clamps so get a more accurate idea of whats what.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0120.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0119.jpg)

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on August 11, 2012, 09:43:50 pm
Wow...that's some great work there buddy! Looks odd upside down heheh....keep It up
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 25, 2012, 09:35:16 pm
I admit defeat!  >:(
Going to get the front half of the body blasted, the weather really has conspired against me the last 3-4 months so rather than waste more time waiting for better days the body is off to the blasters to strip all the paint and rust off the front half.

Still feel pretty good I was able to do half the body but I really want to crack on and get all the metalwork completed so that I can start fitting and gapping the panels.
Today's job became scaping / chipping all the underseal off the body and also removing all the rubber gaskets in the front as well as the seam sealer etc from all the panel joins.
The guards and light buckets are in really good shape with only one previous repair on one of the front guards, some bog excavation will be needed followed by a correct repair ::) but its all good.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0012.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0013.jpg)
Looking at it today made me laugh as I remembered saying to Paul a while ago " they just don't make cars like this anymore" to which his reply was, No they make them heaps better now  ;D
In a lot of ways thats true but modern cars have lost something..............or am I just stuck in the old days?

Also cut out both front boot corners, seems an odd place for rust but then I could say that about lots of rust I've found on the thing so far  :P
Anyways its just more metal to replace, I hope to be at the point where all rust repairs are done within the next 2 months at which time I'll drag the floor pan out for a change of scenery  :-/
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0014.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on August 25, 2012, 09:47:19 pm
They may have made cars better but they have lost the sole in making cars....
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: schattenblau on August 26, 2012, 11:22:24 am
Latest episode of Seinfeld's
http://comediansincarsgettingcoffee.com/

Features a beaut '63 Karmann Ghia.

 :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on August 27, 2012, 09:39:06 am
Soul I think you mean ;)

 John you seem to enjoy both old and new cars.
 Many old cars were just crap.
 many new cars are just crap.
 But some are great fun.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 06, 2012, 08:04:38 pm
At last.............progress, sandblaster picked the body up this morning with his big ass truck saving me faffing around with a trailer.
Lucky he's only 5 min down the road so nice and easy, called in there this arvo and they had just about finished blasting the whole front end and should have been primed last thing today.
Body should be back sometime tomorow if the weather holds.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 07, 2012, 07:48:34 pm
Well we're back on track, body delivered at lunch all clean and primed...........the weather can get stuffed now for all I care!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0004.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0003.jpg)
Lots to do and quite a few more holes found, some parts look like swiss cheese but the important areas are fine.
Soo much nicer having it all clean and de rusted, stayed behind tonight and got on with some welding.
Filled some small holes in the inner sills and welding on the rear lower guard as well as the wiring tube and front heater outlet pipe.
All these parts I made a while ago so it was real easy just placing them and welding it together, once that was done and seam sealed I re primed the inner sill so that it will be dry tomorow for me to weld the outer skin on.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0002.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0001.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0005.jpg)
Blasting also uncovered this mess, this is a typical American repair  ::) drill holes, dent pull and bog it up.............I mean WTF???  >:(
Just a joke, obviously not capable of anything else.....................will probably cut that whole area out and make a new panel for it as trying to fix that swage line could be interesting  ::) :-\
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0006.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on September 07, 2012, 08:51:50 pm
Well we're back on track, body delivered at lunch all clean and primed...........the weather can get stuffed now for all I care!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0004.jpg)

More curves than Pamela
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on September 08, 2012, 08:08:05 am
That repair job is abysmal... :-/

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Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on September 08, 2012, 08:16:28 am
I bet the repair looked fine and it isn't rusty so they sealed it up ok.
 Its a cost thing, most people do not want to pay for a whole panel to be cut of and remade so they just do what they have done there and get the job done looking fine for sensible money.
 Its good you want to do better but a bog repair is fine if that's what you ask for.
 I know you will all now say "insurance" but maybe it was not insured.
 All shops do pull and bog repairs, hardly anybody will go to the lengths you go to Vert. ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Trofeo on September 08, 2012, 09:37:04 am
So the blasting takes off all the surface rust? And then the paint primer seals it so the rust won't come back? The result looks great btw! Wish I had the patience and enthusiasm to do something like that!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 08, 2012, 10:11:44 am
Yeah sandblasting takes off all the paint, rust and bog leaving you with just clean metal then epoxy primer seals it all up preventing it rusting again.
It can be a scary proposition getting a body blasted as you just never know what is under all that paint and bog, I had to laugh as there was a Mini at the blasters which was just rooted from end to end with gaping holes and dents everywhere...............even Dave said hmm I hope the guy was expecting all of this  ;D

Apparently a few people have come to collect their body and just abandoned it right there on the spot!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on September 08, 2012, 11:44:10 am
Its fun blasting things back seeing how bad or ok sonethong really is under rust...

1mm of steel can expand out to about 10mm of rust scale.. pretty scary

You find on double skinned truck chassis when rusting has occoured the power of the corrosion has pushed the chassis skins apart yet when its cleaned out you often find that there is still 5.5mm left of the original 6mm plate...


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Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 08, 2012, 10:18:40 pm
Its quite freaky how rust just pushes metal apart, there's just no stopping it but to cut it out and replace it.

Been giving serious thought in the last week to putting a turbo on this thing, just can't really imagine only having 100-120hp even though its going to be 2000cc  ;D
Since I'm going to use the whole engine management inc all sensors, MAF and crank trigger from a AUM 1.8T I thought I might as well use the KO3 I have and boost it.
Keep compression low to keep heat down as much as I can should still go well.
Firing order is different aircooled to watercooled but thats the easy enough to change.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 09, 2012, 11:57:09 am
Had a hugely successfull day on the body yesterday just carrying on from Friday, and with the epoxy now dry enough I got to work attaching the outer sill skin.

A bit of last minute trimming and welding could begin, again just taking time to not heat the area too much it took more than half the day to get this section finished and ground up.
Certainly changes ones perspective once big parts of the body get completed so onwards we go.
I do ask myself sometimes though what is it about us car guys that we look at an old pile like this and think yeah yeah I could fix that   ::) ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0007.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0008.jpg)
With that out of the way I carried on with one of the swiss cheese areas found from blasting, best thing was just to cut it all away and start a fresh with all new metal.
Made the new pieces just like the factory did also with a strengthening plate behind the captive nut.
Got all the pieces done and double checked them holding them in place with vise grips, last thing for the day I welded the parts in and ground everything up......rust gone!
I'm going to try and get back to doing an hour or so after work each day to try and get on top of the rust work in the body but we'll see how that goes.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0009.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0010.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0011.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0012-1.jpg)

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on September 09, 2012, 01:34:07 pm
Woa that repair around the swage line, what a mess! Looking much better now though having been blasted and primed.
KO3? Pffft, I'd expect better from you John
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on September 09, 2012, 01:48:33 pm
Its quite freaky how rust just pushes metal apart, there's just no stopping it but to cut it out and replace it.

Been giving serious thought in the last week to putting a turbo on this thing, just can't really imagine only having 100-120hp even though its going to be 2000cc  ;D
Since I'm going to use the whole engine management inc all sensors, MAF and crank trigger from a AUM 1.8T I thought I might as well use the KO3 I have and boost it.
Keep compression low to keep heat down as much as I can should still go well.
Firing order is different aircooled to watercooled but thats the easy enough to change.

watercooled/aircooled?  are you considering a wasserboxer motor?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 09, 2012, 03:02:41 pm
Woa that repair around the swage line, what a mess! Looking much better now though having been blasted and primed.
KO3? Pffft, I'd expect better from you John

Bhahahaaa thought you might say that, I agree KO3 is for pussies but heat and aircooled don't mix hence a tiny turbo  ;D

Sticking with aircooled Steve, want the car to appear as "stock" as possible
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on September 10, 2012, 01:07:42 pm
Leave it NA is what I would suggest, but then I'm too lazy and broke to do what you seem to do so well :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 14, 2012, 08:01:29 pm
What a huge difference a couple of hours each day make, been doing more rust rust and some rust.
The sandblasting revealed lots of pinholes and very bad pitting in the front boot area and after trying to weld up the pin holes it became evedent pretty quickly that wasn't going to work how I wanted it.
2 options, bodge it or cut each area out and make new pieces................guess which one I went with.....
First area to be done was around the front hinge and boot corner so with new pieces made they were welded in and cleaned up, quite a tricky area to do as there's not really any room for a grinder or such.
Did most of it with a die grinder which was pretty slow going but its looking a whole lot better.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0015.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0017.jpg)
Next the area of the inner guard which was holed / pitted really badly so quite a big section cut out and replaced, multi curved panel created a few challenges...............
End of the heater channel closed in on that side as well so now just a couple more patches to go on this front corner  ;D will it ever end?
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0018.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0025.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0016.jpg)
Brings me to tonights efforts, even some of the wiring hold down straps had rusted away but at least they were a 5 min job to re make and weld on which pretty much completed the left front corner. Hopefully getting the lower nose welded back together tomorrow.
I'm gaining on the rust, slowly its all going away!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0026.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0027.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on September 14, 2012, 08:59:12 pm
Looking good man

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Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 16, 2012, 10:42:11 am
Some pretty epic progress made yesterday welding its face back together, helps having all the pieces already made so got started drilling holes in it for the plug welds and then lining up the new panel on the body and holing it in place with panel clamps and vise grips.
Double check everything before tacking it in place, took me quite a bit of time to make this lower nose so the last thing I need is to screw it up welding it in place!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/T34jpg.jpg)
Happy with where it sits I began removing the clamps one by one welding as I went being carefull not to build up too much heat.
Concentrated on the center section and worked outwards, grinding up each area and metal finishing as I went along, being that there's a big hole just underneath the weld area it made it a lot easier to work the panel with the dolly / slapstick.
Seeing it all come together was an awesome feeling, not often I'm impressed with what I've done but I'm pretty stoked to get where I am with this.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0030.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0029.jpg)
So after about 3/4's of the days work on the nose its pretty much done, all welded, ground and metal finished.
Still have a couple of things left to finish on it, especially on the inner side but its another big piece done and back together.
Once its primed I'll block it and see if I can pick out some of the smaller lows and bring those out as well, would be nice if I can do a no filler repair on it.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0032.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0033.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0031.jpg)
With a few hours left in the day I took out a bunch of other dents in the body and started looking at repairing the spare wheel tub.
It would probably be easier finding another wheel tub but its almost impossible in NZ so I'd have to import one which takes time and $$ so I'll just fix what I have instead.
As you can see its quite a mess of dents and rust holes so my aim is to fix each end of it and cut out the center section and replace that as its rusted.
Before and after, this is after about an hours work with the dolly / slapstick coming out better than I thought.
Hopefully on monday do the other side and then fix the rust.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0035.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0036.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0034.jpg)
 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: johnp on September 16, 2012, 07:56:08 pm
John since you are busy slapping it with the schlap stick, are you tig welding?
I have never had much success schlaping panels if there has been mig welding as the mig weld is high tensile and the panel is not.
Whats the go?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on September 16, 2012, 08:09:30 pm
Vert you are a top class welder, just amazing how invisible your welds are!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on September 16, 2012, 08:11:25 pm
John since you are busy slapping it with the schlap stick, are you tig welding?
I have never had much success schlaping panels if there has been mig welding as the mig weld is high tensile and the panel is not.
Whats the go?

From what I have seen Johnp, verty does it all with a Wizzbang Mig welder,

Have you been using Flux Core wire johnp as I think Flux Cored is Higher Tensile then regular solid core wire...?

then again I'm pretty new to welding and my Welds still look like Seagulls were fed laxatives and let loose....
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: johnp on September 16, 2012, 08:18:44 pm
From what I have seen Johnp, verty does it all with a Wizzbang Mig welder,

Have you been using Flux Core wire johnp as I think Flux Cored is Higher Tensile then regular wire...?

then again I'm pretty new to welding and my Welds still look like Seagulls were fed laxatives and let loose....

No , I use argo sheild with non fluxed wire. Welds are fine, my migtronic is a thing of beauty when it comes to welding,  but as I say you end up with the steel being much stiffer on the weld bead. Makes it hard to slap and dolly. (yes john I am finally doing the 1303 !)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on September 16, 2012, 08:31:04 pm
I think vert just grinds the welds back so perfectly the same thickness as the steel and only has to slap a few bigger areas as his patches are such superior fits as well.
 
 I have had to do a few weld in the middle of doors and I know just how easy and massively panels can warp and buckle :P Vert is a pro.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 16, 2012, 08:40:24 pm
I just use 0.6 wire in the welder, same Migatronic as you have...............just such a great machine!
The trick I learned not long ago is that you have to be able to grind the weld flat on both sides and that way even though the mig "weld" is harder as such you can slap it flat with relative ease.

The thing that helps more than anything else is to use the panel clamps to keep the 2 panels lined up and even, no matter how slow you weld large panels always distort and I always used a hammer and dolly without much succes until I learned about dressing the weld on both sides and using a slapper.

I actually made 2 of them, one light file for thinner steel and one heavy duty one for thicker steel and weld joins.
The nose of the Ghia is 1.0mm so it takes a bit of effort to beat into shape.
Finally you are working on it, how long has it been?  ::) ;D
The little things I have learned along the way has been awesome, just takes time and patience to to a no filler repair..........something that has eluded me for years but can now do  :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on September 16, 2012, 08:43:53 pm
Be nice to see some of your slapping tools etc
 Im not sure how to do slapping at all really :( Is it different that hammering with a dolly etc?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 16, 2012, 08:59:55 pm
They are just old files Jeremy, just cut and welded to shape.
You can also heat them up and bend them to shape.

I never really got anywhere with hammer / dolly work, just didn't work for me and since no one taught me I had to figure it out myself.
Once I watched this video
http://www.youtube.com/watch?v=LdLDOkEPFgA
lots of stuff started to make sense and doing this work on the Ghia I learned heaps of little tricks just by having a go.......I mean whats the worst that can happen?
Mess up a panel which is poked already?  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on September 17, 2012, 09:47:08 pm
Hes good that guy.
 A really good teacher.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: dubstar on September 18, 2012, 03:10:19 pm
I always wondered why they used old files.  Question answered...
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 20, 2012, 09:09:45 pm
Worked on the tyre well every night this week so far, monday I hammered out the dents on the other side and then cut a big hole in the center where the worst rust was.
Took 3 goes at if before I figured out where to shrink / stretch the patch metal to get it to go where I wanted it.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0009_zps219e5f4f.jpg)
With some more work in the english wheel it started to look ok so I began welding it in place, working it with hammer / dolly as I went.
There were 2 other rusted out parts to replace also which were easy enough once the main panel was in.
Quite a few test fits in the body to make sure it was still going to fit in the hole before final welding the whole thing.
Just about there, decided to stick at it tonight and finish the damn thing, in all there's 8-10 hours work just repairing this stupid piece  :(
Welded up all the un needed drain holes and just drilled one main one at the lowest point.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0012_zpsd3cd42d9.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0014_zpsa9106e8c.jpg)
Dropped the gas tank in and bolted tyre well in, had a brief look at the spare wheel cover which is next on the list this weekend....................looks like I'll be making another................this one is toast  :-[
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0013_zps5e30227b.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 23, 2012, 10:37:42 am
Righto bit of an update from the work done yesterday, since a replacement tyre cover has been offered I just concentrated on finishing the rust repairs on the front half of the car.
Finished welding on the last lower repair piece on the right pillar and got the lower guard attachment lip ready for making the new guard bottom once the doors are back on.

The Ebay door bushing kit should be here next week which means that job will be next, repair hinges and fit the doors.
With the doors in place I can final set the front guards and bolt that door edge back on again.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0005_zps56593eed.jpg)
Little bit of work on the other pillar also done that completely finishes that area too.
Front boot area is also done after welding up lots of pin holes and replacing a couple of smaller areas which were too big to just fill.
Other side boot floor corner welded in and completed, feels good to complete sections of the body, we are getting somewhere.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0006_zps0c2d1352.jpg)
With all the structural repairs done I could cut out the X brace I put in at the start so that I can get at the dash better.
I did wonder if the whole thing would go booooiiiinnnggg when cut out but no such thing happened  8-) solid as a rock.
Dash, well can't say I've ever had a rusty dash on any VW but this one does, last job for the day I cut the rust out, will start making the patches next week.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0008_zps445f5716.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0010_zps619dfff2.jpg)
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on September 23, 2012, 11:56:50 am
Should just cut and paste comment here..... More good work vert.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on September 23, 2012, 02:34:35 pm
what's the pan like?  a lot of work there?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 23, 2012, 02:49:15 pm
what's the pan like?  a lot of work there?

Ummmm yeahhhh, you think the body is bad............ ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on September 23, 2012, 03:04:04 pm
at least you can get replacement panels for pans  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on September 23, 2012, 03:42:22 pm
Vert probably won't be happy with the s**tty replacement ones (if they are) and make his own out of thicker better steel 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 23, 2012, 04:34:07 pm
Nup already have replacement pan halves, bought them when I bought the car.
Made in Colombia of all places, nice and thick just like factory  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on September 23, 2012, 09:19:44 pm
You must be pleased to have the pans vert,the replacement T1 floors are rubbish,I had to reinforce one with flat bar it was so thin.
By the way top work.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 30, 2012, 11:08:22 am
Yeah I think fixing the floors will be the easy part.............he says full of confidence  :-X >:D

The door hinge rebuild done I could now fit the door to see where it would sit and look at making the front lower guard piece.
Bolted the door on and although it sat at the right height I felt something wasn't quite right as the door gap at the front was quite a lot bigger than at the B post.
Maybe they are like this factory (almost certain they are,no adjustment for this) but that's just not going to cut it here so I ended up taking the door off and massaging the metal in a little where the hinges bolt on.
I now have 5mm at the A post and 4mm at the B post, can almost live with that but may try and get it better.  ;D
Door lines up pretty nice and ghost line on the 1/4 I replaced seems good as well which is a relief!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0017-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0021.jpg)
Happy with the fit of the door meant it was ready for its missing guard piece to be made this weekend so I moved on to making the missing bits for the dash instead.
Used a contour gauge on the left side to determine what curve it should have then used the shrinker to replicate that on the patch panel.
Quite a few interesting angles and curves on these cars, certainly don't see that anymore these days let alone a metal dash.
Both pieces made, welded them and ground up the holes are gone.......... :P
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0016-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0026-1.jpg)
Filled some more random pin holes I found in the pillar and where it meets the roof finishing that for now.
That brings us up to yesterday..........I try not to set goals / achievements with this car so that I'm not disappointed if I don't meet them  :( but in the back of my mind I thought it nice to finish the whole right side of the body.................can it be done?

Started off with attaching a straight edge to the bottom of the sill to be able to judge where the lower guard should sit.
Pretty quickly I had that section roughed out and sitting there.
But...........that was the easy part............
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0027-1.jpg)
Next comes all the tricky stuff like forming the wheel arch, folded edges etc.
Hardest part was where the panel folds a full 180 at the A post, ended up clamping it flat to the bench to be able to hammer it over without distorting the rest of it.
Took a little while to work out the best way to do this but it will make the other side a lot easier.
Welded it on late afternoon............yes it took the most of the day to make  :-X
Right hand side is D.O.N.E!!!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0028.jpg)
Few hours left in the day I began looking at the mess on the left front guard,  Lars's panel from Norway turning up during the week I cut out a big section which was to be replaced.
The donor section isn't quite the same profile but certainly close enough for me to modify and a whole lot easier than making it from scratch.

With a big hole cut I filled the antenna hole some hack cut in there and repaired / metal finished the top of the guard as well as repaired below the cut out metal.
Next week I can start looking at shaping up the new piece to go in there, will have to hang that door for that as well (which is full of filler too by the looks)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0029-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0030-1.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RevHappy on September 30, 2012, 03:35:45 pm
Top Effort man. i wish i had the skills you have. have you teached yourself everything off videos?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 30, 2012, 03:56:48 pm
Just years of having a go at things, learn by doing.
You'll be amazed what you can learn from youtube.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 03, 2012, 09:59:04 pm
Looks like this project has taken another turn, ground all the layers of paint and bog off the door and in some places it was 1/2 inch thick.
Funny thing was when you hold a straight edge against the good door its pretty flat where as the bad door has a huge bulge in the middle so now that all the bog is gone its back to being quite flat again.
To sum up 3/4 of the poo did not need to be there!!! Guy must have been blind.

I've started removing the skin from the frame as the bottom of the frame is pretty rusty as is the lower skin plus more drilled holes than you can poke a stick at.
Its a lot of work to repair a door but this way I'll be able to repair the frame nicely and replace the lower part of the skin as well, repairing the top of the skin around the razor edge will be a lot easier too with the skin off.

Once that is done I'll figure out how to correct the tight gaps and try to match them to the other side, for me gaps and panel fit are pretty important so I want them right.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 05, 2012, 07:54:58 pm
Managed to split the door apart the other night, slightly nervous as to wether it will work out but that door wouldn't be any good to me the way it was so can't really make it any worse by trying to repair it.
Quite a mission to peel the outer skin off but finding the right tool for the job made it a litte easier.
The frame isn't too bad at all but the skin is another story, Daylight saving started last week so tonight after work I sandblasted both the inner parts of the skin and frame epoxy priming them before going home.
Hopefully they will be dry enough to start work on tomorow, the frame needs a few patches in the lower part and the skin needs a whole pile of work top to bottom.
I'm feeling a bit more confident now that both parts are clean and I can see whats involved to make it right.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0007-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0008-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0009-1.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 07, 2012, 03:34:43 pm
So yesterday the repairs on the door began, starting with the frame which was the easy part!
Always start with the easy parts, gives you more time to think about the difficult parts to come  :P :)
Cut out 4 sections of the frame and replaced them, thats the beauty of blasting first.....allows you to see exactly what needs replacing and what is just surface rust.
The door frame took most of the morning to weld and grind up but it came out pretty good.
While the door is apart it made sense to drill out the rusted screws for the rubber wedge and 1/4 vent frame as these didn't want to budge anymore.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/IMG_0002.jpg)
After a nice Cafe lunch with a buddy of mine I started on the outer skin in the afternoon, well!! what a mess..............
Suppose its start at the top and work down............... :-/
Most of the accident damage is above the razor edge so I started the panel work there, with a quick guide coat of fast drying paint and then block sanding revealed all the lows to be brought up by dolly / slapstick method.
The next picture I'm about 3/4 done with the top section, checking the profile as I went with a profile gauge and the finished job after that.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/IMG_0003.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/IMG_0004.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/IMG_0005.jpg)
With a little time left I worked on re shaping the razor edge and welding up all the holed drilled directly in its flat face, ground those back and got the face a good as I could.
Now its a case of deciding what next, do I cut the lower skin off and repair it off the door or mount it back on the frame and repair it that way...........not sure.....
Both solutions are fraught with their own problems........
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on October 07, 2012, 04:20:40 pm
Wow Mr K.
What a transformation of that upper door! From twisted metal to smooth as a babies! Well... Within reason anyway.
Combo of dolly and Shrinker?

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on October 07, 2012, 04:22:41 pm
Know I read it properly :o.....Dolly and slapstick. 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 09, 2012, 07:16:22 pm
Otherwise known as a slapper.................. ;D

Its too late to turn back...............cut the bottom off the door skin in the guillotine tonight, removed all the rust in one go   :-X
Also did some measuring of the door openings and have found the reason for the discrepancy in my door gaps, door opening is 3mm shorter on the left side (exactly what I'm missing, 1mm at B post and 2mm at A post) thats the downside of a hand built car although a few Superbeetles I have owned had simmilar issues.

Soooooo what to do to rectify, my preference would be to correct the body but that's just not feasible without major surgery so I'm probably going to adjust the door length to suit.

Started on making the new lower skin which is going pretty well all things considered, certainly up there on the difficulty scale for me.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 11, 2012, 08:45:47 pm
Worked on the door a bunch this week, tried the frame back on the car and the news was all bad as it had distorted quite badly from all the welding.
Didn't fit the body well at all so that was first on the list to correct because if thats wrong then everything will be wrong.

With a few cuts, tweaks and welds the frame sat where I wanted so using the old piece of the skin which was cut off as a template I made a new bottom section.
All things considered it was pretty easy only taking about an hour to make and came out pretty nice!
Test fitted it on the frame to double check.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0017-2.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0015-2.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0016-2.jpg)
In the middle of the door it didn't meet the frame quite right so a few shrinks in the shrinker of the lower frame edge corrected that and fits really well now.
Fitted both skins on the frame to trim them to size and also to tack them together in place, I knew welding this on was going to be tricky to say the least but never thought it would go this badly  :-[
There is only 4 things you can do with sheet metal, you can cut it, bend it, shrink it and stretch it and with a combination of those 4 you can make anything you want.........................sounds easy huh?........................well............... its not!!  :( ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0018-2.jpg)
Last night I started welding them together clamped to the bench but very quickly realized that the joint was pulling badly and distorting completely out of shape (was trying a new method of welding)
Thankfully I pulled the plug early and went home before making a mess out of it, thiking about what to do next I came up with a new idea and put that into action tonight.
Using the airsaw I cut down the length of the seam inc the welded sections from yesterday and then went back to using my trusty weld clamps.
Those things are just the best thing out there, very patiently welding the whole seam over the course of a couple of hours letting it cool between every 5-10 spot welds.
Kept distortion to a minimum that way and 1000% better than where I was headed yesterday.
Ran the skin through the english wheel a few times which put a bit of a crown back into the panel and clamped it on the frame to see where its at.
Still needs a bunch more work to get it straight but its not looking too bad right now, certainly a vast improvement on what I had........
Hopefully sandblast the repairs tomorow and get it ready to install the skin / hammer over the edge this weekend.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0021-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0022.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on October 12, 2012, 09:05:35 pm
Extremely hard to weld a door skin.
 Good work.
 I welded a car around the screen with the screen out the other day.......then wondered where all the smoke was coming from and was looking at the roof lining where I was welding only to find the seat had caught fire :P Melted center console and side of drivers seat.
 I was at the garage I work for and hadn't taken my leather and the guy gave me this blanket he said was fire proof....it wasn't.
 Oh well new console $50 and getting the seat side repaired.
 Happens when welding rusty cars with interiors in.

 But John you are getting a 100% mark on this car 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 12, 2012, 09:19:54 pm
Yep that would be one of the hardest things to do (if you don't want truckloads of bog in that is)
Did a bit more on this tonight and made a cardboard template of the curve on the good door which made things a lot easier to hammer it to the correct shape or at least close enough to install the skin tomorow after which I'll dress the rest of the door skin.

Yeah I'm really loving this, never been able to do this sh*t before to any decent standard so its pretty cool now that I've learnt a thing or two.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 14, 2012, 11:46:07 am
Door assembly time!! Finally........
Managed to blast and prime the parts on Friday which was lucky as it rained pretty much all day yesterday.
Started out fitting the skin to the rebuilt frame making sure it was lined up at the bottom so that my previously cut lines are back to where I started.
Took some further measurements of the razor edge height to double check things were going to line up.
With it all looking ok I started folding the edge over little by little which was pretty tiring swinging that panel hammer, lots of potential for disaster but luckily things went well.  >:D
RESULT!!  Proof you can make something out of rubbish, just don't ask how long it took  ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0023.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0024.jpg)
Mounted the door on the car and was surprised just how good my gaps were, with a twist here and there I was ready to plug weld the skin to the frame as its still moved around a lot at this stage.
Welding complete and metal finished the lip I went around the door straightening the edges as good as I could made easier by having the door on the car meaning I used the body as a reference.
Me very happy at this point   :P
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0026-2.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0025-1.jpg)
At last back to the point I was at 2 weeks ago, looking at repairing the guard with the donore piece I got from Norway, now that the door is done I finally have a reference for the guard repair.
The shape of the razor edge is surprisingly different front to back (donor piece is from rear guard) but some hammer work on the bench slowly changed the shape to suit.
Once happy with the curves I began cutting it to size and final fitting to the body using the door as a giude to make sure the razor edge is straight.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0027-2.jpg)
It was getting pretty late in the afternoon by the time I started welding but after an hour or so the lower half was done and ground up, last thing for the day I started metal finishing the patch and will complete welding the top half next week then moving on to setting the door gap at the A pillar.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0029-2.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0028-1.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RevHappy on October 14, 2012, 11:56:35 am
WOW everyday im amazed by this. Total devotion to your own patience
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on October 14, 2012, 12:31:45 pm
the thing that amazes me is that John has the presence of mind to stop and take such good photos while he's working, I know that I'd just get totally absorbed and forget about stuff like that!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 14, 2012, 03:38:24 pm
Haha Photo's are a good excuse to take a break.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on October 14, 2012, 08:10:07 pm
Do you feel like this VW still has reasonable good thick steel that can be still worked (obviously it can be!) but if it was any thinned like a .5 japper you couldn't?
 You say this is .8 isn't it?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 14, 2012, 08:33:04 pm
Sheet metal is sheet metal, all can be repaired.
Most of it is 0.8 and the guards are 1.0
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 18, 2012, 08:54:34 pm
Got a bunch more stuff done this week, last few things on the door and finished off the upper guard repair.
Last piece of rust repair on the front of the body was the lower guard piece on that side which I made up and welded in.
Changing the door gap at the A pillar wasn't easy at all but I'm 90% there now after having the door off and on like 20x
Still a bit of fine tuning to do on it but its looking better all the time, also cut the hole for the side marker light in the replacement panel.
The front 1/4 panel still isn't quite good enough for my liking as its got a bit of oil canning going on and just doesn't want to play ball right now, just dunno what I'll do about that...........fill with bog?......maybe not....
Saturday is supposed to be a fine day so I'll blast all the repaired area's on the front and epoxy them as some of it is going surface rusty......the joys of a damp climate...........NZ's finest  ::)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0033-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0034-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0036-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0040.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0041.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on October 18, 2012, 09:06:22 pm
Oil canning?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RevHappy on October 18, 2012, 10:29:48 pm
time for some oxy acetylene shrinks then? or do you have a carbon rod?

Have used a carbon rod attached to a car battery. +ve on the rod -ve on the panel and just swirl out from the middle of the stretched area and then quench
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 19, 2012, 08:55:12 am
Problem is that with the panel popped out its actually the right shape but has no real strength to it before it pops back in............if that makes sense.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RevHappy on October 20, 2012, 12:13:57 am
yup needs a couple shrinks then beating out without stretching (off dolly hitting) so shrink the panel. then dress up to correct profile (if not oil canning) if it is oil canning may need a carbon shrink (causes less panel distortion)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 21, 2012, 10:18:43 am
Bit of a milestone for me yesterday completing all the rust / body repairs on the front half of the car.
Made the last patch panel for some rust in the inner roof frame and welded that in along with a new foot plate for the jack, had a fantastic day weather wise so I sandblasted all the previously repaired areas on the front as well as the tyre well and door which I've been working on.

Next week I'll start on the remaining 2 rear panels to be done completing the rust work on the body.
Might be able to drag the floor pan out of hiding to start working on that.
Sure looks a lot better now than when I started, sometimes I have to go back in this thread to remember just how bad it was. :-X
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0042.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0043.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0044.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on October 21, 2012, 10:51:29 am
Whats that? We had some good weather!
 Not for long.......................... :P
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 21, 2012, 10:54:49 am
Was just thinking I was glad to do that blasting yesterday.............yup damnING rain again today!!!!!!!!!!!!!!!!!!
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on October 21, 2012, 11:12:47 am
Congrats Vert. More great work!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on October 21, 2012, 11:16:50 am
Good work John, I love your persistence.
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on October 21, 2012, 07:53:13 pm
Link us to your thread on the Ghia forum vert? I'd be interested to see some of the feedback you're getting.
I'm sure they would be pretty impressed? Like your Jetta surely it would have to be classed as world class
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on October 22, 2012, 10:11:15 am
A perfect job is a perfect job 8) John ticks all the boxes, skill, the right workshop, enough money to see stuff to the end and most of all he just works so damn hard.
 Yea the weather is just awful I'm so sick of it now.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 28, 2012, 11:03:45 am
I had a few other things to do yesterday so not much progress on the old girl i'm afraid, did manage to nearly finish off the lower guard panel for the left side which I've been working on making during the week but have mis placed my big chassis punch to enlarge the torsion cover hole to its correct size.
Thats the last thing to be done to that piece, have one small rust hole to take care of on the inner structure before blasting that area and welding it all back together.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0059.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0060-1.jpg)
Rather than dwell on my missing tools I carried on cutting the lower rear guard off and what a surprise (not really but sounds better that way  ::)) more rust!!!
Man these things hide rust well, don't think I'll have to make the inner parts like on the other side but then I haven't blasted it yet so may eat those words............
Next step will be waiting for better days for sandblasting, if the weather isn't condusive for it next weekend I'll drag the floor pan out and start on that instead.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0061-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0062.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on October 28, 2012, 03:35:32 pm
Must have been just bare steel welded together and then painted where they could, no submerge paint baths or anything?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 01, 2012, 05:08:59 pm
Nup no dip priming so thats one reason why they pox out like this.....
Quick update from this week, thought I only had 2 pieces left to make which turned into 5!!
But more nasty swiss cheese areas replaced ready for the final outer skin to be made which hopefully I'll start on this weekend.
Also repaired the wheel arch and the big crease from another fender bender at some stage in its life.
Can't wait to get this part of the body work completed and on to the next thing, would like to get a rolling chassis done and drop the body on to make sure everything is A OK.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0065-1.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 04, 2012, 12:30:46 pm
Well the end is near  ;) finally got on to making the last lower corner of the body and remembered all the trouble I had making the last one so tried a different method this time round using just the shrinker and english wheel, actually a little tip I picked up watching a youtube video of Lazze metalshaping (please look that up, just an awesomely talented guy!!)
Anyway doing it this way turned out to be a lot quicker and gave a better result, test fitting along the way checking fit as I went.
Just needs a final trim before it gets welded in place, with the panel pretty much done I'd hoped to sandblast the inside of the rear 1/4 so that these last panels could be finished but as usual the weather had other ideas   >:(
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0066.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0069.jpg)
What to do now................go home or...............  ;D
Decided that going home is for quitters so I dragged the chassis out of hiding and began looking at that, quite a sight to behold really...........some in genius solutions for holding the battery in too in the form of an old rotten piece of timber   ;D under which was a huge rust hole!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0070.jpg)
This is probably the worst condition floors I've come across but a nice set of funky green Gerson specials will make it all better, just soo awesome somebody has taken the time to reproduce these floors.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0071.jpg)
First order of business was to make a drawing of the floor to record measurements from the tunnel to the pan holes and also where the seat tracks sit in relation to the tunnel, I also recorded measurements for the rear seat support etc.
With that out of the way I started salvaging that parts which would be required later such as seat tracks, rear seat support, jack supports, pedal stop, gas pedal bracket etc etc.

My seat tracks may just be salvageable so on the one side I cut them out of the floor and then ground through each spot weld to remove the excess metal which turned out to be painfully slow, on the other seat track I went back to drilling out each spot weld which to be honest isn't really any faster and you really can't be too brutal removing them as you'll just end up distroying them.
They are pretty rusty as well but with some repairs I'll re use them.
Quite surprising just how many spot welds hold them in place, obviously didn't want them coming off!!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0072.jpg)
Next thing I cut off all the other parts to be saved which I clean up later before they go back on, just roughly cut them out with an air saw.
With those out of the way I simply cut off all remaining remnants of the rusty pans which makes things look better right away.
All thats left to come off now is just the excess metal at the front and rear plus the tunnel which will be trimmed to suit later.
My chassis had reinforcing plates on the front so i drilled the spot welds out and removed them giving access for the front metal to be removed, same story at the rear (will post pics of these areas next time)
That was about it for this weekend but next will be trimming the new floors to suit.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0074-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0073.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Filx on November 04, 2012, 12:54:48 pm
OMG those orignal pans were toast!!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 08, 2012, 10:15:34 pm
Funky green will make it all better  ;D
Once I cut off the remaining bits of the floors the cleanup of the edges can begin, drilled out the spot welds front and back peeling the excess metal away and cutting the floor flush with the tunnel edge.
Since the T34 floor is constructed differently to a Beetle its not quite as simple to weld new pans in and on mine I wanted it to look quite factory so I decided to butt weld the new floors on instead of doing an overlap joint.
There are many ways you could install these but I thought I'd share the way I did it.
Its more work and more tricky but should end up with a nicer factory looking result as well as the factory spot welds still in place.
Below pics show the front and rear of the frame with old floors removed.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0078-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0077-1.jpg)
Going by my measurements I took before I started cutting I placed the new floor half on and lined it up clamping it in place where it measured right.
Ran a scriber along the tunnel marking out the metal to be cut off the new floor, trimmed the new floor to suit with tin snips.
Really impressed with these pans, thickest metal floors I've ever come across.
Once cut I clamped it back in place and began tacking the pan in place adjusting the fit as I went trying to keep both pieces of metal level with each other, just takes time and patience to get it nice.
Bonus with thick metal is that the welder can be on high producing a nice strong weld and things don't tend to warp much at all.
Grinding is a little tricky and time consuming but I'm really happy at this point with how they are looking.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0080.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0079-1.jpg)
Other side is just a repeat of what I already did, one thing though worth noting and my only criticism of these floors.
The holes for the body bolts tend to vary quite a lot and are punched very nicely in the middle on the right half where as they are punched on the outer edge on the left half, maybe just on my set but it meant I had to trim more off one pan than the other to make my measurements correct for the body bolts.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0081.jpg)
The center pivot for the rear subframe has a plate that attaches to the floor with 4 bolts and on the inside of the floor there are 4 reinforcement plates with captive nuts on them, now mine were completely beyond saving so here's how I made new ones.
Managed to figure out what they looked like and bent a 25x5mm piece of steel to the correct angle to use as a die if you like.
Cut some strips of 2mm steel plate to the right width (38mm from memory) and used a vise to clamp the 2 together, bent the plate to the shape of my steel die and clamped together with vise grips.
Now comes the fun part (make sure your vise is REALLY tight)
just using a hammer you beat the edge over little by little, takes quite a bit of effort but you should end up with the correctly shaped pieces and a folded edge.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0075-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0076-1.jpg)

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SZC on November 09, 2012, 05:07:13 pm
Shucks good effort, Looks OEM
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on November 09, 2012, 09:11:56 pm
Awesome work Vert..... But man the pan was rotten!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 09, 2012, 09:27:46 pm
Awesome work Vert..... But man the pan was rotten!

It was just trying to keep up with the body  ;D
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on November 09, 2012, 09:29:09 pm
In that case it had success!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on November 10, 2012, 07:07:04 pm
Nice little bracket bits you made.
 Will you weld those nuts on and drill a hole?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 11, 2012, 10:58:46 am
The nuts are a press fit so they should stay there as they are.

Even though we had fabulous weather for blasting I just couldn't be bothered dragging the body outside so carried on with the chassis instead.
Mounted the rear subframe pivot plate to mark out the 4 holes to be drilled, with those done welded the 4 support plates on and also mounted the pedal cluster in order to find the right spot for welding the gas pedal bracket on.

Decided that I won't weld on the jack supports till the body is sitting on the pan as there's just too much chance for them to end up in the wrong place as the body has just a small recess for it to sit into.
Seat tracks require rust repairs as well so can't do them just yet either  ;D ::).
Looking at the pan holes along the edge something caught my eye which didn't look light so started doing some measuring, took measurements from one of the frame head bolts on the body (the 2 side by side at the front of the body) and measured back to each bolt hole in the heater channel and recorded those on paper.
Compared to the holes in the floorpans I found that the holes on one side are as much as 15mm out.
When you eye up the stamped hole in relation to the pressing on the pan half its plain to see that they differ left to right and clear that its not placement of the pan half on the chassis at fault.
(i'd be interested to know if they are still like this as my pans were one of the first sets Gerson made so this may have been corrected by now)

Obviously the body would never fit with the holes where they are so I set about moving them forward, ranging from only 5mm to the worst one being 15mm.
Easy enough to do by clamping a copper block underneath and welding up most of the hole then using a die grinder to create a round hole further forward.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0082.jpg)
Happy and confident that everything will now fit the rusted rear seat support is next, best way really is to re make both lower portions of it so by days end I've nearly got one side made.
Made it bigger than needed so that there's plenty of choice on where to cut and join it to the main panel.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0083.jpg)

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on November 12, 2012, 09:46:05 am
I don't understand how those nuts press onto the little brackets you made?
 Can you show a photo of the other side........I'm interested, really I am!
 Man you have done so much amazing panel making and just perfect welding.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 16, 2012, 08:07:32 pm
Continued with the rear seat support this week, not happy with the panel I made last weekend I binned it and started again, always easier the 2nd time around and came out how I wanted.
With a matching one for the other side also complete I could look at the best place to cut the rotten bits off the existing panel, figured the best place was just above the diagonal pressing.

Cut both lower parts off and mounted the remaining back on the chassis to be able to accurately mark out where to cut the new panels.
With those trimmed to fit I ended up doing a lap joint, I wasn't going to put the rectangular pressing in but not knowing what it was there for I thought I might need it so a little more effort has made it like it was originally.
The whole deal didn't really come out as good as what I had planned but I'm not making another so this will have to do.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0069-1.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0070-1.jpg)
So I thought that's it! I'm DONE with the chassis...........WRONG, seat frames to repair........  :'(
Picking up those rusty seat frames I thought does everything on this car need repairing?? I guess the answer to that is YES   ;D
Anyway, a quick sandblast to reveal the true condition of the frames I quickly realized that all the base plates would need to be replaced as well as all of the strengthening pieces on the ends of the seat runners.
Took some 1.5mm plate and cut it into strips, marked out the notches to be cut.
With the base plates cut and trimmed to fit I welded those on as well as the new end pieces I'd made.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0075-2.jpg)
Pre drilled all the plug weld holes, finally ready to weld that sucker on.
Finished one side tonight and the other will be done tomorrow.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0076-2.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0077-2.jpg)
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on November 16, 2012, 08:16:39 pm
Again...... Nice work. But s**t it's rusty!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 16, 2012, 08:20:10 pm
Could be worse................A Fiat.........Bahahaaaahaa, but seriously yes its a very rusty POS but getting better every day.
Won't be long now and I'll have a rolling chassis on 16" Fuchs with 944 brakes  >:D
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on November 16, 2012, 09:16:40 pm
Haha rustier than any fiat I have come across.... Looking forward to seeing its progress.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on November 17, 2012, 08:50:37 am
Agreed. Fiat is no longer the benchmark for rot, Karmann now takes top spot!!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 18, 2012, 03:47:42 pm
Top honnors, I can live with that  ;D
Floor pan now done, finished up the other seat base yesterday and welded on, all grinding completed so now ready for blast and paint.
Before that happens I'll assemble a rolling chassis and test fit the body, besides I'm quite keen to figure out an acceptable ride height and wheels....... :P
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0078-2.jpg)
Pan finally dealt with and out of the way I got the rear subframe down and started work on that, some time ago I bought an IRS rear frame cut from a Beetle as I'd intended converting the Ghia from swing axle to IRS.
Getting that rear cut kills 2 birds with one stone as it gives me something to make the alignment jigs on as well as factory IRS mounts which I cut off the scrap frame once the jigs were made.
Got to say the jigs worked a treat in placing the mounts with just a case of welding them on, tacked one first and test fitted the spring plate and trailing arm which worked out great so finished up welding both in.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0080-1.jpg)
Mounts in, it's just a case of bolting on all the Beetle IRS arms, spring plates etc which I already had.
Plan to run some better brakes rather than the all round drums it came out with so Porsche 944 rear backing plates, discs, calipers are a direct bolt on............. ;D Bet most Porsche guys don't know their 944's have BEETLE rear trailing arms hahahaaaa!!! And those that do would probably deny it!  >:D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0081-1.jpg)
I have a few wheel options currently as in 17" Cup 1, Cup 3 or 16" Fuchs, kinda feel the 17" Cup wheels are too big and modern looking for the classic lines of the body so settled on the Fuchs a while back however they don't clear the calipers that well meaning a spacer is required making the whole rear axle 4cm too wide overall to fit under the body.
Somehow I need to remove the spacers and narrow the whole lot some more, will start looking at that next week.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0082-1.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 23, 2012, 07:50:44 pm
Things have been a bit quiet on the Ghia front, been slacking this past few weeks achieving very little...........but ya get that sometimes   8)
Anyway remembered that my kick plates for the front footwells were in pretty dire shape as well so rather than repair I settled on making a couple of new ones using the old ones as templates.

Marked everything out on flat sheet and began rolling the beads straightening / shrinking the sheet as I went, rolling beads which stop before the edge of the sheet really distort pretty bad so shrinking the edge flattens it all back out again.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0087.jpg)
Then its just a matter of folding edges etc and checking the fit as you go, in all about 3 hours work to make both of them obviously the driver side one taking longer with the added cut outs for the pedals.
Just have to finish the locating tang on the drivers one tomorow.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0089.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0088.jpg)
IRS is out too, not gonna work without narrowing the arms which I can't be bothered doing so going back to swing axle which I hate but its easy  ;D
Will run 1200 axles and tubes which narrow the rear end about 60mm solving all my clearance problems in one hit.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on November 23, 2012, 11:01:32 pm
you probably know that the type 3 selecta has a "razor edge" option where you can try out wheels, I think the Empi 5s suit the car quite well but the Fuchs look good too

http://www.typethreedetectives.com/type-3-selecta/ (http://www.typethreedetectives.com/type-3-selecta/)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on November 25, 2012, 09:01:44 pm
Amazing work as always,how will the axles go with your engine plans?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 25, 2012, 09:43:06 pm
Should be ok I hope, lot less spline contact with short axles so fingers crossed.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: bigbumper on November 25, 2012, 10:53:39 pm
Saw one of these on the back of a trailer this afternoon - red with black roof, roll cage and black minilites... looked pretty cool.

Must've been a VW thing on in Melbourne today 'cos we passed a mint early 60's Beetle convertible a few minutes later, also on a trailer
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 02, 2012, 03:43:03 pm
Time for the front end to loose its appaling drum brakes in favor for 944 4 pots, I had most of the parts already except for the discs which were easily sourced locally from Autostop.
Using the 944 alloy front hubs is the easiest way to go, it has the correct offset for the rotor as well as the right stud pattern for Porsche wheels obviously.
The bearings are different sizes so I had to make steel adaptor rings so that the Ghia's original wheel bearings could be used on the Ghia stub axle.
With the hub mounted I could look at making a caliper bracket, the T3 front end is completely different to a Beetle one and doesn't lend itself to this type of conversion at all plus I need to have this as narrow as possible so every mm counts.

Figured out a way to make a bracket in the end, one which is completely bolt on with no welding needed (certifiers are not keen on welded brackets)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0091.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0090.jpg)
Used 2 mounting holes for the main bracket and then made another one which picks up one of the holes on the opposite side of the stub axle.
Still have to make solid spacers which will replace the washers from the mock up stage but everything seems to fit quite well, rotor and caliper on for the completed side.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0092.jpg)
Took ages to make that one side but once that was figured out its just a case of copying it to complete the other side.
Both sides done and wheels on its going to be critical to find the right tyre in a hope of getting it all to fit under stock guards, can now assemble a rolling chassis for a test fit of the body once the last couple of rust areas are finished.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0095-1.jpg)


Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: M M on December 03, 2012, 09:01:13 pm
Great work as always! This is coming along nicely.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Filx on December 03, 2012, 10:27:53 pm
Awesome! Can't wait to see it all done with the steering and uprights etc all painted.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 03, 2012, 10:32:37 pm
Made a decision on interior tonight, will be like this but with off white instead of the bright white and leather on seats rather than vinyl.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SOFTLAD on December 04, 2012, 08:19:17 pm
Will you be going standard seats or something more retro lowback bucket?
Or even sculpting the form of the standard ones for comfort & support?
The alloy side detail on the seats in the pic is a nice highlight to the seat
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 04, 2012, 08:21:10 pm
Pretty much as you see it with exception of a nice period woodrim wheel & billet shifter  ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 05, 2012, 09:52:09 pm
Done with the door panels for now, boards are made so will order the material I need to be able to cover them.
Found a source for original cloth for the seats and door panels so hopefully I can get some of that reasonably quickly to carry on.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0103-1.jpg)
Took all the gauges home to play around with, yes those are rusty too  ;D ::)
Something always seemed a little fishy with the speedo but never looked at it closely so now that the cover is off it seems someone has hand made a MPH face and glued it over the original KMH speedo, being that it was a european car imported to the USA they obviously couldn't deal with the metric system  ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/DSCF0101.jpg)
New camera finally so pictures should be a little sharper  :P
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010016.jpg)
Started with the speedo and carefully removed the hand made gauge face to be left with quite a mess of left over glue and black paper residue, trick is how to get that off........
Figured sanding it with fine paper would be the way so started with 1200 and worked up to 2000 grit, still took a couple of hours in total to sand all the glue etc off and then used 3M vehicle cutting compound to polish out the 2000 grit scratches.
Pretty stoked with the results, also reset the odometer back to 0 which is easy to do
and since everything will be new the speedo might as well be at 0.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010004.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010011.jpg)
On to the outer face, just thoroughly cleaned this with the 3M polish and re painted the little white stripes with Tamiya model paint.
The KM speedo has a red stripe right at the 50km mark so I painted that as well, the button in the center of the face is actually brass so with a little polish it cleans up real nice!
Another evening gone, more stuff done.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010014.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: weta.worker on December 06, 2012, 06:01:00 am
i love this thread!  its like watching a master at work!  your attention to detail is outstanding!  not to mention the skills you have to do all of this!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 06, 2012, 07:50:50 am
Thanks, attention to detail is what makes the difference in the end product  ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: weta.worker on December 06, 2012, 08:08:57 am
have you done many of these rebuilds?  Just wondering what happens to the end product?  Do you sell them on because you love the restoring process or hang on to them forever?

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 06, 2012, 08:27:43 am
Yeah have done tons, still have quite a few cars but eventualy they get sold on and seem to start another and another and another  ;D
Figure this will be a keeper though, have wanted one for some years and think if I do another aircooled car it will be an early 911
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on December 06, 2012, 11:38:19 am
Tampering with speedos!!! :police:
Quick call the authorities!! :police: :police: ;) ;)

Gotta have something on the go does MR K. Keeps him from beating up his customers!
Some stress relief on the most part.
He's been a source of inspiration for many people's beginning a project or sticking with one too.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 09, 2012, 01:50:41 pm
Gauges are nearly done,
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010038.jpg)
Yesterdays weather played ball so even though I didn't feel like it I made the final assault on the rust by blasting the inside of the other rear quarter panel, all nicely primed ready to have the last 2 pieces welded next week completing 99% of the rust work.
Not sad to see that part behind me either, still a few tiny spots to do but a few extra hours will knock those over.
Then I just have one door, boot lid and hood left to strip and the hollidays will see some of the body work and sealing started.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010037.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010035.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 13, 2012, 09:12:40 pm
The final assault on the rust has yielded good results, both lower guards welded up and finished.
Now the serious body work can begin but I feel like its now in the pre paint stage which sounds a hell of a lot better than the "rust" repair stage.....
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010039.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010042.jpg)
Took the body out of its rotisserie as well as removed the pivots for the first time since I built the rig, found some dents in the nose so I dealt to those before I start to paint prep the boot / inner nose area.
Car has never been hit in the front but obviously bumped into a few things.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010043.jpg)
Since I'm doing some interior stuff on the side and made door / quarter panels a week or so ago I also dismantled the rear seat which was in very poor condition, the wooden base boards were completely rotten so I've made new ones from 18mm plywood.
Oddly enough the original base is ply wehere as the back rest is not......
They have a thin ply panel where the oblong holes are to give the back support some spring as such but I think I'll use webbing instead which will do the same if not better job.
Not that its much of a seat anyways as a adult would never fit back there  ;D
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010044.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on December 13, 2012, 09:45:39 pm
Not far away from painting John,what colour?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 16, 2012, 11:56:01 am
Gonna be off white with black roof,
Spent a very frustrating day working on the front boot area, sanded the hard as cement epoxy in preperation for the 1st coat of sanding primer to go on.
There were a couple of areas which were badly pitted from the rust after sandblasting and since they are in a visible area I wanted to just skim over them, I thought I was doing the right thing by buying a quality filler (Wurth) but it turned out to be the worst filler I ever used.........very greasy and instantly clogs the sandpaper.

What do you do then? You take it all off again thats what, and re applied with a different product.
Something which should have taken a few hours took all day but I did get primer on so at least its a step ahead and not backwards.
Rear seat also in for a test fit, all good so far.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010046.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010045.jpg)[/quote]
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on December 16, 2012, 05:12:54 pm
Strange about the filler.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on December 16, 2012, 06:10:03 pm
Nice one. Final outcome is quite a change as was quite pitted. Looking good.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on December 16, 2012, 06:53:46 pm
Looking Slick there mate! 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: John Stone on December 16, 2012, 08:03:12 pm
Nothing comes close to what you're doing here John....this is awesome stuff and I'm always always looking for updates ...
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 18, 2012, 04:58:20 pm
Good to see people interested in a poxy old aircooled rustbucket  ;D

I'd forgotten just how mind numbing boring sanding is!!
Still, better get used to it as there's lots of sanding to be done on this old girl.
Started on the interior dash and front foot wells by scuffing up the epoxy with 120 grit paper and seam sealing all the seams.
I managed to get a gun for spraying seam sealer from a body shop down the street which was closing down so this car is the first time I used it and must say I really like the modern OEM finish it gives.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010049.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Omes on December 19, 2012, 09:17:33 am
mmmmm loving those period gauges.

Your work is top notch Mr Kanters!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 21, 2012, 09:36:04 pm
This week has been a hot one weather wise so I've been busy on the inside of the body, got the whole dash area sanded and rust repair areas filled / finished ready for sanding primer.
Also finished up the rear seat area with more pin holes to fix as well as tidy some of the ugly pitted areas.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010054.jpg)
Its really cool to see it at this stage as during all the rust repair you wonder if you'll ever get to this point.
More work with the seam sealer gun tonight and a final coat of primer over the whole lot.
Plan to sand the engine bay tomorow, seam seal it and prime it.
Been looking into how to make new door / qtr caps and also dashes which is looking promising but will require a ton of work on my part making molds etc, all my interior door / qtr tops and upper / lower dash pads are rooted so making new ones is the only option  ::)
Found the right vinyl so far and worked out what foam to use but first I will make the C pillar caps as they are by far the simplest to make so I'll try and work on that a bit in the hollidays.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010055.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 23, 2012, 11:11:10 am
Back on sanding duty yesterday this time tackling the rear boot area and the rear upper deck / parcel shelf.
Did the seam sealing in the rear as well as minor filling of the previous leaded areas as some of the lead has been blasted / ground away during the paint stipping process.
Next will be putting the body back on the rotisserie to attack the underside and gravel stop the wheel wells etc, its quite good to break the body into manageable chunks and doesn't take as long as I thought although the hardest part is yet to come..............getting the outer panels straight!
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010056.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010057.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 24, 2012, 05:00:14 pm
Nice pre Christmas surprise today from the USA, original seat / door panel material from SMS came in the post.
Must say nice people to deal with too, no fuss about sending through the mail so just the vinyl to turn up now and I can start making door panels.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010060.jpg)
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on December 24, 2012, 06:22:18 pm
Nice
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 29, 2012, 05:11:47 pm
Another day blown working on the Ghia, started off this morning by putting the body back in the rotisserie so that I could start attacking the underside.
Sanded all of the underside of the trans panel and both wheel tubs, once all the sanding was done all the seams could be sealed ready for the primer and stone guard / sound deadener.
I masked off all the areas where I didn't want sound deadener and then sprayed on a coat of epoxy sanding primer and let that flash off before spraying on the sound deadener.
Once all of that is dry I can sand / prime the underside of the engine bay before moving on to the front wheel tubs.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010063.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010064.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010065.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on December 29, 2012, 05:19:41 pm
Man you love working on cars John!
 I am supposed to be doing some stuff to mine but its just to damn hot and I just must be too damn lazy :P
 Hope I can muster some enthusiasm soon as I need to get stuff done........
 The vinyl and buds are just too seductive 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 29, 2012, 05:27:12 pm
Would rather work than sit on my ass getting bored LOL, aint gonna get done by itself is it?
Just seems a painfully slow process is all, still a long way to go.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on December 30, 2012, 09:20:44 am
It certainly would not get done.
 The amount of work you are doing is impressive to say the least!
 I never seem to get bored sitting on my bum seems to be the problem I have :-[

 Also the weather is too hot or too wet at the mo.
 I'm doing stuff round the house so all good.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RevHappy on January 14, 2013, 10:19:50 pm
Any new year updates?

Sent from my GT-I9300T using Tapatalk 2

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 20, 2013, 09:24:32 am
Took a break from working on the car over the Christmas hollidays but time to get back on track with it, must say it took a little effort to get going again as its definately easier to do nothing  ::)
Just more of the same really, sanded the front underbody and wheel tubs so that these can be seam sealed and primed.
With everything sealed I got a coat of sanding primer on and once that had flashed off followed that up with the water based sound deadener.
All of this should keep things sealed for a few years to come.
The whole underbody is now pretty much done meaning I can get on with straightening up the outside of the body, I'll do all the lower parts of the nose and rear 1/4's with it upside down in the rotisserie which should be a lot easier.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010079.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010080.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010085.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010084.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on January 20, 2013, 10:26:28 am
Is that the Wurth protectant/sound deadener you are using?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 20, 2013, 12:06:19 pm
Yep, Wurth waterbased......SKS I think its called.
Really great stuff, nice finish and dries very quickly unlike some of the solvent based ones.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on January 20, 2013, 12:17:12 pm
Yeah, I thought so, used that on a couple of my projects and is the best stuff I ever used
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 27, 2013, 09:56:57 am
On with more bodywork, started on the filler work yesterday which I'm really not a fan of at all but I do want it really straight so its gotta be done.
You very quickly realize how big this journey is when you try and do everything yourself, rust, bodywork, paint, chassis, motor/trans, interior etc etc etc as opposed to sending it from shop to shop and manage that process but thats no fun now is it...........
I'm very happy though with how little bog its taking to get things looking right, just little bits here and there to feather out panel joints etc, ultimately though my goal would be for no filler repairs but I'm not there yet.
Right rear 1/4 and top of rear deck are now close enough for a 180 grit block but I'll get the rest of the body to this stage first and hopefully I'll be at that point just before the new roof gets here.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010093.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on January 27, 2013, 10:53:36 am
Was just showing my mate this build and he is just amazed at the level of quality and skill.
 Good on you John.
 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 03, 2013, 09:40:15 am
Back on the bodywork, managed to get the other rear quarter done and the lower half of the nose as well.
With the sun beating down outside it was ideal to prime those areas and guide coat them.
Its all actually coming up better than I thought it would, can't wait to have gone right around the body and will then do a 120 grit block before doing 180 then 600.
I guess its not crazy far away from getting some paint on it but once the body is ready for its final 600 I'll leave it to settle so that all the primers and any filler have a chance to shrink while I paint and build the chassis and motor.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010106_zps1872749f.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010109_zps84f87d00.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on February 04, 2013, 11:18:02 am
Smooth 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 07, 2013, 09:54:30 pm
What better thing to do than use Waitangi day to do sanding  >:D spent half of the day at work to finish off sanding the front end to get the body in primer, the left front guard was the previously badly repaired one and even though I'd done a pile of work on it including welding in another section I still wasn't 100% happy with it so now that it had the epoxy on it I just hit it with 80 grit to reveal all the lows and had another go at beating those out.
Got it a lot better without being silly about it which suits me a lot better, did a little filler work and primed the front end.
Roof arives 3 April so I gotta get my s**t together and finish this body, its funny I look at it now and think oh wow its actually a pretty nice body  ::) ;D
This weekend I'll start the 120 grit blocking so we'll see then just how straight she'll be.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010116_zps8d07f852.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010115_zpsf08ed586.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010114_zpse5793b89.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on February 07, 2013, 11:30:27 pm
Its a better than new body with all that modern non rusting thicker steel in it.
 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spud mk2 on February 13, 2013, 05:08:30 am
A nice T34 has just turned up on 'Bring a Trailer' . Cool looking car.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 17, 2013, 10:21:42 am
Time to carry on with paint stripping panels, bare metaled the outside of the other door during the week and was surprised to find no rust holes, bog or dents......Bonus!
Quite the opposite to the passengers door which I've already repaired, still to blast the inner frame etc which I had planned to do yesterday but ran short of sand and had to keep recycling what I had as it was just to be able to finish the decklid.

Used the same method on the outside of the decklid as I did on the door, purple paint stripper discs on a grinder which work well on multi layers of paint, don't think blasting would be an option when there are so many layers of paint to get off.
Stripped the louvres by hand with an angled air grinder and an 80 grit wheel which was fun..............NOT  ::) :(
Sandblasted the inside and over the louvres as well once most of the paint was gone, the decklid was very surface rusty, especially under the paint for some reason but it came out pretty mint really with no repairs needed at all.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010124_zps46486fb0.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010126_zps759618d0.jpg)
Sweeping up constantly and re using the sand got pretty annoying but did that just long enough to blast the inner rain try as well, at least thats another part done.
Will have to go get more sand next week to finish off the other door and front hood which I know has a couple of rust holes in the very front of it.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on February 17, 2013, 05:07:34 pm
what a trooper!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 17, 2013, 07:13:12 pm
Doing another side project at home, this time making the interior panels.
Armed with the OEM cloth and some Bus center panels I've started with the door panels first, taking my time measuring before cutting anything the 1st one has come out awesome.
Really like the combination of the red and off white material, getting on with the other side tonight and will sew up the door pockets during the week.
Still to find some staples short enough so that they don't poke through the other side, quite like doing upholstery stuff even if the house reeks of glue now  :lol:
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010128_zps159c619e.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on February 17, 2013, 07:58:50 pm
nice...im following this closely!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on February 18, 2013, 04:59:34 pm
Ohhh interior, nice. That colour combo looks great
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on February 18, 2013, 05:25:22 pm
you'll have to change the title of this thread to ex-rustbucket, John!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on February 22, 2013, 05:11:12 pm
Doing another side project at home, this time making the interior panels.
Armed with the OEM cloth and some Bus center panels I've started with the door panels first, taking my time measuring before cutting anything the 1st one has come out awesome.
Really like the combination of the red and off white material, getting on with the other side tonight and will sew up the door pockets during the week.
Still to find some staples short enough so that they don't poke through the other side, quite like doing upholstery stuff even if the house reeks of glue now  :lol:
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010128_zps159c619e.jpg)

 That is awesome :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 23, 2013, 09:51:39 pm
Not much motivation to work in the heat this morning but felt I really should do something at least so started paint stripping the bonnet, tried a few different methods now and paint stripper discs in a grinder are by far the quickest but there's a big difference in quality as per usual.
Smith and Arrow coarse blue paint & rust strip are the ones to get, last longer and cut through the paint quicker, you do have to be carefull of how much heat you build up though especially on something thin like this t34 panel.
Pretty much worked my way right around the whole thing and also did part of the inner frame and inner flat areas too.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010140_zpsf46b61db.jpg)
Right at the front were a few rust holes so the only way to repair it right was to cut and remove a section of the inner frame so that I can blast it, repair and prime it after which I'll just weld the section back in.
Couldn't be bothered blasting this afternoon so worked on one of the doors instead before packing it in early.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010141_zps69271eb5.jpg)
Made more progress on the door panels too during the week, finished the other side and made new map pockets which were stapled / glued on like original, pleats worked out exactly how I wanted.
Last night I made the first of the rear panels which worked out nice, heat seamed lines didn't line up unfortunately so had to make some "adjustments"  :lol:
One more to make tomorow and the welt to staple on, SMS auto fabrics sent me the wrong welt in the wrong colour and are also being a pain about fixing their mistake, what is it with companies these days?
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010142_zps86c9e6d9.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010143_zps00504326.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: M M on February 24, 2013, 07:48:56 am
That looks great! Can't wait to see the interior put together. The color combination reminds me of strawberries and cream.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on February 25, 2013, 10:41:58 am
Rhubarb and custard :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Omes on February 25, 2013, 12:41:01 pm
WOW & WOW to the door cards!

Anything you can't do Mr Kanters?  :laugh:
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 25, 2013, 04:12:02 pm
WOW & WOW to the door cards!

Anything you can't do Mr Kanters?  :laugh:

I know, pretty sharp huh.  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on February 25, 2013, 04:19:57 pm
are those the badge holes on that panel with the vents?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 25, 2013, 04:27:03 pm
Yeah, its got a really cool Karmann Ghia script to go on there.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on February 25, 2013, 04:38:49 pm
Yeah, its got a really cool Karmann Ghia script to go on there.
sweeeet!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 01, 2013, 08:11:21 pm
Had a go at repairing one of my aluminium moldings which go on the bottom of the door panels, one was ok the other not so much......
Had a bunch of bends and large dents in it as well as a near 90 deg bend at one end so I thought I didn't have much to loose and everything to gain besides its would be good practise for the rocker trims which are dented from one end to the other  ::)

Started out by making a nylon chaser which the molding could be slid on to allowing gentle taps and bending to straighten it out.
Most of it came out good and the nylon chaser was well worth making, the 90 deg kink however was quite a bit of work.
Below its been straightened out quite a bit and still took a couple more hours of gentle tweaking from here.
Sanded both of them 180 grit, scotch pad then 1200 grit, will follow that up with 2000 grit and polish.
Pretty sure these were clear annodised originally so will have to investigate some way of stopping them going dull again.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010153_zpsbf0c15c9.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010155_zps45cd0f6a.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SZC on March 02, 2013, 09:30:08 pm
Brilliant!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on March 02, 2013, 09:44:51 pm
Excalibur's sword! 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 03, 2013, 10:03:50 am
Got done with the last of the blasting yesterday (until I start on the roof that is  :roll: )
First repaired the front of the bonnet, only a couple of holes but quite a lot of it was pitted pretty bad so the metal was wafer thin.
Decided that all those pitted areas should be welded as well.
After lunch I set up my blasting gear again and completed the bonnet and the inside face of the drivers door.
Managed to get right inside the door to get the worst of the rust off but of course you can't get all of it so a good rust wax once back together should help preserve it.
Now that the whole thing is in epoxy I'll weld the frame back in and finish that off, the bonnet is actually in pretty good shape other than a couple of small dents which I took out as well.
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010156_zpsd4d0d192.jpg)
(http://i290.photobucket.com/albums/ll272/vert111/Type%2034/P1010159_zps826e7063.jpg)

Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on March 03, 2013, 10:32:41 am
Do you think this is your calling more than spinning spanners?

More great work.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on March 03, 2013, 10:50:59 am
Do you think this is your calling more than spinning spanners?

More great work.

I think that the amount of time one is prepared to spend on a personal project, especially to this standard, would not be economic if being charged out to most potential clients as the customer base would be pretty small
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on March 04, 2013, 07:51:54 pm
I think that the amount of time one is prepared to spend on a personal project, especially to this standard, would not be economic if being charged out to most potential clients as the customer base would be pretty small
Yea, maybe one of the best around anywhere,rustorations are nothing more than a labour of love @ the end of the day.
Have been checking the yankie 911 resto threads and they are getting a POS longhood purchased for bugger all and turning them into a 60-80+ grand car (dependant on model),appears there's the rich and the poor over there but theres always a market for restored cars like VW's and Porsches.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 04, 2013, 10:01:13 pm
I think that the amount of time one is prepared to spend on a personal project, especially to this standard, would not be economic if being charged out to most potential clients as the customer base would be pretty small

There are people who want it done right and 100%, just not many in the VW world.......Porsche however is another story.
Many Yank muscle cars / hot rods are costing 250K upwards.
For me its just doing the best I possibly can and learning as much as I can, doing everything myself is just a way to do quality on the cheap.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 10, 2013, 04:05:37 pm
Thanks Greg thats what I suspected, will weld it up in that case when I do the roof.
Anyone else dislike the new Photobucket? I think its turned to poos in more ways than one, just a complete headache to use now.
Anyways enough about that, all the body panels are at a point where I've been around them at least once so got back to concentrating on the body again, took it out of the rotisserie yesterday so that I can get at the rear panel and also finish off the nose.
Stripped back both jambs as I hadn't even touched where the door bars bolted in, blocked the rear 1/4 panels again as well as an 80 grit on the rear panel before priming everything in one go.
Bit dismayed to find out I wasn't really at the point I thought I was as far as things being straight but then I'm pretty particular about how I want it to look so its just more work ahead really.
Next job will be to hang the doors and set the front guards in place for good, test fitted the bonnet before I welded the front section back in too which was just as well.........amazing how things move around.
(https://lh3.googleusercontent.com/-JdJ0ThnOkZc/UTu4kjAFS6I/AAAAAAAAAAo/RKjvJrYkwU4/s576/P1010165.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on March 10, 2013, 05:11:49 pm
I gave up on photobucket ages ago, find imgur much easier to use, drag'n'drop from explorer to upload
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 15, 2013, 08:40:39 pm
Few more things done on the sh*tbox, sorted through all my parts to be chromed and got that warm fuzzy feeling along with $$$ signs quickly realizing just how much stuff is rooted and has to be re chromed  :( ;D
Also sorted through all the aluminium trim of which there is a lot too, quite a few pieces need dings etc taken out and all of it needs stripping of its anodizing.
Will strip them myself with sodium hydroxide then do repairs, polishing before I get them re bright anodized.
Thought about how to make a long but thin bath for the stripping solution and suddenly thought why not use a piece of gutter?
Cut some down to length and made end caps for it, should get the sodium hydroxide on Monday.........let the fun begin!
One of my headlight rings had a couple of decent dents in it and even though I could get one overseas I thought it more fun to try and repair it, cut the right radius out of a piece of ply and started hitting it  ;D quite a tough little bugger too but its coming together nicely.
Really need to get the chrome stripped off now to properly metal finish it.
(https://lh5.googleusercontent.com/-utErmNQnN04/UULMNmfkb8I/AAAAAAAAAEY/4Dhq3zi23kE/s576/P1010186.JPG)
(https://lh5.googleusercontent.com/-NQcwuO2rbcY/UULMOnN4mgI/AAAAAAAAAEY/mjaxMytszO4/s576/P1010187.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 17, 2013, 10:33:54 am
Yesterday I fitted the hinges and doors trying to line them up as best as possible then set the front guards in place bolting them on for good.
Having some trouble getting the body to a point where I'm happy with the straightness which lead me to think about how good would these cars have been right out of the factory? Am I getting to fussy?

The drivers door had some odd stuff going on with the B post gap from where the skin had been removed so rather than wait I thought now was a good time to correct that.
Simple enough to grind back the edge to where the gap was acceptable and weld the edge back together again (the folded over lip had now split apart)
 (https://lh5.googleusercontent.com/-f37WK-dIncU/UUQAsoQeGHI/AAAAAAAAAFU/zEFS5UlgQ9w/s576/P1010191.JPG)
The doors are actually giving me the most grief because they are so flat and don't have much strength the panel flexes when sanding it so I ordered sheets of dynamat to stick inside the door, hopefully this will stiffen the panel enough to help.
I wanted to dynamat the doors and 1/4 panels anyway so might as well do it now.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: AngleBox on March 17, 2013, 10:36:01 am
What's the engine plan? By the way I am truly impressed John - great talent.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 17, 2013, 10:55:52 am
Thanks Angle, 2.0 flat 4 fuel injected.
By the way must catch up soon.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: AngleBox on March 17, 2013, 11:27:48 am
Yes, long overdue. I'm off to the Leadfoot Festival next weekend. You doing Beach Hop?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on March 17, 2013, 01:26:29 pm
If there was ever a time to be fussy it is now, especially on the drivers side or you will see what ever is bugging you every time you get in an out of the car.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: JPK on March 18, 2013, 05:12:36 pm
Saw one of these last night. '74 GHIA' number plate. Paint job wasnt the best though.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 18, 2013, 09:55:14 pm
You would have seen a Type 1 Ghia, quite a different beast
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 22, 2013, 08:23:50 pm
Finished up the last of the anodizing stripping, glad that's over with too.
Sodium Hydroxide is some seriously nasty stuff but the upside was that the gutter worked beyond my expectations!
Just perfect for delicate long aluminium trim, just a word of warning though if you do have ago at this its best to do it outside as the brew gives off Hydrogen gas  >:D ;D
(https://lh3.googleusercontent.com/-PbB4K-8oH_E/UUwDPJcq7gI/AAAAAAAAAH4/ntmU2yZguno/s576/P1010202.JPG)
(https://lh5.googleusercontent.com/-Y6KjBpfuF3E/UUwDODdcrDI/AAAAAAAAAH4/fN5-JWo7Q2s/s576/P1010205.JPG)
Within minutes its furiously bubbling away, did 4-5 pieces at a time leaving them in for 15-20 min.
Wash them off once out of the brew and you're left with a dull finish so now I can clean up all the marks and polish them.
There is quite a bit of pitting in some of it which is too deep to do anything with so will just have to live with that unfortunately.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 05, 2013, 08:19:18 pm
A couple of weeks ago I went and saw a chrome plater I used many many years ago for another car I built, took a whole lot of parts down with me and left them with him to work through.
Once those are done I'll send him some more stuff till its all done, like the aluminium trim its got a lot of chrome too (read $$$$$$$$$  :()
While talking to him I mentioned I was going to get the ali trim re anodized to which he said nooooooooooooo!!! don't do that.............. :(
The one company who do it is useless apparently, just my luck once again..............still, better to find out before rather then after when all my unobtanium trim is ruined.
Soooo, plan B is to polish all of it and use a 2 pack ceramic clear over top of it which should slow down its decay.
Over the last few weeks I've been trying to do a few pieces a day, not a fun job but have no choice.
All of the pieces are soft as buggery so very difficult to polish as the polish itself scratches the surface, never will be perfect but a lot better than it was.
(https://lh3.googleusercontent.com/-5-kCXgLvF9M/UV5Gx0bh59I/AAAAAAAAAI8/cbuaTZUxXvQ/s576/P1010212.JPG)
(https://lh4.googleusercontent.com/-dZn3Dx5qWJk/UVzpz_aEeqI/AAAAAAAAAIc/SzBHmBdoGIA/s576/P1010211.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 06, 2013, 05:48:47 pm
Not much in the way of enthusiasm this morning, didn't really have a clear plan in mind which was half of the problem.
Did however manage to finish the headlight ring as the chromer had stripped it along with the 2 fog rings (were badly cracked at the bottom) and sent them to me to repair.
The headlight ring had a few cracks where I'd beaten it so I silver soldered the crack and metal finished it, looks just like a bought one  ;D
Pretty surprised to find that all the rings are made from brass and the headlight ones have a welded join at the base, quite amazing how they are constructed.

Both the fog ones had cracks which were also silver soldered, quite tricky since they are very very thin.
Used regular solder to fill in a couple of low areas, fitted them to the body to check and will send them back to the plater on Monday.
(https://lh4.googleusercontent.com/-xRi8CBxD4Xg/UV9T7m1WaXI/AAAAAAAAAJo/eygv-9PFa2E/s576/P1010215.JPG)
(https://lh3.googleusercontent.com/-NhYO7kTHEFM/UV9T650g0MI/AAAAAAAAAJo/WbYpRe7t93I/s576/P1010213.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: M M on April 06, 2013, 07:05:46 pm
Good progress on this. I kind of like the fact that the polished pieces aren't prefect. I think there is a certain beauty in parts which have marks or inperfections from their lives over the years. Gives character.
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on April 06, 2013, 07:46:24 pm
Good progress on this. I kind of like the fact that the polished pieces aren't prefect. I think there is a certain beauty in parts which have marks or inperfections from their lives over the years. Gives character.

Agree. Good work Vert
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 06, 2013, 07:54:45 pm
Yeah I get what you are saying and I constantly have to remind myself that all of these parts already have 50 years of service under their belt  :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 11, 2013, 04:45:58 pm
First lot of parts back from chroming, shame there's so much more to be done...........want to be installing this stuff now  :(
(https://lh3.googleusercontent.com/-RG3uDmr971E/UWY-1GJ0rFI/AAAAAAAAAKw/O236hbnklMo/s640/P1010242.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: weta.worker on April 11, 2013, 05:30:40 pm
First lot of parts back from chroming, shame there's so much more to be done...........want to be installing this stuff now  :(
(https://lh3.googleusercontent.com/-RG3uDmr971E/UWY-1GJ0rFI/AAAAAAAAAKw/O236hbnklMo/s640/P1010242.JPG)

whoa!  shiny!  very nice  :D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 14, 2013, 10:08:40 am
At long last my roof came in last week, time to crack on and finish the body work.
The donor roof is perfect rust wise which is just unheard of and a true stroke of luck, way beyond what I expected to get  ;D
First job is to prepare the roof to get it ready to be blasted and primed, decided which way I'm going so started unpicking the drain box from the main roof which was relatively easy.
They used a combination of spot welds and brazing which was common of the day.
(https://lh3.googleusercontent.com/-Zwcn3uAKkeY/UWkYhVDwq_I/AAAAAAAAALo/-aY6qldv8z8/s640/P1010254.JPG)
With the drian box removed the rest of the un needed crap could be cut off / removed leaving me with just the pieces I want.
Hopefully next week the weather plays ball for blasting but at least during the week I'll strip the outside with the stripper disc and prime that first.
(https://lh4.googleusercontent.com/-q7bl3OnNSzU/UWkYhaNx0TI/AAAAAAAAALo/yT1ZGEaiZow/s640/P1010255.JPG)
More work the way I'm going to do it but should give the result I'm looking for, I feel that cutting the pillars is just cheating and a potential nightmare getting the window openings correct again not to mention the drain pipes down the front pillars.
Also going to replace the rear inner structure of the roof at the same time as mine isn't looking too flash where as the donor one is perfect.
(https://lh3.googleusercontent.com/-1fmAXs4-6eM/UWkYyEJhIRI/AAAAAAAAALo/_p_cNxWRDbA/s640/P1010257.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on April 14, 2013, 06:23:38 pm
Just an insane amount of work gone into this.
 Blows me away.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: AngleBox on April 14, 2013, 06:34:48 pm
What was wrong with the 'original' roof?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 14, 2013, 07:21:41 pm
it didn't have a hole in it  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Fizz on April 14, 2013, 07:29:43 pm
Fantastic work John!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on April 14, 2013, 07:34:31 pm
What was wrong with the 'original' roof?

Needed to be at least half vert...
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: AngleBox on April 14, 2013, 08:24:10 pm
it didn't have a hole in it  ;D

You are something else John..... ha, ha, ha. My hat is certainly off to you mate.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 14, 2013, 08:31:04 pm
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.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on April 15, 2013, 05:14:50 pm
Certainly you are a talent, with the skills, money and workshop. But mostly just so hard working and dedicated.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on April 15, 2013, 05:41:43 pm
Well put.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 28, 2013, 08:33:20 pm
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
(https://lh6.googleusercontent.com/-qVmE_uNBn4I/UXzbnAX5uGI/AAAAAAAAAMs/LfeKNAacjFI/s640/P1010295.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 04, 2013, 09:03:09 pm
Too late to turn back??  ::) ;D
(https://lh6.googleusercontent.com/-SELoDmcFCKo/UYSTnebMLyI/AAAAAAAAAOM/TGq875sOihI/s512/P1010319.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 05, 2013, 10:34:25 am
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:
(https://lh4.googleusercontent.com/-gRkl0RzuV5I/UYSTmdUuAWI/AAAAAAAAAOM/vXrFPshRJh0/s512/P1010322.JPG)
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.
(https://lh3.googleusercontent.com/-7Jjod-rqTwI/UYSTm_IP0BI/AAAAAAAAAOM/OU8z8HVRUc0/s512/P1010321.JPG)
(https://lh4.googleusercontent.com/-Ffgz6NNJIto/UYST3hw5YpI/AAAAAAAAAOM/rJ__xGe7_74/s512/P1010323.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: AngleBox on May 05, 2013, 12:09:33 pm
Wow! Very, very cool John. Thanks for putting all this work into my car.
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 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
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: AngleBox on May 05, 2013, 08:15:12 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)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 07, 2013, 09:12:36 pm
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.
(https://lh6.googleusercontent.com/-XKeSt9Ak11A/UYiIjAm9ZcI/AAAAAAAAAOw/9LQ6J1tNm8Q/s512/P1010324.JPG)
(https://lh3.googleusercontent.com/-DOzNxkYvCHs/UYiIjDKC5nI/AAAAAAAAAOw/km9L1Qb6az4/s512/P1010325.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Fizz on May 07, 2013, 09:27:54 pm
Great work John, wow! I think u should design and build ur own car next. U have all the skills :D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 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
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Fizz on May 07, 2013, 09:32:57 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
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 07, 2013, 09:43:58 pm
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
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Fizz on May 07, 2013, 10:05:02 pm
Awesome, think i need to pay u another visit soon  :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 07, 2013, 10:12:43 pm
Anytime mate.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 09, 2013, 08:58:43 pm
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
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on May 09, 2013, 11:11:11 pm
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?? ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 10, 2013, 07:26:12 am
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.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 11, 2013, 09:36:00 pm
Need more LOW DOWN  ;D ;D ;D
(https://lh3.googleusercontent.com/-d3lzRAKYLKw/UY4LycjzGlI/AAAAAAAAAPg/c4w_a_YAZv0/s512/P1010334.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: John Stone on May 12, 2013, 08:12:24 am
Couple of bags of cement should do the trick John.....
Looking smart 8)
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on May 12, 2013, 09:50:35 am
Slam that bitch!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 12, 2013, 11:00:46 am
Couple of bags of cement should do the trick John.....
Looking smart 8)

Haha John, there's 2 bags of sand in there now ;D Ddin't seem to do all that much though.
Just needs the front torsions adjusted waaaay down.

Roof is on for good, all welding done apart from a few of the stays that attach the drain box to the inner frame but I'll get those done next week.
Didn't think I'd get this far yesterday but there you go, sometimes stuff just works out.
(https://lh5.googleusercontent.com/-xryXeIve2rU/UY4LBwMD7II/AAAAAAAAAPI/JM1mqwRP61s/s512/P1010331.JPG)
With that out of the way I lifted the body on to the chassis for a test fit and found a couple of areas of concern, few of the holes don't seem to line up all that well but really need to put the bolts in first to make sure what's actually going on.
Seems like one of the pan edges is too wide pushing the body over to one side too much at the front so grinding that back should sort most of that out.
(https://lh5.googleusercontent.com/-UpaGP-ZTsew/UY4LB62PC_I/AAAAAAAAAPE/G9tsq-KIvOk/s512/P1010332.JPG)
Still not a fan of the big / little tyre combo but looking at what clearance I have now I should be able to run a bigger tyre in the front to match the rear a bit better.
Was always going to be close with 944 brakes and Fuchs under stock unmodified guards.
I think a 185 50 16 should be better on the front making things look more even.
(https://lh3.googleusercontent.com/-d3lzRAKYLKw/UY4LycjzGlI/AAAAAAAAAPg/c4w_a_YAZv0/s512/P1010334.JPG)
Had to laugh when I saw those floors remembering what they used to look like, nice not to see just rust and holes!!! :lol:
(https://lh3.googleusercontent.com/-Ry2JiqWnNqw/UY4LCYGX_fI/AAAAAAAAAPM/g9tr4mU8k44/s512/P1010333.JPG)
(https://lh6.googleusercontent.com/-mIJakz6k6dk/UY4LzZsqLRI/AAAAAAAAAPo/kzLxJtd_lko/s512/P1010335.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on May 12, 2013, 02:11:44 pm
This has to be the best thread there has been on here
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 19, 2013, 05:34:46 pm
Whole days work yesterday pulling stuff apart, chassis is ready for the stripper tomorrow along with all the rear subframe and other susp parts.
Also cleaned off 5 decades of old grease / crud off the front end which I completely pulled apart as well, have to replace the lower arm bushes which are no longer available but have found some which are 1mm smaller on the inner dia so they should work.
All going well i'll machine down the front arms 1mm taking off the little wear they have to give a nice surface for the new bushes.
Next couple of weeks should be cool as newly painted parts start coming back, will have to get my chemicals together to start plating all my chassis bolts and other hardware.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 31, 2013, 09:08:53 pm
Picked up all the powder coat this week, chassis was finished yesterday which has come out pretty sweet.
Ordered a box of chassis related parts last Saturday from the US which turned up today, 6 days total which is damn good service!
(https://lh3.googleusercontent.com/-7FIMt1mYwl0/UahndTrJxWI/AAAAAAAAAS4/vQ5DmEKA0iY/s640/P1010359.JPG)
Once I make some space the chassis will go together fairly quickly since all the brakes an other modifications have been figured out and mocked up already.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 01, 2013, 10:02:48 pm
Made some progress towards assembling the chassis today, sorted out most of the chassis bolts and where they go as well as assembled some smaller parts.
Luckily I took pictures of the caliper brackets I made as I couldn't for the life of me remember how it all went together  ;D
Really need to clear a space now where it can sit while I put it together, tomorrow I'll order the parts I need to rebuild the transmission as I also pulled that apart.
(https://lh5.googleusercontent.com/-zaJkYLTcnUI/Ual8Ry2wwnI/AAAAAAAAAUA/dVt9DC6TQOg/s512/P1010362.JPG)
Does anyone know what the 3 big washers at the bottom of this picture are for??? Pretty sure I can place 2 but not the 3rd one......... :?
Stub axles and steering rods together, Another annoying this is that the nuts securing the ball joints to the front arms don't fit the new ball joints  :-\
(https://lh4.googleusercontent.com/-ZeVvWXxBumQ/Ual8R-ivAUI/AAAAAAAAAUA/TdLSM5t95uU/s512/P1010363.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on June 01, 2013, 10:32:30 pm
Shiney  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on June 02, 2013, 06:41:01 pm
Pretty sure there are only 2 large washers needed. Used for main fixing points for body to the pan, accessed from rear engine cover area.
Small version of washer is for the front beam / body fixing if my memory serves me correctly.

Some mexi-can may have doubled up your washers somewhere!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 14, 2013, 09:33:15 pm
Jetta done and back on the road, bay window bus sold means I now have the time and a assembly space for the Ghia.
Been looking forward to starting on this, just love packets of new parts.....seems like Christmas every day!
Bolted the rear subframe on and flipped the pan over setting it up on jack stands, bolted the front end on tonight and started making new hard lines.
(https://lh4.googleusercontent.com/-Lx1CfiEPy_0/UbrfElDzA_I/AAAAAAAAAYw/hQ847tL4Ry0/s512/P1010413.JPG)
(https://lh6.googleusercontent.com/-fwQh6o1uWwQ/UbrfGrwlaDI/AAAAAAAAAYw/Y2jyVSMB1Kc/s512/P1010414.JPG)
Stripped the brake calipers pulling out the pistons and all seals so that they can be powdercoated, incredibly tough paint on them what ever that might be!
Just no point getting it all off so a good blast was all they needed.
Once coated I'll sand off the raised Porsche casting to highlight it.
Tried masking off the area of the piston holes but that didn't work out very good so the solution in the end was very simple, cut slightly oversize cardboard circles and push them in to the holes.
(https://lh3.googleusercontent.com/-7G7pmwdRpeI/UbrfKcBj-BI/AAAAAAAAAY8/DK5_LYNkrPE/s512/P1010412.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 16, 2013, 11:50:20 am
The fun stuff continued yesterday finishing off the hard lines, I just used one of those universal kits but none of the lengths are actually suitable for Type 3's but at least they are new and I just cut them to length and re flared one end.
I'll probably put the pressure switch where the line joiner is which should work ok.
It's a shame that the 944 one gets in the way of the steering rods as it fits soo nice where it is and haven't given up on using that one just yet.
(https://lh5.googleusercontent.com/-mmp0XZhQsZs/Ubwwn_dldjI/AAAAAAAAAaA/PoPhuUFaiiw/s512/P1010417.JPG)
Had a little fail moment putting the pedal cluster together, once installed the spring it pulled the pedal towards the master cylinder and strangely I didn't think anything of it till later on when it was all completed realizing the spring was on backwards DO'H  ::) ;D
With that corrected the rest of the front end went together with little fuss.
(https://lh3.googleusercontent.com/-QrXQBIPz21w/Ubwwe0H3dEI/AAAAAAAAAaA/7k2i4hkq-4o/s576/P1010416.JPG)
Onwards with the rear end, got the spring plates in, hard lines finished completing the rear until the transmission is back together.
Not a whole lot more left to do till I get my brake calipers back to complete the front end, all gone together pretty quickly really.
Better get my act together and get back on to doing the body to get some paint on this sucker..........still, there's always the engine to build as well  >:D
(https://lh3.googleusercontent.com/-Br0QQjL1Zoc/UbwxREGajkI/AAAAAAAAAaA/pOf85dZpeI8/s576/P1010418.JPG)
One strange thing is this pan has no provision for the rear brake union to screw on to, no evidence of there ever being one there either :(
Not sure wether to just leave as is or make something for it.
(https://lh3.googleusercontent.com/-IcPmGtqYDcE/UbwxQ1cfAiI/AAAAAAAAAaA/ZuXs8U_vnQM/s576/P1010419.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: nacnud on June 16, 2013, 12:03:33 pm
 8) 8) Brand new!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Omes on June 16, 2013, 12:21:09 pm
The level of details!!!! I love this s**t!   8) 8) 8) 8) Gona be too clean to take out on a rainy day even!

You wana preserve that under chassis just as it is now.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 16, 2013, 12:27:17 pm
Mate this will never see rain, way too detailed for that hahahaaa
Bit OTT but it sure looks good.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RobClubley on June 16, 2013, 02:45:40 pm
Better than new!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on June 16, 2013, 07:54:10 pm
Purrrty!
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on June 16, 2013, 08:09:00 pm
Nice work
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SZC on June 16, 2013, 10:28:54 pm
Looking on point! Wish i had your patience and skill. Definitely my favorite build in progress to get updates on at the moment  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Fizz on June 16, 2013, 10:33:01 pm
looking good john! good progress  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 21, 2013, 09:02:48 pm
A rear support bar would be beneficial  to help keep the motor/box in place but I'm determined not to modify the stock body in any way so that it can all be unbolted and be returned to 100% stock.
That means no welding in mounts or drilling holes for mounts.  :'( ;D

If I didn't care then it would be running a quad cam Subaru turbo.........doing that though the T34 purist fraternity would probably castrate me haha.
Anyway, got my calipers back and have nearly finished re assembling them, didn't help that I put the dust seals back to front so that wasted another hour taking them back apart again.
Front hubs and bearings greased and installed along with the new rotors, pretty happy how all of this just bolts on.
Will have no problems certifying it this way as welding any susp / brake brackets can be a nightmare to get legal.
(https://lh3.googleusercontent.com/-8hNw-Qf_PSo/UcPdkWmmZkI/AAAAAAAAAck/NEOROLWNYrI/s512/P1010429.JPG)
(https://lh4.googleusercontent.com/-qXSPhZKaImY/UcPdiJ8cxYI/AAAAAAAAAck/qyNFAKhSPnU/s512/P1010428.JPG)
Have the trans in pieces as well with most of it cleaned so far, I'm using a later T3 IRS trans with splined shafts which I'm converting back to swing axle.
Again that way the weaker stock trans can just go back in for originality if ever needed.
Building the new box with super diff, extra spider gears, welded 3rd / 4th, steel shift forks, new bearings and synchros.
That's the next big job to be able to complete the rear half of the chassis.
(https://lh6.googleusercontent.com/-e6UPbYKoKDA/UcPdkI7-R0I/AAAAAAAAAck/q4YfXPmPnxA/s512/P1010430.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on June 21, 2013, 10:01:27 pm
Can you run a set of cup bar thingies from the shock towers etc?
You do have the one rear support off the fan housing but thats a rubber thingy and doesn't do much.
You might be able to get a bar off the rear bumper mounts?? But access is difficult to get to the case for mounting. Hmmm where there is a vert1 there is a way!!

Lookin the shizzzz as always. BBJ!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on June 21, 2013, 10:06:52 pm
Hahaha you sound like Tristan - "I want to keep it so I can return it to factory"

Yea right  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 22, 2013, 09:18:54 pm
Hahaha you sound like Tristan - "I want to keep it so I can return it to factory"

Yea right  ;D

hahaaaa had to laugh reading this........... soooo true!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 30, 2013, 11:30:05 am
With nothing further left to do on the chassis until the gearbox is done I'm forced back on to paint prep which isn't a bad thing as its easier not to do it.
Haven't really been very happy with progress so its time to knuckle down and get this body in paint.
Finished welding in all the inner supports for the sunroof as well so that's 100% fitted and finished now.
Block sanded the rh door and nearly the whole rear end of the body which is looking pretty good now, have a minor thing to change on the lower left 1/4 which is better to do now rather than be unhappy once its painted.
(https://lh6.googleusercontent.com/-hi0lAj4D8G8/Uc6EPI4LR5I/AAAAAAAAAec/dNEi-ZxJkvU/s512/P1010452.JPG)
(https://lh5.googleusercontent.com/-WX8Dnth1HUw/Uc6EPD0eMaI/AAAAAAAAAeg/d5g1l3J5Fdk/s512/P1010453.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on July 04, 2013, 03:14:34 pm
Thanks Angle, 2.0 flat 4 fuel injected.
By the way must catch up soon.

Engine details please? should be a T4  ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 04, 2013, 08:22:40 pm
Type 1 for this one, 78x90.5
Brand new Scat engine bought as a kit a few years back, everything new inc the case and all hardware so should
be nice to put together when the time comes.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 14, 2013, 09:36:14 am
More sanding yesterday but I'm very very close to being done with the outside, have decided to paint all the inside and underneath and then
mount the body back on the pan and bolt it down.
Doing it that way will ensure nothing weird happens to my panel gaps
once paint goes on.

Printed out the pictures a guy kindly posted up for me and had a go at making a radio blanking plate.
Bit of guesswork and I'm sure its not 100% correct but it looks close enough to me, changed it a little anyway and deleted the strap to hold it down and instead used a couple of M6 nuts so that it can be bolted on.
Not sure what I'll do for an escutcheon yet but still thinking about that.
I may hide a modern stereo under the dash and a couple of speakers under the seat but then I may just not have one at all.
(https://lh6.googleusercontent.com/-BkNiCBwPNYI/UeDvJ26y61I/AAAAAAAAAgw/dqxHOJ6Knr8/s512/P1010459.JPG)
(https://lh6.googleusercontent.com/-aTswsgvlrWk/UeDvIstnQ8I/AAAAAAAAAgw/8zUZcAcD-14/s512/P1010460.JPG)
(https://lh3.googleusercontent.com/-w6_3uvwXIkc/UeDvKtvspYI/AAAAAAAAAgw/2dRz5hJBYmk/s512/P1010461.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on July 14, 2013, 12:20:15 pm
You didnt think of a Becker retro radio John?

http://www.retrosoundusa.com/products/details/id/236
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 14, 2013, 02:35:53 pm
Actually I did but prefer the clean dash look on these cars
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 26, 2013, 08:12:43 pm
Got the trans together, looked pretty good inside but replaced all the synchro's anyway, Scat super diff and a solid spacer to replace the spring as well as a heavy duty side cover.
Had read that welding 3'rd and 4'th gear to their hubs would distort them requiring honing to correct the distortion but I wasn't keen on doing that so I machined a solid steel pin which I pressed the gear on to, welded it and let it cool.
Once cooled just pressed the gear off and no distortion, used the same pin to do the other gear.
Assembled the gearbox these past couple of nights completing it tonight, will install the axles and tubes tomorrow as well as put the rear brakes together.
Nearly a roller!
Engine's next, have to find a clean ish piece of the shop to put it together  :lol:
(https://lh6.googleusercontent.com/-b0eX6mQ7YpI/UfH_Z5HtedI/AAAAAAAAAh4/Yj-tgjwi9pg/s512/P1010465.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 28, 2013, 02:22:55 pm
Completed the transaxle and got it in the chassis, for some reason it took me ages to put the axles and tubes together...........don't know why but most of the afternoon was blown just doing that.
I did get there however and the results speak for themselves, new bearings, boots, gaskets and seals should make it leak free and reliable.
Sandblasted the disc backing plates and dust shields and also fitted those, still to make new hard lines to the calipers.
I want to strengthen the rear cradle a bit more before that gets painted and put on, nearly ready for the body!
(https://lh3.googleusercontent.com/-whZ-kOK_gzo/UfNYsBpTVmI/AAAAAAAAAiw/U-_2FapdoNU/s512/P1010467.JPG)
(https://lh4.googleusercontent.com/-uoFwCKIAwh0/UfNYwG-oSLI/AAAAAAAAAiw/QaZvqjxSPZs/s512/P1010468.JPG)
Have found powdercoat to be a hassle when fitting parts and would probably go back to just painting everything again if I was to do it over again, having said that it does look good when its all together.
(https://lh3.googleusercontent.com/-IxoMYKL2mEo/UfNY8GrH53I/AAAAAAAAAiw/xVdNzTf6Hww/s512/P1010469.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on July 28, 2013, 03:08:24 pm
Ohhh, looking good
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on July 28, 2013, 05:42:35 pm
Looks awesome. Clear coat or going black on everything.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 28, 2013, 06:52:54 pm
Are you talking about the yellowy colour on the trans?
Its a transparent etch for aluminium so will stay like that, just to stop the case going powdery
from corrosion.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 04, 2013, 10:59:12 am
More work done on the pan, made the last of the brake hard lines as well
as making suitable handbrake cables for the 944 brake shoes.
I just took ordinary T3 cables and cut the length down as well as turned up 
new ends for them where they slip in to the Porsche backing plate.
Reinforced the gearbox cradle a bit more and painted the last of those parts.
Pan is 95% done now, just need to give the Koni shocks a birthday as well as
plate the last of the caliper hardware.
Was going to run the 16" Fuchs with a black center but have decided on fully
polished now as it will suit all the bright work on the car more, will send those
out to be polished...................just easier  :-\
(https://lh3.googleusercontent.com/-Vs32J5oMFs4/UfyYRNz9C6I/AAAAAAAAAlU/ha0VkQ5YLDc/w404-h303-no/P1010476.JPG)
(https://lh5.googleusercontent.com/-_V7kg6QhYdI/UfyYRt6BpVI/AAAAAAAAAlU/fB2NTSqRIpY/w404-h303-no/P1010477.JPG)
With nothing really left to do on the chassis right now I made a start on the engine
and pretty quickly ran in to problems, have had this Scat volkstroker 78x90.5
kit for 2-3 years now but never inventoried it when I got it but instead just stuck
the boxes on the shelf as you do  ::)
Pretty quickly realized that there was no cam gear, rockers and a few other minor
parts and the annoying thing is that I had all of that in my pare stash of parts which
I sold a few weeks back thinking I would never use D OH! Murphy strikes again!
No biggie really though as they are easy enough to get, it is really nice though to start
with brand new stuff instead of filthy crud covered rubbish which first needs cleaning  :lol:
Got started on putting a short block together so that I can start dialling things up to
work out cam timing and compression etc.
(https://lh6.googleusercontent.com/-VFR_-T2iens/UfyYSsw-XEI/AAAAAAAAAlU/J5x9bcKFS8g/w404-h303-no/P1010478.JPG)
(https://lh6.googleusercontent.com/-cO_oY6cbYYU/UfyYhrDSHWI/AAAAAAAAAlU/zXelSL3hKE4/w404-h303-no/P1010479.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: weta.worker on August 04, 2013, 12:23:33 pm
that thing is AMAZING!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on August 17, 2013, 10:31:54 pm
Kinda surprised you are running a t1 considering you have a lot of t4 experience,I know you can box up a good powerful t1 but the case is always a weak point,not being critical just asking,what did you do for gearbox axles in the end ,cheers
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 17, 2013, 10:42:51 pm
Kinda surprised you are running a t1 considering you have a lot of t4 experience,I know you can box up a good powerful t1 but the case is always a weak point,not being critical just asking,what did you do for gearbox axles in the end ,cheers

T4's are too expensive to build these days and for the very very limited use this
car will get a T1 will be more than enough, especially with a little turbo on it ;)
I guess the truth of it is that aircooled cars just don't hold the appeal they once
did and the thought of sinking 15K+ in to a motor just seems stupid.
Doing pre assembly at the moment, have the deck heights set right now busy
cc'ing the heads after which I'll set up the rockers and dial up the cam.
Did a 1200 sort axle conversion to get the Fuchs under the stock guards.

I really need to make the effort to get back to this because there have
been watercooled "distractions" recently.............. ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: AngleBox on August 18, 2013, 09:21:38 am
I really do envy your talents (plural) John. The project looks fantastic as it comes together.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 25, 2013, 10:56:07 am
Ok time for a little update, the last few weeks haven't seen any action due
to a few reasons and distractions.
Have come to a difficult decision but something I've wanted to try for a very long time so this may just have to be the car to try it on.
Want to do a small turbo set up, nothing wild but enough to make a decent power adder something like 10-12psi.
Due to this my cam isn't really ideal so I'll have to get another more suitable grind.
Cc'd the cylinder heads which were very very close and proof that parts from
reputable manufacturers are better, 3 chambers were dead on 60.6cc and the 4th was 60.4
(https://lh6.googleusercontent.com/-ECB_ecKtIRU/Uhg2ix_HM5I/AAAAAAAAApc/7y9Gjp2-tpg/w484-h363-no/P1010502.JPG)
Also shimmed the solid rocker shafts eliminating the factory wavy washers and springs.
Dialled up the cam which was pretty well spot on but to go turbo I'll need to change that out for something else.
Good thing being all my CR's are super close and good enough to break the
motor down and send the bottom end out to get balanced.
(https://lh5.googleusercontent.com/-EdDpIV8xEfo/Uhg2n-J2scI/AAAAAAAAApk/Pgj2_GVGxCo/w484-h363-no/P1010501.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on August 27, 2013, 10:38:10 am
ahhh the antiquated old air cooled lump!
good to see it getting some BBJ love.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 27, 2013, 08:01:48 pm
Had to go see Steve Murch today about a turbo issue which was cool to catch
up with him again after many years, discussed turbo options for this and
have a direction to go down.
KO3 is out, bigger turbo is in  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on August 27, 2013, 10:42:46 pm
.....not surprised,  ::)
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ritmo on August 27, 2013, 11:36:35 pm

.....not surprised,  ::)
X2
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Filx on August 28, 2013, 01:11:21 pm
I quite like the look of how tis has been setup. No idea if that packaging would work on a T34 though???

(http://image.hotrod.com/f/10269922/113_0708_25_z+vw_beetle+cb_performance_turbo_kit.jpg)

With a big(ish) turbo and low boost levels it's likely not to need an intercooler. Or if it does a water/meth kit should probably suffice if additional charge cooling is required.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 28, 2013, 01:49:49 pm
I quite like the look of how tis has been setup. No idea if that packaging would work on a T34 though???

(http://image.hotrod.com/f/10269922/113_0708_25_z+vw_beetle+cb_performance_turbo_kit.jpg)

With a big(ish) turbo and low boost levels it's likely not to need an intercooler. Or if it does a water/meth kit should probably suffice if additional charge cooling is required.

Wrong style engine I'm afraid, that's Type1 upright vs Type3 pancake but good thought none
the less.
Cooling will be the big thing, need external oil cooler and I'll also try and at least run a GTI
intercooler if I can fit it all in...............I do this every time, over complicate a simple car  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on September 27, 2013, 08:02:37 pm
Bypass cooler with thermo fan,g60 charge air cooler or similar compact size,head temp sensor linked into timing control,or what ever direction you are going,reckon you will make 160hp+ dependant on boost?it will be fun go for it John.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 27, 2013, 08:13:59 pm
Got a box of used turbo's today, K24 and K26's will give all of it to Steve Murch to make one
useable unit.
With low boost should still see a couple of hundred hp, more than enough for the old girl.
Starting back on the car tomorrow after being away in the US, plan is to have it pained by
Christmas  ::)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 29, 2013, 10:22:13 am
Back to reality this week and back on the old girl.
Got back on Monday and ordered the L282 and L41 paints which were delivered later this week so yesterday I started wet sanding the insides of all the off panels.
Made decent progress and sanded the hinges, bonnet, bootlid, one door and rear air rain tray.
Made a bit of a cock up with the primer as its difficult to sand due to it's rock hard nature but that's life I guess, will just take a little more time.
(https://lh5.googleusercontent.com/-6AXwuiCy2CU/UkdFEBf2odI/AAAAAAAAArc/KYNu5MTtX08/w484-h363-no/P1010511.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 02, 2013, 04:47:34 pm
First parts painted with mixed results or I'm too fussy  :-\
Can't say I'm 100% on the colour either, just not quite what I expected to see as
its quite a bit more yellow white rather than off white but hey its on now and
i'm not going to change it.
Should still look ok with a black roof, seems a bit lighter when in direct sunlight
so we'll just hope for the best.
The coming weeks will see the underside of the body gone through, still lots to do
if I have any hope at all of painting the outside over the hollidays  ::)
(https://lh6.googleusercontent.com/-FtFUns2chX0/UnRzrOTxJyI/AAAAAAAAAw4/TCV6-Ldeec8/w702-h527-no/P1010561.JPG)
(https://lh5.googleusercontent.com/-T7Upr3YJ_Wk/UnRzPzP5xYI/AAAAAAAAAwo/4UXDcYOPhBE/w702-h527-no/P1010560.JPG)
(https://lh6.googleusercontent.com/-LJDB9JfxCuE/UnRzq6FC1EI/AAAAAAAAAw0/5BHUP90WwPw/w702-h527-no/P1010562.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on November 02, 2013, 10:28:10 pm
More ivory colored
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on November 04, 2013, 09:47:28 pm
always hard to tell due to monitor and card issues, but I think it'll look amazing
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on November 05, 2013, 09:08:10 am
^^ I second that! Great colour for that era of car.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 17, 2013, 10:11:30 am
An update from past few weeks and we are finally making some progress again, have come to the realization pretty quickly that the epoxy is just too damn hard to sand.
In fact it's so hard that it ruins 600 grit paper pretty much instantly so unfortunately have had to face the fact that the whole body needs to be 180 grit sanded and a suitable sanding primer applied, short cuts almost never work and I should have known that  ::)
Spent pretty much a whole day sanding and found that even 180 grit was hard going but got all the way around except for the roof which I did later in the week and re primed it after work last Friday.

I'm sure most are sick of seeing this in primer as I am but here's a few pics anyway.
(https://lh3.googleusercontent.com/-FGKRW0q1DS4/Un3kc0pat4I/AAAAAAAAAys/3Fu94a2PXs8/w702-h527-no/P1010571.JPG)
(https://lh6.googleusercontent.com/-eMgKWe7W9a4/Un3kbASMAHI/AAAAAAAAAyc/v9tpXU1xd3k/w702-h527-no/P1010572.JPG)
(https://lh5.googleusercontent.com/-DrAn8WrQDDA/Un3kcA3_AtI/AAAAAAAAAyo/GtX6FDrVqzA/w702-h527-no/P1010570.JPG)
All going well that's pretty much it for the outside at long last.
This whole process hasn't been without its problems but I'm certainly glad to be at this point right now, realized I'd also need a rolling chassis fairly soon so on Friday I took the Fuchs to the polisher to have those done.
That's just one filthy job I'm just too lazy to do and would probably never get as good as Jack who has 44 years experience!  :o
Imagine doing polishing for 44 years...............WOW!

Yesterday I started off by getting the door braces back in and the body back in the rotisserie to make painting a little easier, I'm usually a fan of wet sanding as it makes less mess in the shop but for the inside of the front cargo area I thought dry sanding would be best so that there's not so much sludge mess to clean up and water + T34 isn't a real good idea  :P
Once the body was mounted I just started with 400 grit which is a little coarser then i'd like but should be ok for an area covered up later, at least its quicker to sand.
By early afternoon I'd kinda had enough of sanding so instead of moving on to the rear I decided to paint the front half, pictures speak louder than words.................  >:D ;D >:D
Paint at long last!
(https://lh3.googleusercontent.com/-kI0OIg8BKgU/Uoc_4lrHLiI/AAAAAAAAA1g/0ymKQdZZHMk/w489-h367-no/P1010598.JPG)
(https://lh4.googleusercontent.com/-QVOgqZWJnKw/Uoc98t-I9SI/AAAAAAAAA0w/mjfVEXOUDZ4/w489-h367-no/P1010593.JPG)
(https://lh3.googleusercontent.com/-Cc0RwxTs-Gc/Uoc-BjlTrZI/AAAAAAAAA1A/fhCzqttTX1Y/w489-h367-no/P1010595.JPG)
(https://lh5.googleusercontent.com/-19vGbhEnsJE/Uoc-ie3ecfI/AAAAAAAAA1I/QoCG4-HbbaI/w489-h367-no/P1010596.JPG)
(https://lh3.googleusercontent.com/-6-jbmJYp928/Uoc-Afj4iqI/AAAAAAAAA08/23eOPwk_n3Y/w489-h367-no/P1010594.JPG)
(https://lh6.googleusercontent.com/-0GiOBXjHixA/Uoc_8hJaEtI/AAAAAAAAA1o/QxeklS9OFtE/w489-h367-no/P1010589.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on November 17, 2013, 08:53:28 pm
Creamy / Ivory goodness!!
WOW!
Pics show completely different colours. Classic ivory hue in the flesh though. Sweet!
Been imagining it with the polished wheels.....hmmmmm So cool! Highlights of red through the spokes. Stuff dreams are made of!!

Your interior has red highlights aye?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on November 18, 2013, 09:31:09 am
ivory with a black roof?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 24, 2013, 09:46:43 am
Yep will go with a black roof,
Anywho more progress, been sanding the whole of the rear end this week in the hope of painting on Saturday, happened to see the weather forecast for the weekend which was meant to be sh*t and since Friday was a total ripper with hardly any wind I made a last minute decision to do some painting after work.
The paint supplier must have given me fast activator because even painting the front half I found the paint to dry a bit too fast which left me a with a little problem doing the rear as that area is more complex and bigger.
Trying to hit all the edges and corners takes a lot more time then just spraying a flat panel hence I'd asked for slow activator but I have what I have so had to make the most of it.

At first I thought I might break it in to two sections but once I got going I thought damn it I'll paint the lot, what I did in the end I put 2 decent cover coats on all of it and ignored the dry areas (paint dried THAT quick, combination of activator and a hot day) then reduced the paint I had left by another 25-30% making the final coat a very thin wet coat over everything which worked out great.
Hard to see in the pictures but it has a very wet glossy look to it, such a dramatic change from the pile of rust that it was................. ::) :P
 
(https://lh5.googleusercontent.com/-7nHYTRH_kTk/Uo8PnWrOGdI/AAAAAAAAA3Q/VUUdQ3dNVUY/w489-h367-no/P1010604.JPG)
(https://lh6.googleusercontent.com/-bb1orB1Z3VM/Uo8PnGGQJGI/AAAAAAAAA3M/Kv5Gtf0HHBY/w489-h367-no/P1010605.JPG)
(https://lh5.googleusercontent.com/-7RiGnh_WbVg/Uo8QSxIczZI/AAAAAAAAA3s/Pjy8YZoTDpA/w489-h367-no/P1010607.JPG)
(https://lh4.googleusercontent.com/-DQFF5AhSStE/Uo8Qf_TLDqI/AAAAAAAAA34/Yb51FgaCaeo/w489-h367-no/P1010603.JPG)
(https://lh4.googleusercontent.com/-2QJSAhrvqaQ/Uo8QQW158PI/AAAAAAAAA3k/VHk7sZTDSDA/w489-h367-no/P1010609.JPG)
(https://lh4.googleusercontent.com/-0DsEIn6fzh0/Uo8PofXpkGI/AAAAAAAAA3U/g2yuzvUzG1I/w489-h367-no/P1010606.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 24, 2013, 09:49:24 am
Couldn't believe the weather yesterday, rain and thunderstorms didn't eventuate so rather than take a breather and be lazy I cracked on with the doors.
Sanded the insides of the doors and found a way to hang them up for painting, by the time I was ready for spraying the wind had died down almost completely it seemed like the gods were giving me a break so I made the most of it.
Painted the doors which puts another tick in one of the many boxes and looking at the time I realized it was actually early enough to do a bunch of the small parts so I sanded the hinges, hood springs and torsion covers as well and painted those outside in the heat.
Great thing about hot weather is that by the time you've finished one coat you can almost immediately start your second coat  :lol: Although you have to be careful to not get runs, I got a couple of very small ones which will be easy to sort out once everything is dry.
(https://lh6.googleusercontent.com/-SxO7Q86Hb8E/UpEHdGIG-0I/AAAAAAAAA4Y/XW-5TkvcboQ/w489-h367-no/P1010613.JPG)
(https://lh3.googleusercontent.com/-mEUvv1T-3XA/UpEIQn-tGsI/AAAAAAAAA4w/aVzCJmh_QHo/w489-h367-no/P1010614.JPG)
(https://lh3.googleusercontent.com/-VDegt113RpA/UpEHcQs-CXI/AAAAAAAAA4U/Y0fEF0po7QQ/w489-h367-no/P1010615.JPG)
(https://lh3.googleusercontent.com/-2L7TvhsABgw/UpEILE2DLyI/AAAAAAAAA4g/iBRPqnQdpvI/w489-h367-no/P1010612.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: AngleBox on November 24, 2013, 11:12:51 am
Reading your thread is a mixed blessing - what you are doing is inspiring, which is almost immediately followed by a feeling (upon self reflection) of laziness and incompetence :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on November 24, 2013, 12:27:43 pm
Reading your thread is a mixed blessing - what you are doing is inspiring, which is almost immediately followed by a feeling (upon self reflection) of laziness and incompetence :)

amen brother, amen
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spud mk2 on November 26, 2013, 11:42:42 am
Check out the latest issue of 'dune buggies & hot VWs'.  (Jan. 2014)
There's a nice T34 on the cover with the full story inside.
P.S. Reading your build thread is like watching an episode of 'overhauled' ,but instead of watching a team do a rebuild, we get to watch you do it all "solo"  Well done!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 01, 2013, 04:02:45 pm
Well here we are at the weekend again and had high hopes of painting the interior on Saturday but the wind was just way too high so had to put it off.
Sunday came with improvement, still a little windy but good enough to finish the inside off.
Got going on masking a few last things up and shoving some paper in some of the cavities that might let over spray get on the bits I'd already done.
With that out of the way she got pushed outside for paint, came out good enough to be covered with carpet  ::)
I'm nearly through my gallon of paint so I'll have to order some more to do the exterior but I'll have enough left to finish the jambs next week.

I'll try to get the pillars and inside of the roof done if we have a still night next week and then the final bit in the weekend before I start 600 sanding the outside.
Providing the next couple of weeks play ball I'm still on track to paint the exterior in the Christmas holidays..................all going well  8)
(https://lh3.googleusercontent.com/-HE1cJQEm_bI/UpqiDzCNA3I/AAAAAAAAA6A/s14n4P9x7O8/w702-h527-no/P1010623.JPG)
(https://lh5.googleusercontent.com/-N9FVZfo8lXE/UpqiNWXJliI/AAAAAAAAA6Q/cPgHzB23Pyo/w702-h527-no/P1010624.JPG)
(https://lh6.googleusercontent.com/-d-2NaWi8D7k/UpqiFK7jUwI/AAAAAAAAA6I/fYcKNXWb8L8/w702-h527-no/P1010625.JPG)
(https://lh4.googleusercontent.com/-Oaq41-LW648/UpqinAf5-UI/AAAAAAAAA6g/Tf8ZwBQrcg4/w702-h527-no/P1010626.JPG)
(https://lh4.googleusercontent.com/-qroeYiRtv14/Upqim3Da6bI/AAAAAAAAA6c/j50djrhcKXk/w702-h527-no/P1010627.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 06, 2013, 08:25:12 pm
Really cooking with gas now, finally starting to feel like I'm getting somewhere.
Looked at masking the body to paint the inside of the roof and thought it seems like a whole lot of work for no real gain so a quick scuff and a 2nd coat of Por15 did just as good a job all in under an hour.
Once dry it could be taken out of the rotisserie and back on the dolly wheels so that the door braces can be removed and sand the jambs.
With the last of the hard primer dealt with I masked the body to paint the door shuts which went pretty well after work yesterday.
Body is now pretty much ready to be final 600 sanded, not getting my hopes up but would like to reunite the body and chassis next weekend if things go my way.
But anyway enough waffling............pictures....  ;D
(https://lh4.googleusercontent.com/-vO3weNvUWhs/UqD1TuvbD5I/AAAAAAAAA7I/glxIcT3S_98/w674-h505-no/P1010647.JPG)
(https://lh5.googleusercontent.com/-e2URBmCFfI0/UqD1VQ1NgMI/AAAAAAAAA7Y/c2xuyV8SgV8/w674-h505-no/P1010648.JPG)
(https://lh4.googleusercontent.com/-ndJnJ_W0FRs/UqD1VAABzzI/AAAAAAAAA7U/W3fdPI4SiJM/w674-h505-no/P1010649.JPG)
Sure is starting to look Purdy..................
(https://lh6.googleusercontent.com/-B8fCXLNEzsk/UqD1vAKjFfI/AAAAAAAAA7g/RsOdwfQ75Ao/w674-h505-no/P1010650.JPG)
1st lot of essential plating done as well, sure is nice to transform and good for nothing pile of rusted parts to something that looks brand new again.
(https://lh3.googleusercontent.com/-JRU6_cMpe2Y/UqD1yv_qSXI/AAAAAAAAA7o/_ZdFS_q-k34/w674-h505-no/P1010651.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on December 06, 2013, 08:35:47 pm
This just gets better and better
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: John Stone on December 07, 2013, 06:25:10 am
mmmmmmmmm!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on December 07, 2013, 09:58:30 am
juice, milk and K-Gs come in 2 litres  ;D ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 15, 2013, 11:01:49 am
The part of the project I've been waiting for has finally come, reunite the body with it's chassis, always a big milestone with any VW project confirming you're heading in the right direction at last.
My wheels didn't make it back from clear coating on time but lucky for me I still had the Boxter wheels that came off my Super vert so I'll roll on those for now, body bushes sorted I was ready to go.
(https://lh4.googleusercontent.com/-0vUofKRy1Nk/Uqwbg2i7bII/AAAAAAAAA84/_IKi5m-dSeI/w680-h510-no/P1010654.JPG)
I didn't expect it would be as easy as it was though, took a calculated gamble and decided I'd put the body back on the same way I took it off, with the overhead gantry!
Lifting straps around each roof pillar with another strap through each of the corner straps seemed to work quite well, body was a little front heavy which surprised me as there's more rear over hang.

With thoughts running through my head of everything that could possibly turn to sh#t I got on with swiftly positioning the chassis underneath and lowering the body down wanting to very much minimise the length of time the body was suspended from its roof!
Found that the body needed to go down in the rear first to clear the rear seat support and once that was down the front just dropped in to place with the whole process only taking 10 minutes  ;D
(https://lh4.googleusercontent.com/-U8XyANfJX2w/UqwbkeVZkJI/AAAAAAAAA9E/qNzNgU0NkyE/w680-h510-no/P1010655.JPG)
Body down and positioned I thought it prudent to first install all the bolts first and then go around and tighten everything up, no real dramas here just one stripped thread which I recoiled.
A few hours later she was all done leaving me with more than half a day left, always nice when things happen faster than what you think.
(https://lh5.googleusercontent.com/-VgDDdwU-sTc/UqwcST9-6nI/AAAAAAAAA9Q/arOxZtwaCrI/w680-h510-no/P1010657.JPG)
Hmmm what to do now, be lazy or carry on?
Carry on of course, it aint going to get done by itself.
Blocked the doors and fitted the hinges spending most of the afternoon lining them up and setting the latches so that they operate nicely.
Really happy with the fit of the doors and everything seems to work nice.
Alles sauber!
(https://lh3.googleusercontent.com/-VbZl9Nd8nwo/UqwcSvKHDhI/AAAAAAAAA9U/c-pgsMXvSJk/w680-h510-no/P1010658.JPG)
(https://lh5.googleusercontent.com/-RE_2ujn5eeg/UqwcUk_x5iI/AAAAAAAAA9c/gQFS3hx--0M/w680-h510-no/P1010659.JPG)
(https://lh3.googleusercontent.com/-LVJ1T425aec/UqwdCsunsxI/AAAAAAAAA90/dhYxL6LqgPg/w680-h510-no/P1010662.JPG)
(https://lh4.googleusercontent.com/-u0OCI5TTSEQ/UqwdBp6QbQI/AAAAAAAAA9s/F8rbU681GPw/w680-h510-no/P1010660.JPG)
(https://lh5.googleusercontent.com/-xnreoyFP3kQ/Uqwc-6tUK4I/AAAAAAAAA9k/rHWCCe2IVTc/w680-h510-no/P1010661.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RobClubley on December 15, 2013, 11:08:12 am
Awesome, must be a really satisfying milestone.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on December 15, 2013, 11:38:11 am
Fantastic!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on December 15, 2013, 02:46:47 pm
a satisfying day's work, she's going to be a little pearler!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on December 16, 2013, 01:25:43 pm
Almost a shame to hide that chassis
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Fizz on December 16, 2013, 01:34:03 pm
agree looks good against the white body  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on December 16, 2013, 01:47:07 pm
Who needs floor coverings?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 22, 2013, 11:16:42 am
Got off to a bad start yesterday and couldn't quite believe the stroke of bad luck I was dealt, early in the morning I had the tyres put back on the 2 Fuchs that were finished ( the other 2 is another bad story) but I was keen to see what its new shoes would look like so as I tried to undo the last wheel nut the stud stripped in the hub and both spun together............... :-\ WTF do I do now?
The only way to get the hub and disc off would be to first get the caliper off with the wheel still attached which would never be an easy feat, after a few hours of not really getting anywhere I had visions of destroying a lot of had work done so far.........

In the end I managed to put enough force against the stud to be able to get the wheel nut off, I did get the pads out and within 1-2mm of being able to remove the caliper but it just wasn't going to happen so had I not been able to remove the wheel nut who knows where I would be now..... ::)
At least the 2 wheels I do have look good!
(https://lh5.googleusercontent.com/-sv1GD7yvjQY/UrUmoThOocI/AAAAAAAAA-Q/kaQ677EcEPM/w685-h514-no/P1010668.JPG)
Anyway with the whole morning gone but fortunately a problem solved I could get back to paint prep and sanded the bonnet first
Bit of a mish fitting it by yourself but worked out a way supporting one corner on the body on a thick towel which worked well.
Did the rear lid next which also went well thankfully and used the same method to fit that by myself as well.
(https://lh5.googleusercontent.com/-XUSmimpAeXw/UrUnj1cwPOI/AAAAAAAAA-k/TMaXtLV-A6c/w685-h514-no/P1010670.JPG)
(https://lh4.googleusercontent.com/-ytTYwQxglcw/UrUmnyBP3_I/AAAAAAAAA-M/T0Xj6U7WiGA/w685-h514-no/P1010669.JPG)
By now its getting pretty late but felt like doing a bit more due to the wasted morning so I started on the masking doing soft edges around the engine bay, got most of the back of the car masked by days end.
Last day of work tomorrow before the holidays so right on track for paint.
(https://lh4.googleusercontent.com/-9_9LN6dL-yY/UrUm3omEedI/AAAAAAAAA-Y/gZkdWbkvSMU/w685-h514-no/P1010671.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on December 22, 2013, 10:15:45 pm
 :-*
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 27, 2013, 03:12:03 pm
Ok so the first color is down and came out pretty nice, a little dust but a good cut will see that gone.
Got started this morning fitting the filter and taping up the last bits of plastic and was painting by 10.30
Managed to put on 3 decent coats, thankfully no runs and other than a little dust it looks pretty decent with very little peel.
I'm hopeful of giving the dust a cut and calling it a day as I can live with a little orange peel.
If the body comes out as nice as the roof I'll be a happy chappy!
Left it for a few hours and peeled the plastic off with no over spray to clean up so once its sat for a few days I'll mask the roof up so that I'll be ready to go next week.
(https://lh5.googleusercontent.com/-4wwWh4vstaA/UrzfLTmTzfI/AAAAAAAABA8/NBMJgORQSOw/w702-h527-no/P1010680.JPG)
(https://lh5.googleusercontent.com/-N3Fw28pIFJ8/UrzdllJiFiI/AAAAAAAABAc/Pg038Yxtgds/w702-h527-no/P1010681.JPG)
(https://lh4.googleusercontent.com/-RWd1ERhWP5w/Urzdn0q0J9I/AAAAAAAABAo/mu2Wg1oJFNU/w702-h527-no/P1010682.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on December 28, 2013, 11:16:38 am
Those Fuches wheels are a great choice John ,not to modern for the car,paint looking great also 8).
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 31, 2013, 06:18:11 pm
(https://lh3.googleusercontent.com/-Pvav3GFK27w/UsJSUhMW21I/AAAAAAAABBQ/90oP1ucw3rk/w702-h527-no/P1010695.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: weta.worker on December 31, 2013, 06:34:29 pm
(https://lh3.googleusercontent.com/-Pvav3GFK27w/UsJSUhMW21I/AAAAAAAABBQ/90oP1ucw3rk/w702-h527-no/P1010695.JPG)

Damn!  those are some nice angles and shapes that car has going on

:D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on January 01, 2014, 09:00:04 am
(https://lh3.googleusercontent.com/-Pvav3GFK27w/UsJSUhMW21I/AAAAAAAABBQ/90oP1ucw3rk/w702-h527-no/P1010695.JPG)

(http://www.sportscardigest.com/wp-content/uploads/IMG_1739-248-Chevrolet-1963-Corvette-FI-Roadster-30867S100015-620x465.jpg)

???  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on January 01, 2014, 09:07:33 am
Crisp!
Job done JK!
Gotta admire that you get things done!
While others waste time and effort preparing to have a hangover....others are productive and produce works of art!
Brilliant work as always!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 01, 2014, 01:08:59 pm
Thanks, would rather do something constructive instead of dealing with a hangover  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 02, 2014, 07:38:13 pm

Pulled the car out yesterday and de masked most of it so that I can start color sanding it in preparation for buffing.
Most of it came out ok other than debris landing on the flat surfaces along with some dry spray due to the lack of available light so rather than do bits here and there I'll flat the whole thing down and give it a cut.
I'm not looking to eliminate the peel completely but 90% of it will suffice as it will give a more modern car paint finish.

Cut the roof yesterday which has been painted for nearly a week and its already pretty tough to buff so I'd better not leave it too long, I did the top of one guard yesterday and it polishes up pretty easy still so hopefully I'll get all the way around before the paint sets.
Here's some pics from yesterday, not bad for a home job I think.

(https://lh6.googleusercontent.com/-syNwRvHzTsE/UsPBwDUacGI/AAAAAAAABCM/iAcXGLrdwRs/w702-h527-no/P1010694.JPG)
(https://lh3.googleusercontent.com/-FxCIb_Tn8cQ/UsPBGgip4bI/AAAAAAAABB0/95rusLl7T7Y/w702-h527-no/P1010693.JPG)
(https://lh3.googleusercontent.com/-ts479ifxFc0/UsPBv3ucCQI/AAAAAAAABCI/mhsudxJBU9E/w702-h527-no/P1010696.JPG)
(https://lh4.googleusercontent.com/-ILQmcCVYZQs/UsPBspvq7fI/AAAAAAAABB8/OFJ9qneIKmM/w702-h527-no/P1010698.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 02, 2014, 07:42:25 pm
Paint wise things are looking up, spent most of the day sanding and compounding even though my good polishing pad decided no more and started to fly to pieces.
Since all the paint stores are closed for the holiday I had to make do with my back up, I guess things could be worse and not have one at all!

Sanded most of the top side of the front with 1200 and followed that up with 2000 making cutting a lot quicker, certainly worth the extra effort sanding it with finer paper.
By days end I've ended up finishing the whole front, right door and rear quarter so all going well I'll finish the rest tomorrow.
Once the outside is done the rest of the masking can come off and I'll then blend the jambs.
(https://lh4.googleusercontent.com/-iqlPHBqrJUo/UsT0FMYPOGI/AAAAAAAABC4/uczSNX03DSo/w685-h514-no/P1010706.JPG)
(https://lh3.googleusercontent.com/-Wm1XKuz_dIY/UsTz2acBJ-I/AAAAAAAABCs/kjSpFdghltI/w685-h514-no/P1010704.JPG)
Light colours don't seem to photograph all that well but you can see the reflection of the jack stands in the door  :lol:  YEAH baby!!
(https://lh3.googleusercontent.com/-f6Cbd8bMUeA/UsTz3aiRxVI/AAAAAAAABCw/MyV6VJ04T6w/w685-h514-no/P1010703.JPG)
(https://lh6.googleusercontent.com/-yGTAbW5G2TI/UsTz2XU0D1I/AAAAAAAABCk/RTLu1hykgJw/w685-h514-no/P1010705.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: weta.worker on January 03, 2014, 07:44:48 am
this thing is amazing!  well done

:)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on January 03, 2014, 11:20:06 am

Light colours don't seem to photograph all that well but you can see the reflection of the jack stands in the door  :lol:  YEAH baby!!
(https://lh3.googleusercontent.com/-f6Cbd8bMUeA/UsTz3aiRxVI/AAAAAAAABCw/MyV6VJ04T6w/w685-h514-no/P1010703.JPG)


is there clearance on the back tyres with the motor in?  or is that another day's problem?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 03, 2014, 11:43:52 am
Yep there is, about 2-3mm  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on January 03, 2014, 12:18:36 pm
whew, relief!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on January 04, 2014, 10:58:23 pm
Bugger I was on a ride out west today and went past your place, should of popped in I didn't even think of it. It's looking good!
Do you think you're going to catch the tail end of Summer with it?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 04, 2014, 11:19:55 pm
Bugger I was on a ride out west today and went past your place, should of popped in I didn't even think of it. It's looking good!
Do you think you're going to catch the tail end of Summer with it?

You should have called in, was here too.
Nah don't think so as all the parts which have to go back on are all knackered as well and need restoring, realistic goal will he 6-8 months away.
Besides I have the Porsche to distract me now as well which got some TLC today.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 05, 2014, 07:28:26 pm
Now that the paint is done I shifted it out of the workshop this afternoon to a more clean area for assembly, was also able to temporarily fit the new steering wheel I bought about 4 years ago at a VW show in Sydney  :lol:
Looks a whole lot different in natural light I think.
(https://lh5.googleusercontent.com/-R6Y2uRD5lvU/Usj6Zq-sy7I/AAAAAAAABDQ/7CBrPxYoosY/w674-h505-no/P1010707.JPG)
(https://lh5.googleusercontent.com/-w_RVf92s0s0/Usj6Zj7YrvI/AAAAAAAABDU/PKkVodRoYT0/w674-h505-no/P1010709.JPG)
(https://lh3.googleusercontent.com/-gqMSh0mi_Mw/Usj6aoa260I/AAAAAAAABDc/YF-u_kCZQVg/w674-h505-no/P1010708.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on January 13, 2014, 09:04:05 pm
Wow.....beautiful buddy ....wow
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 09, 2014, 10:53:13 am
Came to a dead end on the 911 yesterday so carried on with the Ghia, pulled the fresh air boxes out of storage to start working on those.
Feared the worst as these are normally rusted beyond belief but to my amazement mine are pretty much perfect just needing a sand blast and paint.
The flaps will need replacing as well as the cable outers at least that is the easy part.
 (https://lh5.googleusercontent.com/-7t9h5emvbJ8/UvWmMRWpAcI/AAAAAAAABD8/T7ZmCGIP7eY/w667-h500-no/P1010712.JPG)
I want to do a run of black soon while the weather is still good so the more parts I can clean up the better, While blasting I also blasted the spare wheel cover and epoxy primed all of it once done.
When I got this car it had a Beetle gas tank in it and was fortunate to find a Lhd type 3 tank very early on which had already been acid dipped and sealed with tank sealer.
However it being a late tank it doesn't line up with the vent line on the body which I was just going to live with but have now decided to do properly.
(https://lh6.googleusercontent.com/-NZPhqiHS04I/UvWmNNTriyI/AAAAAAAABEE/-0vjbQVkgfs/w667-h500-no/P1010713.JPG)
(https://lh5.googleusercontent.com/-4Lnut39Bqc0/UvWmKX99DmI/AAAAAAAABD0/PEavXbTp4QY/w667-h500-no/P1010714.JPG)
Sooo, cutting a hole in a perfect tank..........
Not that smart but it needs to be right, cut the vent pipe out and started making the new piece to go in which is actually quite a difficult shape to make.
Once I'm happy with how it looks I'll weld it in and check it for leaks before painting the tank.
(https://lh6.googleusercontent.com/-8wNwI-uEfCA/UvWmpRVeNEI/AAAAAAAABEM/KGm2i9yxHXE/w667-h500-no/P1010715.JPG)
(https://lh5.googleusercontent.com/-fTBr-QMVYGo/UvWmq0LHvnI/AAAAAAAABEU/Uorv-to5ni8/w667-h500-no/P1010716.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on February 09, 2014, 07:15:40 pm
"I have decided to do it properly"....does vert have any other way?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 09, 2014, 08:33:00 pm
"I have decided to do it properly"....does vert have any other way?

LOL yeah, laughed as I typed that........
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on February 11, 2014, 09:44:35 pm
have you got the motor done yet John?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 11, 2014, 09:46:27 pm
Nah been slack, distracted by the 964  ;D
New projects are always more interesting.........
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: watercooled on February 12, 2014, 09:04:15 pm
Ha ha no worries,did you get the 964 from the states when you were @ the Cup?pics or resto thread coming up ,how about it?,cheers
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on February 12, 2014, 09:05:39 pm
Nah been slack, distracted by the 964  ;D
New projects are always more interesting.........

Come on John, give us some info on the 964.

Also, a 964 C4 was crashed at HD today - brakes failed.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 12, 2014, 09:58:43 pm
Come on John, give us some info on the 964.

Also, a 964 C4 was crashed at HD today - brakes failed.

Wow really? the white one with the ducktail?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on February 12, 2014, 10:07:30 pm
Wow really? the white one with the ducktail?

No, not Johns (different John to you obviously) car. The crashed C4 was a US import. The owner immigrated from the US recently, got his car on the road weeks ago then this.
I see if I can grab a pic.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on February 12, 2014, 10:11:36 pm
Here you go:

(http://i42.photobucket.com/albums/e348/Golfboy666gti/810f393f0769c767d72137817720c26b_zps2c6c968e.jpg)

Poor bugger.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 12, 2014, 10:15:02 pm
Yeah just saw it on Rennlist, that shell is toast.........bent front to back.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on February 12, 2014, 10:16:54 pm
Yeah just saw it on Rennlist, that shell is toast.........bent front to back.

Thats what I thought.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 16, 2014, 10:00:21 am
Finished off the tank yesterday, quite a complicated piece to make being quite small and fiddly.
I'm sure its not 100% the way it should be but will be pretty close, I should have tig welded it in but didn't have any gas for the welder so had to mig the whole thing instead and as a result spent over an hour chasing leaks from all the tiny pin holes mig welding tends to leave behind.
Case of fill with water, mark leaks, empty, weld, grind, fill with water etc etc etc...........got there in the end though and acid washed it to remove the surface rust finishing up for the day epoxy priming it.
(https://lh3.googleusercontent.com/-7-_47BKQn74/Uv8ALhksiUI/AAAAAAAABEs/J1sPHmTInNg/w667-h500-no/P1010720.JPG)
(https://lh3.googleusercontent.com/-2M4q6FTUTqk/Uv8AMfqdu0I/AAAAAAAABE0/pRauLpor5Lc/w667-h500-no/P1010721.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on February 17, 2014, 04:47:23 pm
To do a quick weld on a fuel tank the same day or even hour you remove a tank you run a hose from an idling car into it then there is no oxygen to ignite. Old school trick, still Id rather leave it a few days to air out after washing it all with copious water.
Looks nice John I like that epoxy grey primer you use, looks very smooth and sealed. Good painting and coverage.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on February 17, 2014, 05:45:32 pm
BB returns, where you been?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on February 17, 2014, 09:41:35 pm
yes, welcome back Jem!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SOFTLAD on February 17, 2014, 09:56:08 pm
Here you go:

(http://i42.photobucket.com/albums/e348/Golfboy666gti/810f393f0769c767d72137817720c26b_zps2c6c968e.jpg)

Poor bugger.
Sorry to butt in on this, I was talking to a mate who was there. This car cleared the grass, gravel trap and tire wall and as pictured is actually outside the confines of the circuit in the adjoining work site
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 23, 2014, 10:21:19 am
Made a start on the wiring yesterday and the aim was to replace all of the hard and cracked sleeving and clean up any paint over spray from previous paint jobs, bought new PVC sleeving from an electrical supply shop which was cheap at 10 bucks for a 10M roll.
It was available in all the sizes I needed, 6mm, 10mm and 25mm.
Other than the odd broken connector the actual wiring is still like new so no need to replace the entire harness.

Start by cutting new lengths of sleeve to match what was there and then you can just cut the old stuff off, probably the most difficult part is getting the wiring through the new sleeve and in most cases I had to tape it to a hard piece of cable to pull the wiring through the sleeve.

Quite time consuming but worth it as it makes an old loom like new again, some connectors still to replace but that's the easy part.
Following an excellent write up on the net I also took the push button dash apart and gave it a good clean, putting it back together though was another story...........a lesson in frustration for sure!
Rubber bands just didn't want to work for me holding all of the buttons, springs and contacts down so I used some steel tie wire to do the same job, if you don't tie all these components down it would be impossible to get back together and not a job you'd want to do again........well not me anyway!
New buttons on their way which will complete the dash.

Same deal with the washer valve, couple of new rubber seals and it's good to go again.
Will rebuild the rear part of the harness next week, some hackery been performed there so a few issues to repair but simple cars have simple wiring  :lol:
(https://lh3.googleusercontent.com/-jEzyfkewVgc/Uwg2-BktSLI/AAAAAAAABFs/pLQJEum4oPM/w667-h500-no/P1010711.JPG)
(https://lh6.googleusercontent.com/--_kbuQJqylE/Uwg28Vk_NMI/AAAAAAAABFk/geHIjKdTn68/w667-h500-no/P1010712.JPG)
(https://lh4.googleusercontent.com/-phnkvpUUts8/Uwg3rmDwxwI/AAAAAAAABGI/okd_GxHuA9M/w667-h500-no/P1010716.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on February 23, 2014, 06:31:00 pm
I think there is somewhere making replacement buttons for them? ISP?

Terrible things I believe when they don't work! Used to be able to get factory conversion kits to get rid of all the push buttony stuff.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 23, 2014, 06:37:25 pm
I think there is somewhere making replacement buttons for them? ISP?

Terrible things I believe when they don't work! Used to be able to get factory conversion kits to get rid of all the push buttony stuff.

Yep ordered new buttons from ISP, all looks ok inside so hopefully it still works as its kinda funky.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 09, 2014, 11:02:30 am
The first pieces are going back on to the painted body, have found it quite frustrating to work on the car where it is stored so rather than complain I did something about it and cleared out a space at work where it can sit undisturbed and be able to have the doors open.
Gathered up all of the parts for the car from all the various hiding places and put them all on one shelf which should make things easier in the long run.
(https://lh6.googleusercontent.com/-Tr3XrqIffCE/UxqVRRA4xYI/AAAAAAAABGY/6RpQiz4B7xI/w662-h496-no/P1010729.JPG)
Now all I have to do is take a wall out to get the car in!!  :lol:
Cut the sleeving off the rear part of the wiring harness and began re doing that making repairs along the way, fitted the front harness to the body and already finding parts I need so I'll have to start a list for all those silly little parts you need along the way.
Also fitted the rear air intake on the deck using the old seal which was in remarkable shape being 50 years old.
(https://lh6.googleusercontent.com/-IVTQymOcEtg/UxqVUonvu_I/AAAAAAAABGg/N_b5VCyatWA/w662-h496-no/P1010728.JPG)
(https://lh5.googleusercontent.com/-WtNJAegnEXQ/UxqVV1656GI/AAAAAAAABGo/FhyKs0d659Q/w662-h496-no/P1010730.JPG)
Next week I'll get the car moved so that I can pull the colum out again and do a run of black parts which will give me some more to do.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on March 12, 2014, 11:23:52 pm
wow
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 30, 2014, 11:48:55 am
Wiring harness is slowly being returned to what it should be, cutting off most connectors and crimping on new at the same time undoing 50 years of other owners "handiwork"  :lol:
In all it's actually still in pretty good shape and other then removing a few non standard switches the rest is mainly just replacing sleeving and repairs.
I disconnected everything from all terminals to clean all of it and i'm re wiring as the factory intended.
Some of the dash going back together as well, contacted NHS for a repro tach but they are
not really interested in doing any right now so on the look out for something else.

Mostly the front wiring is in as is the hood seal and latches, waiting on an order from Cip to complete most of the front "seals" and a couple of horns as well.
Installed the rear part of the loom.........if you can call a dozen wires a loom  :roll:
Probably finish up the wiring during the week and will then concentrate on finishing the chassis, steering, shocks & brakes.
(https://lh5.googleusercontent.com/-k07sTykWP9g/UzdJzGdJO2I/AAAAAAAABJM/P9H07vhcHFs/w702-h527-no/P1010747.JPG)
(https://lh4.googleusercontent.com/-OED1WAuKspo/UzdJzrhu-9I/AAAAAAAABJU/p-c-XRUbNuM/w702-h527-no/P1010748.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SOFTLAD on March 30, 2014, 01:00:17 pm
wow
You can say that again, the builds from this garage never disappoint
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 06, 2014, 10:23:12 am
Latest drama is the headlights so currently I'm looking at weather some 7" H4 Hella halogens can be made to fit as I've got just about zero chance of finding genuine RHD lenses and even if I did I wouldn't pay the sort of ridiculous prices being quoted elsewhere..............read 1500 euro :o
Sealed beams are not going to work for me either as we require front parking lights and I'm not really keen on modifying my turn signals to dual filament...........but in the end who knows what I'll end up with, I'm sure a solution will appear.

More assembly yesterday pretty much finished the wiring repairs and then moved on to assembling the newly painted column which went together ok but ended up taking it apart again multiple times for one or another thing that didn't work out, with my parts from Cip turning up on Friday it meant the steering could finally go together for good.
(https://lh3.googleusercontent.com/-C3w_vVyI3S8/Uz-ICz-CigI/AAAAAAAABKM/HKB8QMBX3W8/w662-h496-no/P1010751.JPG)
Also got most of the parts needed to finish the front compartment which went together well allowing the hood to be latched now as well, super happy with the panel fit and over all look of it.
Did have a D'oh moment and only ordered one horn for some strange reason but oh well I'm sure other things will be needed soon enough.
(https://lh4.googleusercontent.com/-a4O3haJTMyA/Uz-ICW0tTsI/AAAAAAAABKI/nJnP6Bj8r-w/w662-h496-no/P1010756.JPG)
(https://lh5.googleusercontent.com/-D6Sr3EtQPX8/Uz-I19sAIZI/AAAAAAAABKk/mHlvgoIdsF8/w662-h496-no/P1010757.JPG)
Onwards with fitting some of the bling, followed with disappointment immediately after I started.
Compared my new side marker lenses from ISP to my faded originals and found them to be a little shorter meaning they don't clip in to the holder at one end and only rely on the screw to secure it..........very annoying, making an otherwise great looking part completely useless.
Will try and paint my originals with clear red paint and see how they look,   I just don't get why companies go to all this effort to make a product which fits 90%.
(https://lh4.googleusercontent.com/-93w7ILV0pYM/Uz-Ivwxb0II/AAAAAAAABKU/jEJLXpl-lRg/w662-h496-no/P1010758.JPG)
Finished off the day assembling a door handle and door lock, the original seals were in amazing shape only needing old overspray removed and a clean to be used again, certainly starting to look like something with chrome going back on, final shot of the day is of the dash getting another step closer to being completed.
(https://lh6.googleusercontent.com/-n5Fyb1bMeqY/Uz-I-_nJbjI/AAAAAAAABKs/ymePCX2pB6Y/w662-h496-no/P1010760.JPG)
(https://lh3.googleusercontent.com/-3FTcDm0C5DA/Uz-Iwy_yWTI/AAAAAAAABKc/4qNpHvDqmNE/w662-h496-no/P1010759.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on April 06, 2014, 12:34:50 pm
a quick troll through tardme showed several 7" high/low beam lamps with parking lights included
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RobClubley on April 06, 2014, 04:59:54 pm
Loving it. Call me daft, but I only just realised the wheel is on the left, doh!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on April 06, 2014, 10:42:50 pm
Beautiful.......im getting all tingly
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: SOFTLAD on April 06, 2014, 10:49:34 pm
Loving it. Call me daft, but I only just realised the wheel is on the left, doh!
You're not the only one mate ::)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: ziptie.nz on April 07, 2014, 06:59:17 am
Verty your inbox is full
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 13, 2014, 04:51:32 pm
Now the fun really begins trying to track down parts no longer available such as the seal for the front tyre pan but that turned out to he easier than first thought.
Went to Para rubber which had a profile just about perfect for the job, fits really well although a fraction too big meaning its a challenge to fit all the screws in place once the tyre pan is in.
The foam rubber is quite dense so over a big length like this seal there's not a lot of give but all worked well in the end.
(https://lh4.googleusercontent.com/--AlkYgzK0NU/U0inGLWVO3I/AAAAAAAABLM/qJ-IDkExDGA/w662-h496-no/P1010763.JPG)
Shocks for this car will be adjustable Koni's I had left over from another car but since they were used they needed to be cleaned up and painted,  I could only get the right red color in a spray can so I decided to sandblast the shocks and then epoxy prime them followed by the red spray paint while the epoxy was still wet   ;D
Gamble which paid off really well, no sanding and the spray paint fusing well with the wet epoxy making the whole finish a whole lot tougher than just spray paint alone.
Also did another run of black so that more parts can go back together and on the car, just have the fuel tank to finish off and paint now.
(https://lh4.googleusercontent.com/-HZL_2JQ0JBs/U0inPQLoIhI/AAAAAAAABLU/UiawqYi1J5U/w662-h496-no/P1010764.JPG)
Got a tube of 3M glue with my order from the US which I used on the door seals, had high hopes for this stuff since a few people recommended it and was pleasantly surprised how well it sticks, tricky suckers to glue on without making a mess!
The first one I did piece by piece which was quite difficult so on the 2nd one I applied the glue on the whole thing, seal and door which was a lot easier.
The T14 seals actually fit really well and give the door a very solid feel when closing.
So far I'm very happy with all the parts I sourced a few years ago, sure you need to take your time to fit them since most are non T34 but seem to fit well.
I guess that's probably one of the most challenging aspects of this car, you just can't get most of the parts so you have to constantly look at other cars of the era to find stuff which may work.
(https://lh3.googleusercontent.com/-0QFNZI4pB2k/U0inzb_PnwI/AAAAAAAABLk/hTcVXq5hcCQ/w662-h496-no/P1010767.JPG)
On to the inner scrapers which from memory are T14 as well, cut to length and re fitted the T34 clips.........presto, done.
Outer scrapers I had like everyone else bought Superbeetle ones which from day 1 weren't going to cut it by the way they are finished on the ends so when I polished all of my trim I also did my original scraper molding knowing
I would only use the rubber from the Beetle ones.
Drilled the rivets out of the new scraper and took it apart, installed the vent frames temporarily to measure the rubber and cut them to size.
The rubber strips fit the T34 molding without issue and both pieces are long enough for the job, fitted them to the door to double check the length which was ok and they look great!
I then used the metal backer from the Beetle scraper as its aluminium, I wanted a very factory look for the fastners and found that eyelets from a haberdashery shop were just about identical and make them very flush fitting once peened over, in all quite a bit of work but very impressed with the finish of a part you can't buy anymore.
(https://lh3.googleusercontent.com/-T-F5XDVA3h0/U0io77_lvTI/AAAAAAAABMM/NNXcobl2eq8/w662-h496-no/P1010768.JPG)
(https://lh6.googleusercontent.com/-fdKkc-iocPU/U0in6YCKOSI/AAAAAAAABL4/5wd8_uafbsY/w662-h496-no/P1010770.JPG)
(https://lh3.googleusercontent.com/-LAIUuZAOhos/U0inlWvj0MI/AAAAAAAABLc/1lHwwCttsio/w662-h496-no/P1010769.JPG)
Last job of the day.......fit the fresh air boxes and wiper motor, what a pain those are!
Main problem being the seals want to roll off the boxes when you try to install them but persistence pays off in the end, another WIN!
(https://lh3.googleusercontent.com/-InuV4DBSgCs/U0ioHunmpII/AAAAAAAABMA/vdUHpBg_yhs/w662-h496-no/P1010772.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 04, 2014, 08:01:27 pm
Finally its headliner time but rather than buy one I wanted to have a shot at making my own, on a 2 week holiday last week I called in to an upholstery supplier in Wellington and picked up some perforated headliner material which was only $50 / m plus a $10 zip from the haberdashery shop I was set to go.
Using the old headliner as a sample I marked out where the zip needed to go and cut the material at the same time applying glue and folding the vinyl over to create a nice clean edge.
Also glued the zip to make it easier to sew the zip once it was nice and straight.
So far so good, headliner for 60 bucks.......... :lol:
(https://lh3.googleusercontent.com/-TGFDXdlRT4U/U2XXFNoJziI/AAAAAAAABNs/vWYZP_nLNhE/w671-h504-no/P1010779.JPG)
Instead of gluing the white vinyl straight on the pillars as per factory I've used some very thin foam to take out some of the lumps and bumps, same thing on the rear pillars as I didn't really like the thought of cardboard sucking up water and holding it there.
Produces a nicer looking final result with a more uniform finish.
(https://lh4.googleusercontent.com/-JTFlL2raJ90/U2XX421r1FI/AAAAAAAABN8/nDzu7BzmMow/w671-h504-no/P1010780.JPG)
Next up I covered the perimeter of the drain box with thin foam and re installed the factory plastic u channel around the opening which acts as an edge protector for the headliner.
Took all morning to get to this point but feeling pretty good about it so far and time to fit up the headliner and see where to from here.
(https://lh4.googleusercontent.com/-G-zUhHZM2NU/U2XXxQ6dPdI/AAAAAAAABN0/CtZHctTl6Kk/w671-h504-no/P1010781.JPG)
Headliner placed I began adjusting it to center the zip as well as making sure it was aligned with the rear edge of the roof, slowly pulling it on each side making tighter and holding it with bulldog clips.
Happy with the placement I glued the middle 10 inches or so at the front and rear pulling it tight at the same time.
Worked my way out to the pillars gluing as I went, with most of the headliner nice and tight I could begin to start looking at doing the pillars.
(https://lh3.googleusercontent.com/-qSfmCGHKHjc/U2XX6YrkX9I/AAAAAAAABOE/Ym0Td1gJbGQ/w671-h504-no/P1010782.JPG)
(https://lh4.googleusercontent.com/-CyLk1ug80VM/U2XYgBL2YGI/AAAAAAAABOM/3cW7uR6qNQE/w671-h504-no/P1010783.JPG)
Thought the front pillars would be the easiest so I started there, folded the vinyl over to have a nice finished edge holding it with glue.
Easy enough to do one side but not so easy to replicate the other side to look the same but starting to look pretty damn good now.
Certainly has come a looooong way from the heap that it used to be.......
(https://lh5.googleusercontent.com/-q8I1NW6KP_M/U2XYoXgmCKI/AAAAAAAABOU/XNrpFwTDC20/w671-h504-no/P1010784.JPG)
Rear pillars....................oh dear!
First mistake was trimming away excess vinyl at the same time cutting off too much which kinda screwed me at this point, the headliner should have come down the pillar a little more but this will have to do but annoying none the less.
In the end its worked out ok but would have preferred it to be a little longer.
Molding and seal on that side completing the right side, by this time I was done for the day so I left it alone till today when I completed the left side and
installed those moldings as well.
(https://lh6.googleusercontent.com/-_OpXiky1avs/U2XZQg4GyrI/AAAAAAAABOk/rjSJlBfK2vA/w671-h504-no/P1010786.JPG)
Potential for another apocalyptic disaster, cutting the hole for the opening!
And I'd be lying if I said I wasn't a little nervous as at this point the headliner was nice and tight with no creases :lol:
Traced around the edge with a pen so I'd know where to pull the headliner to before folding it over the edge.
Next step glue the edges of the roof and headliner, with the glue dry I cut the headliner knowing full well if I f#ck this up I'll be ripping it all out.......
Thankfully that didn't happen and everything worked out great.
Carefully worked around the roof making sure its stuck down nicely all the way round.
Job done and pretty proud of it too, will cover the sunroof panel next and install the cables and other hardware.
(https://lh5.googleusercontent.com/-5KP0PiHFRwk/U2XZYOC3doI/AAAAAAAABOs/DSV-b2RuCio/w671-h504-no/P1010788.JPG)
(https://lh5.googleusercontent.com/-_tSvbOlPL3c/U2XZundxjZI/AAAAAAAABO8/eCxd2H67q1Q/w671-h504-no/P1010789.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on May 04, 2014, 08:25:28 pm
That's bloody amazing. I was reading thinking crap he's going to have cut the sunroof out... :o
What's the zip for?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on May 04, 2014, 08:45:38 pm
That roof came out well. Saw this again over the weekend, pretty amazing...
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on May 04, 2014, 09:29:48 pm
Awesome job John.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on May 04, 2014, 09:48:54 pm
very nice, the key to cutting something like the sunroof opening is a fresh new blade  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 11, 2014, 04:46:13 pm
Righto an update from this last week and yesterday, thought it prudent to trial fit the sunroof and all of the related parts and once the cables and guides were in I attached the panel itself with the immediate result of one of the pot metal guides exploding into 3 pieces  :roll:  What an excellent start!
What to do now...............make one from steel!
Re used the plastic guide and the pin from the old cable and made everything else as close as I could, of course being a rather delicate part it was never going to be able to be mig welded together so I brazed it instead which worked out rather well.
This leaves me with the question of should I also make the other side now before that one decides to break........??
(https://lh4.googleusercontent.com/-0n1fQqtDIm8/U23tGsISVCI/AAAAAAAABP8/DcI0d_28OFU/w958-h719-no/P1010792.JPG)
Bunch of adjustments and small tweaks here and there to get the thing fully operational all is looking good and working well, seals installed as well.
Just have to strip everything again to paint a few pieces and then reassemble for the last time.
(https://lh6.googleusercontent.com/-_OpbVDW6s-I/U23tFB5CBLI/AAAAAAAABP0/uz7k__NKnpA/w958-h719-no/P1010795.JPG)
Also trial fitted all of the seals on the left side along with the vent frame but most of it will have to come apart again due to the windlace having to be fastened under the B post but I'm hugely impressed at the quality and fit of the seals.
The vent frame seals off very nicely and the pop out window also seems to fit really well unlike the WCM door check straps which have already de laminated and fallen apart!
Still have to get the vent frames re chromed but really wanted to double check the fit before I did as this door has had a LOT of work done to it before I was again usable.
(https://lh4.googleusercontent.com/-P9mBH7IPPGE/U23t7n6WiAI/AAAAAAAABQQ/VU7AWIz1eaw/w958-h719-no/P1010796.JPG)
Which brings me on to the windlace, thought this was going to be easy to make.................WRONG, all of them were in no state to be re used so I thought i'd use the inner rubber tube and re cover them with new black vinyl but that proved to be harder than first thought and took me a couple of goes at it before I got it.
Had to make new attachment plates for most of it which is easy enough but actually attaching them to the pillars was another matter.
This is what I had to start with:
(https://lh3.googleusercontent.com/-zqEAYTwyPXg/U23s06EUS6I/AAAAAAAABPs/100vANJDYzA/w958-h719-no/P1010797.JPG)
Once the rubber tube is re used and new vinyl wrapped around it then comes the fun part of attaching it to the pillar, I used screws in the meantime until I can get some carpet tacks or countersunk screws and the latter would be my preference.
I'm still looking for a suitable rubber molding for the groove in the B post as it's completely different to what is used on the A post.
The A post has a P shaped seal which I've found a source for but will wait for it to turn up before I confirm that.
The original one is a foam seal and quite soft for the door to be able to close against it, would be great if the one I have coming does the trick.
(https://lh4.googleusercontent.com/-Qh7W7h-ii-U/U23tr9vxZMI/AAAAAAAABQE/iz0azB79810/w958-h719-no/P1010798.JPG)
(https://lh6.googleusercontent.com/-Ffojm_PYq9E/U23t7p2cEHI/AAAAAAAABQU/OX4LqCVJRtY/w958-h719-no/P1010799.JPG)
(https://lh3.googleusercontent.com/-0JiU-sKn860/U26nxVC1GoI/AAAAAAAABQ0/4C_X8JBRN0Q/w958-h719-no/P1010800.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: gti vr6 on May 11, 2014, 05:03:58 pm
Thats some beautiful work there old mate
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on May 11, 2014, 05:04:47 pm
I'd say definitely make up  and fit another sunroof guide, it'll never be easier to fit and you'll have peace of mind rather than wondering when a known time bomb is going to go off!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: John Stone on May 12, 2014, 07:24:35 am
I'd say definitely make up  and fit another sunroof guide, it'll never be easier to fit and you'll have peace of mind rather than wondering when a known time bomb is going to go off!!

What he said, but then you have probably already done it.....
This would rate for me as the best post I have ever seen on VASK, brilliant work John
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 18, 2014, 08:48:30 pm
What he said, but then you have probably already done it.....
This would rate for me as the best post I have ever seen on VASK, brilliant work John

Thanks John, its always more challenging bringing back a car from the dead!  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 18, 2014, 08:50:08 pm
Woohoo interior work again, soo much nicer than doing rust or sanding.............
Started on the rear seat area and parcel shelf, the rear seat area is reasonably complex to cover with vinyl (read for amateur) but pretty quickly found my stride using a heat gun, most important part is GOOD glue and heat makes things a lot easier.
Worked a little at a time using the heat gun on the depressions first then sticking down the flat area otherwise the vinyl will pull away from the deep depressions.
Really enjoyable work when it goes well, with the other side done I could start on the filler panel under the seat.
(https://lh6.googleusercontent.com/--DYLgSciPmA/U3hYnB3zAiI/AAAAAAAABSU/Rx1T0Z8R2bM/w958-h719-no/P1010811.JPG)
I'd seen a couple of cars which had a filler panel under the seat which was also covered in vinyl, unsure if original I decided to do that as well as it finishes that area quite nicely.
Made up a panel from aluminium and simply held it in place with a couple of pieces of tape.
In hindsight I should have covered the sides and the panel in one piece but   that would have meant that A, it would be more difficult and B, I would have had to cut the vinyl roll length ways meaning meaning more waste.
Once the vinyl was glued on it also keeps the panel in place quite nicely so I probably won't bother with screws there.
Turned out rather well I think.
(https://lh3.googleusercontent.com/-E-04oLl-Bwg/U3hWqe4TZXI/AAAAAAAABRY/4iymDoI-D80/w958-h719-no/P1010814.JPG)
Next up the parcel shelf, from what I've found on line the cars without corner cap covers had these covered in vinyl and are done separately from the parcel shelf itself.
Again patience is key here, did a double lip fold where it fits around the pillar area and then stretched the vinyl around to finish nicely on the bottom face, quite tricky not to get wrinkles but managed it first try.
Did a test fit with the top cap and rear 1/4 panel as well, so far so good.
(https://lh3.googleusercontent.com/-2fkHQ-1nJhI/U3hYI9Kh_7I/AAAAAAAABSE/Sq6uNrHP7wc/w724-h543-no/P1010819.JPG)
(https://lh4.googleusercontent.com/-LBWPzE4KlTg/U3hWq8JGVSI/AAAAAAAABRc/VBhd3owHBvI/w958-h719-no/P1010813.JPG)
With both of those done the parcel shelf can be wrapped, I didn't have any poster board or cardboard for that matter and to be honest I don't like the idea of using it as it can become water logged so I used a thin piece of aluminium I had and used the stretcher and english wheel to curve up the ends so that it fit the parcel shelf.
Used some urethane to hold it down and left it over night.
This morning I carried on and glued down a thin piece of foam to take out any surface irregularities.
With the foam down and edges trimmed it could be wrapped in vinyl.
(https://lh4.googleusercontent.com/-ZsaY4NbhiUU/U3hXZtvbYNI/AAAAAAAABRw/6QctToWq7rw/w958-h719-no/P1010815.JPG)
Rough cut a piece of vinyl to shape and had a think about how I was going to go about it and where to start, though the best place to start would be at the window lip so spread glue on both surfaces and started sticking it down
and as I went also using the heat gun to soften the vinyl making it a lot easier to fold over the lip then holding it there with the bulldog clips.
Made my way all round the window lip and I'll leave the clips on till the glue sets over night.
(https://lh4.googleusercontent.com/-rYsQ0GoJ5CA/U3hXaN7ZW0I/AAAAAAAABR0/NUzKsvhMVIQ/w958-h719-no/P1010817.JPG)
(https://lh5.googleusercontent.com/-JZJMDtCkORo/U3hYJWT9cyI/AAAAAAAABSA/T_WlATJQttk/w958-h719-no/P1010818.JPG)
Where the parcel shelf meets the corner cap I did a double folded lip since that edge is seen through the rear window it looks a bit nicer double folded that way and I'm pretty sure the factory did it this way as well as there's no real other tidy way of doing it.
The front edge is quite difficult to make stick as the edge to glue to isn't very big and if the vinyl pulls away from it over time I'll make a nice polished edge to clip over it to hold the vinyl in place.
Heating the vinyl does make it a lot softer and easier to fold over, it also seems to keep its shape once heated and folded.
Folded the vinyl right underneath the shelf and trimmed away the excess.
I guess I'll be having a go at putting the rear glass in it next weekend to keep all of this stuff in place and another milestone will come and go.
Having windows go in always feels like quite a big step forward.
(https://lh4.googleusercontent.com/-AemdIhrB-J0/U3hYJivbhBI/AAAAAAAABSM/sY3N8WMIWUk/w958-h719-no/P1010820.JPG)
(https://lh3.googleusercontent.com/-W6-iYPVYE8I/U3hYozrZRTI/AAAAAAAABSc/pamd6SiedyE/w958-h719-no/P1010821.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 24, 2014, 10:23:00 pm
Had a crack at installing the A post seal which came in the mail during the week, quite tricky to install being a foam type EPDM rubber most glues don't really want to stick to it if there's anything pulling on the seal.
The 3M weather strip adhesive worked to some extent but the door pushes the seal side ways a little so in the end I used superglue to make sure it stayed where I wanted it.
You can see from the picture just how close the profile is to the original, not easy to install but very worth the effort.
Main problem area is where the pillar curves up to the dash and I actually made a couple of extra plates and screwed them on to help hold the windlace and seal in place.
(https://lh6.googleusercontent.com/-STu26kEIIgk/U4ArDHXRR3I/AAAAAAAABTI/wXAfD7IQpIw/w685-h514-no/P1010829.JPG)
I had already drilled all the extra holes when I trial fitted the windlace so with the seal glued on it was just a matter of screwing the windlace back on with the carpet strips to hold everything in place.
For the seal above the lower hinge I used a section of T14 Ghia pillar seal and glued that in place.
Up top near the windshield I wrapped the remaining pillar vinyl over both the seal and windlace nicely finishing that area then shut the door which presses the seal in to the groove, will leave it like this for a while so the glue can set.
(https://lh5.googleusercontent.com/-0I-OfrDVbDI/U4AqU6PJxQI/AAAAAAAABSw/tOP0Yq8SqmQ/w685-h514-no/P1010823.JPG)
(https://lh6.googleusercontent.com/-iZNpS2-KLGs/U4AqiMpWT1I/AAAAAAAABUI/4e7UfLzN_aQ/w385-h514-no/P1010824.JPG)
(https://lh6.googleusercontent.com/-YQG6af7rCPQ/U4AqiFIBHCI/AAAAAAAABTA/MbKYwVsYZ4A/w685-h514-no/P1010825.JPG)
Repeated the whole process on the other side and slammed that door shut as well, believe it or not installing these silly 2 seals look all morning!
You kinda stand back and go, wow is this all I did this morning?
I put the rubber and trim on the rear glass during the week so that was ready to go and wondered if I could get it installed on my own.........
Placed the rear window on the car and with one hand on the outside pressing the glass a little I just reached in with the other hand and started to pull the rope at the bottom of the glass.
I could tell right away that there was a good chance this was going to go in, worked my way round a little at a time and then used a rubber mallet to smack the glass to seat it in the frame.................easy  >:D
P.S don't try this on laminated glass...................you'll break it!
(https://lh5.googleusercontent.com/-IddfFLxYpI4/U4ArzJ2Yp5I/AAAAAAAABTs/ivtXA3Rt4UU/w685-h514-no/P1010835.JPG)
(https://lh5.googleusercontent.com/-Z60WBB446LA/U4AsB2T1KlI/AAAAAAAABT4/jAaDnrdgxMc/w685-h514-no/P1010836.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on May 30, 2014, 01:22:50 pm
Looking so good, I dribble with excitement over the quality and persistence with the classic!......well done!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 08, 2014, 11:40:36 am
Yesterday finally saw all of the windlace and B post seals completed, I shouldn't try to add up all of the hours gone in to making these and getting them to look as original as possible as it is a LOT but am supremely happy with the finished results.
With that out of the way I also finished the upper roof seals pretty much completing everything down to door level, I still need to get the vent frames chromed and some more plating done before the doors can be finished so in the meantime I'll move on to other jobs.
(https://lh6.googleusercontent.com/-KBKyPgY6aIM/U5KkItchgcI/AAAAAAAABVY/Haog_uIHJ7Q/w685-h514-no/P1010856.JPG)
Since I had freshly chromed tail light housings those were next on the list, first I rust proofed as much of the inner guard as possible which was easy enough to get to through the tail light hole.
Don't know how much it will really help but some is better than none in my book.
I know I've said this before but Simon's seals really are top notch as far as fit goes which was proved again with the housing to body seals.
(https://lh4.googleusercontent.com/-FYuI-_5Lx44/U5KjaK59UuI/AAAAAAAABU4/CrtnQ69jWQE/w685-h514-no/P1010852.JPG)
Here's the fun part of restoring a T34, parts not available?...... make your own!
Needing lens to housing seals I used some 3mm neoprene to make some, used the lens as a guide tracing around them and cut them out.
Not that easy to cut out free hand being that they are not very wide but then they are hidden once the lens is installed so it's not really that critical.
I had one NOS lens and one reproduction both looking as good as each other and certainly better than old faded ones.
(https://lh5.googleusercontent.com/-zoQC9NUH_Wo/U5KjZ7a7HBI/AAAAAAAABU0/2NTUDX_MwrY/w685-h514-no/P1010853.JPG)
(https://lh6.googleusercontent.com/-ajFJmujNwGE/U5Kjbi7F3II/AAAAAAAABVA/3OdvdMHZyh8/w685-h514-no/P1010854.JPG)
I'll wait for some templates to turn up before I continue with the carpet so I've moved on with mechanical stuff again finishing off susp and brakes as well as mounting the remote oil cooler which I'm getting a fan for today.
There's still plenty of money to be spent on the car but I'm trying to do stuff which I've already got parts for thus limiting outlay at the moment.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: DubMan on June 14, 2014, 06:58:22 pm
So excited I am.....that is just awesome
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 15, 2014, 10:42:22 am
Been thinking about what to continue with and since the interior is on hold for now while I sort out what to do with the carpet I've carried on with mechanical stuff on the chassis to hopefully get that completed.
All the bigger stuff is done but there's tons of little things to sort through like external oil cooler which I did yesterday.
Bought a 96 plate oil cooler ages ago which I fitted a fan to yesterday, I also converted the cooler from 1/2 pipe threads to 1/2 BSP so that I could use banjo fittings which makes for a much neater and more compact unit.
(https://lh5.googleusercontent.com/-BldHsDoxR68/U5vbd57y7YI/AAAAAAAABV8/hA0zD1TvC04/w685-h514-no/P1010862.JPG)
I had planned to use an external filter mount and then use a thermostatic sandwich plate for the oil cooler, instead of placing the thermo switch for the fan in line (which looks quite messy) I just drilled / threaded the end of the inlet banjo bolt on the cooler and installed it there.
I wanted a simple clean looking filter mount which I'm happy with but took ages to make but then good things take time!
Probably more so time consuming is to only try and use existing holes to mount things, easy just to drill a hole but I didn't want to do that here.
The location should work well for the oil lines coming from the engine as well as those going to the cooler but I won't know for sure till the engine is in.
(https://lh5.googleusercontent.com/-8i67gCkNpCE/U5vbXKzVBZI/AAAAAAAABVs/mjtTbFWoubk/w685-h514-no/P1010863.JPG)
To mount the cooler I used the upper stress bar between the shock towers and sat the cooler on top of it, at the moment I have the fan setup to pull air through the cooler which I could also add a scoop to from underneath to direct air to it.
Quite a simple solution in the end which just needed a single mount at the rear to hold it in place.
Certainly seems like there's a whole lot more room under there than on a Beetle but I'm sure the exhaust will still be tight.
(https://lh4.googleusercontent.com/-s3ttTxpkXog/U5vbaEIAO_I/AAAAAAAABV0/7aQFNiTXnTI/w685-h514-no/P1010865.JPG)
Those parts mounted I just ran the oil lines back to the sandwich plate, once I blast the bumper irons I'll powdercoat the brackets I made as well.
Next i'll have to find a non intrusive place to run a couple of fuel lines which might be along the pan edge or through the tunnel........dunno.
(https://lh3.googleusercontent.com/-Nk0-HOHF7jI/U5vcFPWLUNI/AAAAAAAABWU/fxBqrMnPilc/w685-h514-no/P1010868.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on June 15, 2014, 01:34:49 pm
you will ahve to rename this thread John, "Once were rustbuckets"?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 22, 2014, 11:58:55 am
Thinking about what to do next all week and since we have some powder coating to get done for work on Monday it was a great opportunity to get my engine tins and bumper brackets done at the same time.
By the time I'd gathered up all of the parts to be done black I ended up with quite a pile of parts to be sandblasted so I spent a big part of yesterday standing behind the blast cabinet hunched over blasting parts which my back is paying for today!
With a few mods I made the blast cabinet works awesome, mainly the fan on the back to suck the dust out is the biggest thing, when the sand has been recycled to many times even the fan can't cope with the dust so then its time to change the sand.
(https://lh5.googleusercontent.com/-NxhHT_gb2TM/U6UWxmrpA1I/AAAAAAAABW0/Y-1UPrDFgXo/w685-h514-no/P1010874.JPG)
The dual port tinware I got for this motor was beaten to sh*t so there was quite a few hours of knocking those pieces back in to some semblance of straightness as well as welding up the plethora of cracks everywhere.
Made sure to test fit each part at which time I discovered that the motor would end up being to wide to fit the car and never having had a Type 3 I didn't know what was the normal thing to do to fit a dual port in an early body so rather than mess with the body itself I've modified the cylinder tins instead by chopping a section off them and re folding the edges.
In all I have about 20 parts blasted and ready for powder coat, still to decide what to do with the fan housing but that will also need blasting and maybe silver or clear coat.
I'll pull the motor apart now and swap out the cam so that I can finally dial that up and at least send out the engine internals for balancing.
(https://lh5.googleusercontent.com/-BzmmuVKM0-I/U6UWx_WIQfI/AAAAAAAABW4/_uFvGcgm1Xk/w685-h514-no/P1010875.JPG)
(https://lh6.googleusercontent.com/-c8WSUxbznvs/U6UWxHyQRqI/AAAAAAAABWw/orIrKbygG4Y/w685-h514-no/P1010876.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 06, 2014, 10:42:44 am
Felt a little under the weather yesterday so not much got done, the combination of a blocked up head and hunching over gluing carpet didn't really do wonders for making me feel any better but we are a little further ahead again.
My local trimmer bound all of the carpet sections I made last week so I only have the tunnel, pedals area piece and rear wheel arches to make which I'll hopefully be able to cut today.
Tried to save the original rubber pieces from the old carpet but they are too far gone and brittle to be of any use unfortunately.
I'll look in to some sort of underlay for the main carpet as I'm not really that fond of dynamat for floors.
Years ago I used a foam type of underlay which is two layers of foam with bitumen between them, good against sound and stops carpet sliding around.
(https://lh4.googleusercontent.com/-tzQOySy9ZkQ/U7eWJGcwEpI/AAAAAAAABYw/s8TxfdXy6bk/w685-h514-no/P1010893.JPG)
(https://lh5.googleusercontent.com/-djjdaqrvNW8/U7eWKzKWU3I/AAAAAAAABY4/PD1YMO33Eb0/w685-h514-no/P1010894.JPG)
(https://lh3.googleusercontent.com/-w2xffOsUJ0k/U7eWMP2Lt0I/AAAAAAAABZA/h1ineWGTDxQ/w685-h514-no/P1010895.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 13, 2014, 11:27:42 am
Picked up the last few pieces of carpet from the trimmer completing all of the binding, didn't manage to get out during the week to source any underlay so yet again can't fully complete the carpeting.
Getting a little tired of working on the same thing over and over but it has to be done how I want it so it takes as long as it takes.
When I replaced the floors I added a lower seatbelt mount as I wanted modern retractable seatbelts from the start so now that it's all together I find out I screwed up the placement of the mount D'OH!
The mount is too far back on the pan leaving too little room to mount the roller which really pissed me off, not cutting it off now so figure out something else.
In the end I made a nice bracket which turns the roller 90 deg mounting it against the back kick plate instead of in line with the heater channel.
Looking at it now it's way better and works way better as well compared to how I had first intended it.
The upper mount is an M24 thread so had to make an adaptor to take that down to a modern M11 bolt, seatbelts done!
Next on the list will be to make new interior quarter and door top pads so that should be quite interesting I think, got a plan in my head so we'll see how that works out.
(https://lh3.googleusercontent.com/-XhpvS214Nb0/U8DKKuVZbSI/AAAAAAAABZw/_YEos5BBjdk/w635-h477-no/P1010922.JPG)
(https://lh5.googleusercontent.com/-qzNtm23rkJk/U8DKJXTE-ZI/AAAAAAAABZk/WV9O8MBw6Bc/w635-h477-no/P1010923.JPG)
(https://lh4.googleusercontent.com/-fY7RcoVPuMI/U8DKKOiQ3WI/AAAAAAAABZs/l98DIK2UVRA/w635-h477-no/P1010926.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 26, 2014, 10:25:18 pm
Been thinking about the next step for a while now and keep changing my mind about how to do it as well as collecting materials for the job.
I found grained dashboard vinyl quite some time ago but in order to do this properly like the factory did it I would need a vacuum table to be able to vacuum form the vinyl over the parts.

Vacuum table is the easy part which I started last weekend, MDF being cheap and easy to cut became the material of choice.
Made a table big enough to also make and cover a dash when I get that far, just have vacuum attachments to install and seal the thing up.
Will then have to make a frame to hold the vinyl sheet and some sort of heating system to heat / melt the vinyl.
Not much information out there (probably no one dumb enough to have a go) on what glue to use, seems to be heat activated which so far I have not found here.

Didn't really feel like more wood work this morning so I moved on with getting more parts ready instead, I did make one of the metal rear 1/4 pad backers some time ago and since all 4 are rusted it seemed like a good thing to carry on with.
Making the other rear one was pretty simple and easy but the door ones are a little more complicated if you want them to look right.
To separate them from the covering was harder than I thought, a combination of rust and old garbage left behind...........why is everything on this car trash........?

(https://lh5.googleusercontent.com/--ZbhHAWBMt4/U9NBPAmCvJI/AAAAAAAABaU/R4nsASsTU0I/w635-h477-no/P1010942.JPG)
The front ones are also a different shape so none of my templates were any good, after what seemed like an age to finally get the correct curve I could work on the ends and try it on the door.
More trial and error later I had something which actually fits pretty well, drilled the holes for the trim also at that stage.
The original ones had 3 tabs which attach to the door under the door card which were easy to make and weld on, was pretty late in the day by now and time to call it quits while still ahead.
Have material cut for the other side which will be a lot quicker now that I know what to do!
(https://lh4.googleusercontent.com/-9BTQGGze4D8/U9NBPxyGKlI/AAAAAAAABaY/-lSmZdhwRGw/w635-h477-no/P1010943.JPG)
3 done, 1 to go.
(https://lh5.googleusercontent.com/-EIxDU38ytxY/U9NBO_-LHFI/AAAAAAAABaM/-EhCTNQHuns/w635-h477-no/P1010944.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on July 27, 2014, 08:12:31 am
I have said it before and I repeat, this has to be the best thread on VASK, great work
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on August 30, 2014, 07:31:48 pm
No updates of late John?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on September 09, 2014, 10:17:33 am
Vert is overseas at the mo.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on September 17, 2014, 04:52:55 am
In Europe for a few months, seems like every 2nd car on the road is a vw / audi / seat or skoda  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on September 17, 2014, 09:27:31 am
In Europe for a few months, seems like every 2nd car on the road is a vw / audi / seat or skoda  ;D

yup, spotted on a news link from Europe, a Passat CC taxi
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 05, 2014, 09:36:43 am
Boohoo holiday over and back to reality, Nordschleife was cool to see even though time was very limited but i'll be back there for sure as it really is the last bastion of freedom for petrol heads.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on November 29, 2014, 08:51:53 pm
Any updates John?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 30, 2014, 02:43:16 pm
Nothing further, some big changes recently so been pretty busy with that but will be back on it pretty soon besides I keep collecting more parts for the 964 so want to start on that as well.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 24, 2014, 07:55:41 pm
Managed half a day on it today and got the latches on the deck lid which I've wanted to finish for some time but a few of the parts were not plated yet.
Everything opens and closes now which is just another little step forward, the window regulators were quite rusty / seized and plating them has removed most of it when they were acid dipped but they were still quite difficult to wind up and down so I used some WD40 to get them freed up then grease / oil lube on all the joints which has done wonders for them.
Did a dry fit on both doors to figure out all the fastners and sort out the best chrome pieces I have.
Unfortunately I'm at a stop with the doors again until I find a solution to the vent glass seals, I thought I had it figured out with a 68 on Beetle convertible seal which I cut / joined to fit the frame.
It looked pretty decent but it's just too thick to work, not going to work good enough for me to be happy with.
Back to the drawing board........
(https://lh3.googleusercontent.com/-zzelKGZ1ReQ/VJpZ7vf4czI/AAAAAAAABes/m9d13DQQUmc/w958-h719-no/P1010991.JPG)
(https://lh4.googleusercontent.com/-kPPBTWjWtls/VJpZ7BlD1WI/AAAAAAAABeo/eYY-gXxQ7U4/w958-h719-no/P1010992.JPG)
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: dubstar on December 24, 2014, 09:26:03 pm
Have you seen this document:  http://www.leehedges.com/t34/puret34/partssource.pdf
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 24, 2014, 09:47:15 pm
I sure have but the vent glass seals have not been available since Adam was a cowboy, helpful list though which I've used extensively.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 28, 2014, 04:07:39 pm
Ok, HEADLIGHTS........these have been a problem for a while and here's my solution at last.
My car obviously has had someone " playing " with it over the years and had fitted sealed beams to semi sealed rings making any form of adjustment impossible.
Due to the unobtanium nature of T34 lights plus the complexity of us being RHD making them rarer than rocking horse poo I decided to look at what could be done.

I had 7" Bosch and Hella H4 lights to look at already form my various Superbeetle's as well as MK1 Golf but of course in VW's infinite wisdom they used a 6.5" light on the T34.
Both the Bosch and Hella are a true 7" on the glass lens so they were never going to work, after looking at a bunch of options I came across a Wagner 7" H4 halogen (RHD Part#7019SS) but in actual fact the glass lens itself is very very close to being a 6.5" making it perfect for the T34 and this is where the fun begins.........this is the as bought light
(https://lh5.googleusercontent.com/-n9iaByql6qU/VJ9qvmipEiI/AAAAAAAABgQ/2TLR3ZTVaww/w958-h719-no/P1020006.JPG)
Of course they were never going to work as is but parts of it would be perfect like the H4 RHD glass lens so I carefully went about cutting the lights apart separating the lens from the reflector and then realizing I could modify the reflector as well to make them in to a semi sealed type of deal.
With the glass lens off I flattened out the rest of the reflector rim and cleaned off all of the urethane.
The rim would end up being big enough that once folded over I could install the rubber adjustment bushes from a donor set of T3 lights.
(https://lh3.googleusercontent.com/-dbRpelyG-FM/VJ9qww0S8gI/AAAAAAAABgg/rU7t2vSftVw/w958-h719-no/P1020001.JPG)
I made a curved piece of steel and welded it to the bench to help hammer the edge back over but on the 2'nd one I do I'll first shrink the edge which will make it a lot easier and neater.
I also used the adjusters and adjustment holder ring from the T3 light but due to this being for a 7" lens a piece must be cut out of it to make it smaller which will then fit the new H4 lens and will then also fit in the headlight bowl of the body.
The next bit is quite tricky lining everything up and making sure things are the right way around, once I was happy with that I marked out the reflector rim and drilled the holes for the rubber adjuster holders.
Trial fit the new parts in the existing T34 adjuster ring and things start to look positive.
(https://lh5.googleusercontent.com/-av3FKfWo24Q/VJ9qFdremLI/AAAAAAAABgI/9lYs5eLrRbQ/w958-h719-no/P1020002.JPG)
(https://lh6.googleusercontent.com/-MJ38al-Poeo/VJ9qD-Zp12I/AAAAAAAABgA/TC3Gwt_mu2k/w958-h719-no/P1020003.JPG)
The factory clips hold the glass lens and adjustment ring to the T34 outer ring just as intended but enabling me to have H4 halogens in RHD with normal adjustment also eliminating the hassle of converting my turn signals to having park lights added as the "new" reflector has already got a park bulb in it.
Still a bit of faffing around to make it all work 100% but this is certainly going to solve my headlight problems in one hit and of course the same thing can be done for LHD as well if you are stuck with incomplete lights like I was.
last thing today was a quick mock up in the car confirming that it will work and one more to make for the other side.
(https://lh5.googleusercontent.com/-cqVskGMiZFs/VJ9qDQI-9AI/AAAAAAAABf8/4g3OK4kd3Z0/w958-h719-no/P1020005.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RobClubley on December 28, 2014, 05:40:59 pm
Amazing, as always!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on December 28, 2014, 06:00:00 pm
You could sell them to t34 owners as remade units. Will the cert guy have to know about this... ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 24, 2015, 10:08:51 pm
Everything seems to get in the way of progress these days and really staring to wonder if this thing will ever get finished but at last had some time for the Ghia today, not much visible progress but it's another step closer.
I literally spent hours trying to fit the seals between the body and headlight ring before finally giving up and gluing them on the rings with superglue, not my preferred choice but it will have to suffice as they are a right mongrel to get sitting right.
Assembled the left headlight as well and trial fitted it, still have the wiring to finish but within reason that should be it for the lights.
(https://lh4.googleusercontent.com/-b51NnWUKZ_A/VMNIK9ZxhlI/AAAAAAAABhk/X65ShjhBWW4/s640/P1020035.JPG)
Now that everyone is back from holidays I'll get another lot of parts off to the chromer which includes all of the fog light parts.
Pretty much forgotten how the doors went together so that's what I sussed out this afternoon, fitted the vent frame, regulator and door glass to see how it would all work out.
Not 100% happy with the fit of the door glass but I've adjusted it as best as I can so I'm just gonna have to live with it.
Have come to realise that nothing is perfect in this world, especially when dealing with old cars.
Not many people seem to share their knowledge on T34's so you just have to figure it out as you go which gets quite frustrating at times.
(https://lh3.googleusercontent.com/-fzB1HP7uyTs/VMNISIof6pI/AAAAAAAABh0/L6tDoK_hOB4/s640/P1020037.JPG)
(https://lh3.googleusercontent.com/-i7LnB9wNhfs/VMNISLAvlDI/AAAAAAAABhw/x2VjbucRocs/s640/P1020036.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 28, 2015, 06:55:00 pm
Most of you have probably given up on me getting this thing done but I can assure you that the project is not dead............yet.
Had a few more things chromed and as usual am pretty disappointed with the finished job, we just don't seem to get good trades people here who give a damn about what they do.

Also to be fair I guess a big part of the problem is trying to make something good from 50 y/o knackered pitted pot metal parts so maybe it's my fault for setting the bar so high.
Anyway part of the chroming was getting the fog light reflectors re silvered and since the outer rings were done in the last lot I set about putting those back together.
Sill need to figure out what to do about a bulb as the 6V bulb holder seems quite a bit bigger at first glance, hopefully a 12V bulb of some sort will fit in there.
(https://lh4.googleusercontent.com/-2r6iiaTIZqM/VPFJV_GkJpI/AAAAAAAABjA/uPVR73JgTUY/w630-h472-no/P1020067.JPG)
Getting these back together along with the RH indicator unit gets most of the light related parts sorted out with minor bits like bulbs and some wiring to sort out to finish it all.
Found some used vent glass seals which are good enough for now to put the doors together till something better comes along at which time i'll change them out again.
My carpet underlay also arrived from Australia so once again I have another problem sorted and the carpet can be completed, it's been a while of doing very little but have enough enthusiasm back to carry on.
(https://lh5.googleusercontent.com/-lSHdRz9_aLg/VPFJWp-W5pI/AAAAAAAABjI/XrkiGY04TvU/w630-h472-no/P1020068.JPG)[/url]
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on February 28, 2015, 07:23:19 pm
What was the underlay you found?
Nothing here I guess. Formans deleted the foam/bitumen stuff.

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 28, 2015, 07:32:14 pm
I found or should say Dubstar found the bitumen type stuff in Australia which is the same as what I had back in the day from Forman, he kindly brought some over for me which was awesome and wish now I'd got some more for the Porsche.
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: dubstar on March 02, 2015, 05:55:00 pm
Will be back over again soon.

Here is the seal place I mentioned.  Maybe they could match a profile

http://www.scottsoldautorubber.com.au/catalogue.htm
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 09, 2015, 05:30:20 pm
Yesterday I thought i'd have a go at attaching the door and 1/4 panel welting, correct P profile welt arrived from TMI late last year and looks to be quite nice if not a fraction smaller than original.
Decided I would glue and staple it on to make sure it stays where it is supposed to be, once attached I test fitted the door panels to see how they would look and also attaching them to the door will keep them flat.
I love how they came together and the edging just adds the finishing touch.
Must get on to finishing my vacuum table to cover the door and quarter tops which will be the final part to complete the doors.
(https://lh5.googleusercontent.com/-j8VNOj5Y1Yc/VP0d58V6W5I/AAAAAAAABkg/tfGFaTuPFzU/w958-h719-no/P1020087.JPG)
(https://lh5.googleusercontent.com/-A3sX0rH1R4Y/VP0d3hALMOI/AAAAAAAABkU/m9imEn2MKgM/w958-h719-no/P1020088.JPG)
(https://lh4.googleusercontent.com/-ldKVKKFP1ds/VP0d3yj1w-I/AAAAAAAABkY/y9Li7GK4U-k/w958-h719-no/P1020090.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 15, 2015, 09:53:11 am
The time has come when I can't put off dealing with vacuum forming any longer, on top of that I HATE wood work especially that sawdust and glue rubbish MDF so a double whammy there but yesterday I got in to making my vacuum table so that I can have a crack at covering the door and 1/4 top pads.
Drilling several 100 holes was a tedious process as well, had a lot of trouble getting the basic box together as you can't really nail or screw MDF as it just splits apart so blocks of wood was the answer there which worked ok.

I made the box large enough to do the dash tops as well when those are ready and for smaller pieces I can just block off half of the table top, once the box was done I stood back and realized that I'd made it way taller than it needed to be so got the skill saw out again and cut 2/3's off it getting it to the height which should work ok.
Also put in a couple of supports down the middle to support the top plate as it might otherwise cave in which I don't really need.
Made an attachment for the vacuum cleaner and sealed the joins with aluminium tape.
Next up will be a frame to hold the dash vinyl and some thinking of some way to heat that up as it will be too large to fit in the oven, some challenges still to over come but that's what makes it fun.
(https://lh5.googleusercontent.com/-5t39cvZoxZI/VQSX0hTIfpI/AAAAAAAABlo/SJWfCiAvTug/w958-h719-no/P1020099.JPG)
(https://lh4.googleusercontent.com/-T-xQRHb5yRg/VQSXzf3ka8I/AAAAAAAABlg/629UCU9vRls/w958-h719-no/P1020100.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on March 15, 2015, 01:26:13 pm
rather than an oven, would working it with a heat gun be a possibility?  you could take it slowly to get a good fit as you work
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 25, 2015, 05:54:42 pm
Ok time to get serious and stop procrastinating over the door and quarter tops, I've spent ages researching various methods of vacuum forming but nothing really to be found about doing dashes.
There are a couple of videos here and there but nothing in any great detail so mostly as always has been guess work / learn as you go  :lol: 
I'd made a vacuum table a while ago but decided that was way too tall so I cut 2/3 of it off and sealed it back up.

Then a frame of sorts had to be made to hold the dash vinyl sheet and as always I over thought it making it quite complicated till a friend of mine suggested making a simple wooden frame and stapling the material to it.........Easy!!
Vacuum table sorted, frame sorted.............next problem heating the vinyl evenly.........looked at a propane torch used on roofing membrane but decided you have no real control with that and wouldn't heat sheet evenly.
Oil heater, not enough heat..........
More google searches later I came up with a radiant heater with a wooden box surrounding it lined with aluminum foil to radiate the heat upwards.
This I decided might work so started building the box...
(https://lh5.googleusercontent.com/-Lq3arIRlI-w/VTshtDinuzI/AAAAAAAABm0/w2i5XdafpbY/w958-h719-no/P1020129.JPG)
(https://lh5.googleusercontent.com/-uf-O-9EVtck/VTshl9ux7tI/AAAAAAAABmk/HsY_MXrWfVM/w958-h719-no/P1020131.JPG)
With the box built and material stapled to the frame for the first time I had the thought that "holy sh*t this might actually work!!"
I did the rear 1/4 pads first and they were small enough to do both at once saving a bunch of material and not knowing if it was going to work I didn't want to waste too much of it as I don't have an endless supply.
I bought the material more than a year ago from the only place in the country I could find which sold it buying their entire stock.....which wasn't much in the end.
Set up the parts on the table propping them up a bit so that the vinyl would hopefully get sucked around the part a little.
Apparently heat activated glue is used in the process but again unable to find any I had to improvise so i decided to vacuum the material over without glue, then peel it off once cooled and glue it.............doesn't work that well..... :roll: more improvising required........
(https://lh5.googleusercontent.com/-6mbwf2_75TE/VTshnZxT9wI/AAAAAAAABms/QJH0qDsSdxE/w958-h719-no/P1020130.JPG)
Moment of truth, vinyl hot enough I figured and seemed pretty even according to the infra red thermometer so suck it up so to speak and give it a shot.
Placed the frame over the parts and pushed it down while switching on the vaccum cleaner, BOOM some sucky action later two covered pads  :lol:
Left the vacuum cleaner on a while till the vinyl had cooled some.
Not everything went to plan mainly I thing due to using closed cell foam over the steel substrate  and thinking about it now it makes perfect sense as air trapped under the vinyl cannot escape through the foam, but it worked well enough to do the job and on the front ones I make the holes for the trim in the foam which will help some overcome that problem.
(https://lh5.googleusercontent.com/-mUAyUGXLbhM/VTsiJa777jI/AAAAAAAABnE/2P4KMFIemdM/w958-h719-no/P1020132.JPG)
By now I'm feeling pretty stoked but that didn't last long as peeling the vinyl off wasn't that easy and gluing it back on was even more difficult.
The front ones will need to be glued at the beginning I think or at least I have to try it that way.
I worked around the whole thing folding over and gluing the edges and in doing so cut the bottom edge of the first one far too short but it will still be ok I think as its hidden by the interior quarter panel.
(https://lh5.googleusercontent.com/-0Gm4DCGoMUM/VTsiGxOe9rI/AAAAAAAABm8/EOiLZFd1q5Y/w958-h719-no/P1020133.JPG)
The second one came out a lot better, nice edge on the bottom to tuck under the quarter panel.
The material itself is a brown ish colour so it has to be sprayed to the colour of choice which of course is black, little glossy for my liking but maybe I can knock that gloss down a little..........we'll see.
Door tops next, have to modify the heating box for those two so didn't get to those today but Monday is a holiday so................
(https://lh5.googleusercontent.com/-SuM1GVL4jZs/VTsiU2WCD9I/AAAAAAAABnM/kNIxCPkR0wI/w958-h719-no/P1020134.JPG)
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Poonmobile on April 26, 2015, 02:47:46 am
Awesome John!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: weta.worker on April 26, 2015, 06:36:03 am
This is hands down the best thread on this forum (IMHO)  :police:
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on April 26, 2015, 08:39:11 am
This is hands down the best thread on this forum (IMHO)  :police:

Agreed. You would never believe this was the same car unless you read the whole thing.
Title: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on April 26, 2015, 09:07:34 am
Impressive!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Filx on April 26, 2015, 05:47:38 pm
Awesome work, making tools to make parts with - next level!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 26, 2015, 07:03:59 pm
Installed one today, not half bad I have to say.
I'm going to have a go at vacuum forming the door pads tomorrow and then on to making a new dash next weekend.
(https://lh5.googleusercontent.com/-FuiWokAk7YQ/VTwrC3CFdEI/AAAAAAAABnw/YlbN6IK3NOM/w958-h719-no/P1020136.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 27, 2015, 12:56:45 pm
Made a start on one of the door tops last night, rain outside and nothing on TV gave me a good enough excuse to head to the shop and play around.
First thing was to make the box longer to account for the larger piece of vinyl for the door tops, easily extended with plywood and covered again with aluminum foil.
I suspected that the one heater I had wouldn't quite cut the mustard with heat output to evenly heat the sheet..............I was right.
150 celcius seems to be the limit of this heater which for simple shapes like this is fine but anything more complicated will need another 50 deg of heat I think.
Since I had everything in place I tried heating the colder ends some more with a mapp gas burner which kinda worked good enough to cover one of the pads.
(https://lh5.googleusercontent.com/-E8s-Ccc8VQc/VT1_O2gZy6I/AAAAAAAABoU/c3NfRDGaf8c/w958-h719-no/P1020138.JPG)
To overcome the trapped air due to the closed cell foam I used I pre cut the trim holes in the foam this time before covering the door top so that the air could be sucked out through the little holes which seemed to work a lot better than the rear ones.
I don't know how well this glue will hold up in direct sun / heat but it's not like the car will be parked outside with the windows up for long periods of time so hopefully it will last.
With the part set up on the table and the vinyl struggling to get hot enough I wondered if I should call it quits and leave it till today but I figured I'm here now so I'll give it a shot, besides whats the worst that could happen right?
Well other than getting the frame not quite lined up meaning I didn't have as much vacuum as I could have it turned out pretty good.
(https://lh5.googleusercontent.com/-yrh6ISOwXqw/VT1_E-TvAnI/AAAAAAAABoI/P3rIWjtHhqg/w958-h719-no/P1020137.JPG)
(https://lh5.googleusercontent.com/-Oq-DGJoB-zk/VT2AQ09AnlI/AAAAAAAABo4/QT_qR3CYILI/w958-h719-no/P1020139.JPG)
Folding the edges over neatly is quite difficult, the originals are just trimmed off at the edge but mine I folded over to make extra sure this stuff stays on and clamping it to the door helps with that as well.
Spent a couple of hours gluing the edges and trimming the panel up, drilled the holes through the vinyl for the trim ready for a coat of black vinyl paint.
By now I'd had enough and left it alone to dry, which brings me to this morning.................I just have to have this installed TODAY you know!
(https://lh5.googleusercontent.com/-PI-yTtNiSM8/VT1_OBWSaEI/AAAAAAAABoY/kHg6Z40IUFE/w958-h719-no/P1020140.JPG)
Cleaned the panel with solvent and layed down a coat of black only to have it dry to a very dull spotted finish, weird..........was fine yesterday........
Suddenly thought that the weather today is a lot colder so I pre warmed the piece with the hot air gun and hit it again, BOOM success!!
Must have been the drop in temperature, who knows.
Vinyl paint is fast drying which suits me well, 30 min later on with the trim and install this sucker.
Nice fit on the door and in some ways seems to fit nicer than the factory ones, over all a great result and pretty much exactly what I needed.
On to the other side now but I'll first have to get another heater........
(https://lh5.googleusercontent.com/-DIU3K7L9oM4/VT1_pwmCb5I/AAAAAAAABog/QZus0LGRHpI/w958-h719-no/P1020141.JPG)
(https://lh5.googleusercontent.com/-6v8esvl1LFo/VT1_0GJYyiI/AAAAAAAABos/u7KToAsrXy8/w958-h719-no/P1020143.JPG)
(https://lh5.googleusercontent.com/-y925AwlpOB8/VT2AWdhLheI/AAAAAAAABpI/TWCHHkLQMfw/w958-h719-no/P1020142.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 27, 2015, 12:57:44 pm
Both parts installed, trim lines up and things look pretty straight, sometimes I amaze even myself.
One door top left to do then on to the dashes, that ought to be fun.
(https://lh5.googleusercontent.com/-6Yc1iQTdUY4/VT2HTBtshhI/AAAAAAAABpc/FZloyYjeJp0/w958-h719-no/P1020145.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on April 27, 2015, 02:29:06 pm

(https://lh5.googleusercontent.com/-lSHdRz9_aLg/VPFJWp-W5pI/AAAAAAAABjI/XrkiGY04TvU/w630-h472-no/P1020068.JPG)[/url]

is a bumper going to obscure this pretty nose, or might you install nerf bars for protection?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 27, 2015, 05:47:58 pm
Yep, bumpers with over riders. Waiting for Stainless ones to become available which will save me getting my pile of rubbish re chromed.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 30, 2015, 10:06:41 pm
Since the vacuum forming was a success I've been thinking about how I'm going to make the new dash pad this last week and I believe I've got a pretty good idea now...............lets see if it works.
I'm sure it won't be as easy as that but as long as there's a positive result i'm ok with that.

RH side completed minus a couple of small items, I don't know where all this enthusiasm has come from but I'll roll with it while it's around.
Door and 1/4 pads installed after rust proofing the entire 1/4 panel and door along with the rocker which also meant I could finally put the long trim on again, last time that was on the car it was completely beat to sh*t!

On a side note talking to Filx today about the fuel system and how our gas rots fuel hose very quickly especially on cars like this which sit around a lot so to over come this I've decided to run plastic lines for supply and return from a MK4 Golf GTI, hey they're free and still keeps it in the family.
With the clever clip together fittings they have they are already set up for a fuel filter and will flow enough for the 2.0 turbo.
(https://lh5.googleusercontent.com/-omyL_OI_Mj4/VUH6auy8GbI/AAAAAAAABqc/TGOzdGCMQnI/w958-h719-no/P1020152.JPG)
(https://lh5.googleusercontent.com/-h608gravyQ0/VUH6a74TTFI/AAAAAAAABqg/hgEBeD9aH70/w958-h719-no/P1020151.JPG)

(https://lh5.googleusercontent.com/-PsyumM8c8_g/VUH6bTLx22I/AAAAAAAABqk/aktw4gBF7RQ/w958-h719-no/P1020153.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on May 01, 2015, 06:22:59 pm
Raising the bar Mr K!
s**t that looks good! As close to a new KG as you can come!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: VW'n on May 01, 2015, 08:10:31 pm
Raising the bar Mr K!
s**t that looks good! As close to a new KG as you can come!

My moneys on Better then new.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on May 02, 2015, 07:21:50 am
To true.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: rambo_005 on May 02, 2015, 09:16:48 am
Looks amazing John; a long way from the first and last time I saw it, not long after it had arrived in NZ.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 03, 2015, 10:05:13 am
Dash top time, had a few ideas rolling around in my head as to how to attack this best and in the end went with none of them.
My original dash is completely poked, the inner steel support is completely rusted through and in one place the dash is completely broken in half.
Most of the hold down bolts are also broken off so there's little option but to make a whole new one.
My first thought was to make a new steel structure and then re use the foam pieces from the old dash but once I started trying to remove some of the foam the whole thing just began to disintegrated in to a pile of rust / rubbish on the bench.
(https://lh5.googleusercontent.com/-VC-NPtpIkAI/VUVDyA2gnqI/AAAAAAAABrE/bz03iDkd6Wc/w958-h719-no/P1020154.JPG)
(https://lh5.googleusercontent.com/-L37BusI7MVM/VUVD5cBp8_I/AAAAAAAABrM/J9G1bHNzWSk/w958-h719-no/P1020155.JPG)
In taking it apart I realised that there's more than just the steel hold down strip in there so that meant re thinking the whole thing anyway so I started by making a cardboard template of the steel dash to give me some idea of shape etc.
It's become pretty evident that I should have made the new dash when the body was still in primer, doing it now that it's painted is a royal pain in the a**
Soo easy to mark the paint and the car also isn't in the same work area but anywho that's life, I'll just have to deal with it.
My first attempt was to make the steel panel from one piece which didn't go so well so by lunch time that went in the bin and I started again.
This time 4 pieces worked ok, not the prettiest thing I've ever made but all going well it will never ever be seen again so I'm good with that.
In all it was a really difficult piece to make due to all of the curvature and making it from too thick panel steel (1.0mm)
Next job is to encapsulate the panel in PU Foam and start shaping it with a rasp till I get the shape I want.
(https://lh5.googleusercontent.com/-f5TxT42y2HQ/VUVD7sCR8yI/AAAAAAAABrU/O9yg66oqVNM/w958-h719-no/P1020156.JPG)
(https://lh5.googleusercontent.com/-aFXhwfHebXM/VUVEFf404DI/AAAAAAAABrc/Fy2JQXMtUdg/w958-h719-no/P1020157.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 03, 2015, 04:00:29 pm
First foam pour on to the metal backer, this might actually work!
The 2 part PU foam sands super easy with 36 grit paper leaving a nice smooth surface to which I'll glue some closed cell foam and then thermo vacuum form the material over it.

I can see getting the shape right will take a little time but the profile gauge will come in handy there.
Have the dash on the bench again now having done the next pour on the under side.
(https://lh4.googleusercontent.com/-jQb969iLp2M/VUWb1RkOTaI/AAAAAAAABr0/v20ES3aVw90/w632-h843-no/P1020158.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 09, 2015, 05:46:09 pm
No time for the Ghia during the week so had to wait till today to start shaping the dash top, good thing is this 2 part pourable foam is very easy to work with and sands really easy with 36 grit paper to rough out to shape then finish off with 80 grit.
Got most of the shape dialed in pretty quickly to the point I could mount it in the car to see where it was at, shape around where it folds over the metal dash was a little tricky to get right but the closed cell foam will also smooth some of this out.
It seems to fit pretty well and looks the part, I've just applied one coat of epoxy resin to protect the PU foam and also to make the whole thing a little more sturdy.
(https://lh5.googleusercontent.com/-rHtQsSJn9gA/VU2bzm_msxI/AAAAAAAABsY/qvNqAfytjnM/w958-h719-no/P1020178.JPG)
(https://lh5.googleusercontent.com/-tB0tXIhWHmE/VU2bp14ONTI/AAAAAAAABsQ/AJH0cWbe8oo/w958-h719-no/P1020177.JPG)
Its quite a messy affair as you can see from the crap on the bench and had to do several extra foam pours in places where I came up short.
The great thing about the PU foam is you can just mix how ever much you need right down to very small quantities for working on small areas.
Dash mounted in the car and looks to be fairly even and straight in all directions ready for a coat of epoxy resin.
(https://lh5.googleusercontent.com/-0XC6VrdXJTA/VU2b2J5Au2I/AAAAAAAABsg/DifinQrvJRo/w958-h719-no/P1020179.JPG)
(https://lh5.googleusercontent.com/-y3YKpF8ShZs/VU2b_FebtbI/AAAAAAAABso/ouyR2lkWbk4/w958-h719-no/P1020180.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on May 09, 2015, 05:48:40 pm
looks brilliant
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 15, 2015, 09:30:42 pm
On to the lower dash, not in bad shape all things considered with one large crack but the vinyl is very brittle due to old age and sun damage so I'll try to remove the vinyl and repair this one.

Its also shrunk some over the last 60 years but most of it will be salvageable I think, plan is to repair the foam where it is very porous and extend the edges where it meets the steel dash as that's where it is a little short.
Once done I'll also cover this with a new layer of 3mm foam before vacuum forming a new cover on.
(https://lh5.googleusercontent.com/-W3SB2tey94I/VVW7bRvubAI/AAAAAAAABtg/5TF1a4uBQT0/w958-h719-no/P1020183.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 24, 2015, 07:23:15 pm
Next on the list was to make a new strip of dash vinyl to hide the painted dash along the window edge, since I still had the original it was easy enough to copy it and make a new one from the same grained material as the door tops.
Had to heat it to be able to curve it in the corners and actually made it in two pieces since my roll of material wasn't wide enough to do the whole thing in one go, coat of black vinyl paint and glued it in place.
By the time i'm done I could probably write a book on restoring this car!
(https://lh5.googleusercontent.com/-XRab0NO2gg4/VWFodblLgeI/AAAAAAAABv8/eDQBDA-inp0/w958-h719-no/P1020197.JPG)
Bought another heater during the week which meant I had to make my box and vinyl frame longer again to be able to do the dash tops, that was yesterdays work along with getting everything ready and set up again for what hopefully will be the last round of vacuum forming.
Early this morning I decided to have a shot at doing the lower dash and to be honest  was pretty nervous as you really do only get one shot at it.
Things didn't go all that well as it turns out and in hindsight I should have gone about it differently but what's done is done.
The vacuum has such force that if the item is not supported correctly it will distort under vacuum which is what happened here, not much I can do about it and after a few hours of corrective work I at least have it in the car.
I'm far from happy with the finished result but I'll live with it for now, all bolted down it looks ok enough.
Probably more because I know where all the problems are but when you consider what most of us T34 owners start off with its not all bad.
Decided against doing the dash top for now, I'll think more about how I'm going to tackle that as that really does have to be right.
(https://lh5.googleusercontent.com/-PxuMkopZqv4/VWFoUHF9_PI/AAAAAAAABvs/iAh22j1shs8/w958-h719-no/P1020198.JPG)
(https://lh5.googleusercontent.com/-jsWYX2Y48zA/VWFociDnAUI/AAAAAAAABv0/LMZadrvtyEA/w958-h719-no/P1020199.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Fizz on May 25, 2015, 10:21:30 am
Amazing work as always John  ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on May 25, 2015, 01:57:07 pm
this car will be a stunner when it's finished, awesome John  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 13, 2015, 10:27:30 pm
Been sourcing and waiting for a few of the little parts needed to finish off certain jobs on this, some parts are better than others as per the norm with aftermarket stuff and usually you have no choice so what's available is all there is.
I was pleasantly surprised with the interior light from Stoddard, looks really nice, on the flipside the interior finger guards from KGP&R are absolute shi#te but with modification they just work and were cheap so...........
After a few weeks break from vacuum forming I decided today was the day to get er done so to speak and put this process to bed, at one point I was close to ripping it all off and starting again but managed to save it through perseverance.
Ran out of vinyl paint so that wasted a good couple of hours finding some more as I was determined this was going to get done today!
(https://lh6.googleusercontent.com/-cumOzky3GX0/VXvEP_rkAJI/AAAAAAAABxA/UjTpApxdNRo/w599-h449-no/P1020204.JPG)
From here there's a couple of hours finishing off wrapping the vinyl over and gluing down / trimming edges etc.
Not half bad after a coat of black! Paint was barely dry and the dash is in my hot little hand on it's way over to the car to mount this sucker.
Pad bolted down completed another step in the interior, also installed the glove box which amazingly was good enough to go right back in after 52 years of service.
Scott's awesome glovebox decals were next, man are those things fragile!
All went well though but a lot of care and patience needed...........patience is not my strong suit..........
(https://lh6.googleusercontent.com/-FnDqOyg5pgk/VXvEOzBo7SI/AAAAAAAABww/joRKaAX3GUY/w599-h449-no/P1020205.JPG)
Last thing for the day I had a go at installing the windscreen by myself as there was no one here to help, the rubber doesn't want to stay on the glass too well but once you install the trim it seems to tie it all together.
A trick I've always used to make sure the rubber seals is to spray a rust preventative like Tectyl on the outside edge of the glass  and then install the seal, with the seal on I again spray the Tectyl on the rubber itself and on the window frame then install the glass.
The screen went in easy as, started seating the rubber at the bottom using the weight of the glass pushing down and once the whole lower lip was seated I gave it a good bash with the palm of my hand, then worked my way up each pillar with one hand pushing from the outside and the other pulling the rope.
Final stretch along the roof meeting in the center it was in, a good number of slaps seated the glass in place and hopefully it seals.
The only hassle with the rust preventative is it gets on everything and everywhere but once cleaned the result is awesome.
I always find that a project feels like its turned a corner once all glass is in and certainly today was one of those days, more parts off the floor / shelves and back on the old girl.
I'm quite amazed how good a shape this 50 year old glass is in, sure there's some de-lamination and a chip or 2 but still pretty damn nice, imagine trying to get another one.... :o
(https://lh6.googleusercontent.com/-hnBjB4Aidog/VXvEoJ4qVnI/AAAAAAAABxI/qyE3ft2ptnA/w599-h449-no/P1020207.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 21, 2015, 05:42:24 pm
The new heater hoses also arrived during the week which meant I could finally finish those off as well, the sizing is pretty good with the outside diameter being a little smaller than original.
Another fail on my part was the metal retaining straps being that these hoses actually use the larger of the 2 sizes used on the T34, good thing I have some coming from overseas.
Starting to come together at last, detail pieces take forever.
(https://lh3.googleusercontent.com/-9uWBdtmQrzk/VYZFsjSbhpI/AAAAAAAABzw/RzXXO_XMOtY/s912/P1020243.JPG)
So the last couple of weeks I've been working on a tach as a side project, since there's little to no information out there once again here's my take on it figuring it out as I went.
Started off with a Bieber 8k rpm tach my Dad gave to me recently, he'd kept it from his days of screwing around with cars. I figured it to be 70's vintage but when I took it apart it had Marz 66 on the inside.
Not knowing if it even worked I wired it up to the coil on our forklift which was the easiest thing to get to and seemed to work fine.
Great! now what..........can't install it as is  ;D, I want it to  match the other gauges obviously soooooo..........
I also ended up with an early T3 clock from a local T3 guy to donate the dial plate and backing plate, ring which holds the lens and the chrome bezel.
First I cut the back off the clock housing leaving me with a ring which by sheer fluke the Bieber housing was a tight fit into so all I had to do was measure how deep the housing needed to be over all and cut the clock housing to length.
(https://lh3.googleusercontent.com/-vR3vxvpV45o/VYZEibujxOI/AAAAAAAABzc/iDBMHmvQXys/s912/P1020223.JPG)
With the depth set I drilled new holes in the clock face, backer and mounted this to the tach movement, it was at this point I noticed a big problem with my plan.................the tach needle does not sit in the center of the face, rather off to one side so the center hole needs to be a lot bigger for the tach sweep. Never mind I'll worry about that detail later!
By now I have too much time invested to turn back.
Mount all of this back in the new housing and used the stepped trim ring from the T34 speaker grill as well as salvaged the brass plate and button from it.
Test fit everything together, looks ok so far.
(https://lh3.googleusercontent.com/-Cc5PKoAxZsE/VYZEkVKBQsI/AAAAAAAABzk/GLvU9hUhtvA/s912/P1020212.JPG)
(https://lh3.googleusercontent.com/-ApfUDK0UxFk/VYZEg7YLtpI/AAAAAAAABzU/HXloMDQKEHU/s912/P1020224.JPG)
Machined the clock face out by hand with a die grinder to be able to clip the brass plate in as well as cut a clearance for the needle to sweep around leaving a little material at the base between the stops. I had to re bend the needle at this point to raise where the bend was to clear everything.
Incredibly fiddly doing this by hand but what else can you do.......
(https://lh3.googleusercontent.com/-4k4W8uFZXhk/VYZGarAJS_I/AAAAAAAAB0A/RR0t_Bn6n8Q/s912/P1020244.JPG)
So at this point I just needed a new lens which I cut from clear perspex and ground to shape, drilled a hole in the center to mount the brass button.
Still to make the tach face which will require some photoshop trickery before that can be printed and then strip everything to paint all the components for final assembly.............and hopefully it still works!
(https://lh3.googleusercontent.com/-aDO-JzIvQNc/VYZGZ7ImxkI/AAAAAAAABz4/Jn6DMc-Yrpw/s912/P1020246.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 05, 2015, 11:31:43 am
Went and collected my newly rebuilt K24 Audi turbo from Steve Murch at MSE turbos NZ, its the last piece needed for getting the engine underway.
Hope to assemble the long block first and install it so that I can get a better idea of where everything will go, with some luck I can incorporate a small intercooler somewhere but we'll have to see if there's room.
Most of the fiddly interior stuff is done now apart from the seats and tach so i'm going to move on to doing mechanical and sorting out the fuel system next.

(https://lh3.googleusercontent.com/-ycIneeDH8aw/VZhrRYuRUWI/AAAAAAAAB1Q/bb0C9QYrfLM/s800/P1020260.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 12, 2015, 11:47:00 am
Made a start on the fuel system and couldn't believe my luck or lack there of!
Before the tank was cleaned and epoxied I welded on a threaded plug for the fuel return line and now that I've come to make fuel lines I discovered that it is in absolutely THE worst place I could have put it on the entire tank!  >:(

It turns out that it's directly above the steering damper so nothing works, not a 45 deg, a 90 or straight NOTHING!  :roll:
Have to make something, made 2 custom fittings which give plenty of clearance to the steering damper and allow the use of Golf plastic fuel lines which A) are free and B) won't rot like rubber.
Also using a Golf fuel filter and if I'd really thought about it could have used a Golf in tank pump as well but I'll use a normal external EFI pump so that the tank remains stock looking from above.
I have several lenghts of plastic fuel line which hopefully will be enough but there's plenty of wrecks around to get some more from.
The fittings are really nice too, o ringed and just clip together so no hose clips required.
(https://lh3.googleusercontent.com/-mTHzT5hvCgM/VaGmqGWdQrI/AAAAAAAAB2I/PWCtUGm2Bzc/s800-Ic42/P1020272.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on July 22, 2015, 09:23:42 pm
 8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 26, 2015, 05:54:24 pm
Finally managed to get an Walbro EFI pump during the week to be able to complete the fuel lines, its much much more difficult to add these kinds of parts without cutting or modifying the original car and making it look like they are supposed to be there.
I don't know why exactly I'm bothering to do it this way but basically it means that everything can be unbolted and returned to standard if I ever desired to do that.
I've run the supply line between the body and pan edge on the left side and the return on the right side, both are completely hidden from view and fully protected.

Made a mount for the pump which bolts up to the inspection plate at the front of the tunnel which also means a very short supply line from the tank.
Since I'm using modern FI components I'll also use a charcoal canister for a closed loop system, I would have had to run an extra hose to the rear but since the original fuel line is still in the tunnel that will do nicely!
All I have to do is connect the tank vent to the hard line at the front and the charcoal can to the hard line at the rear plus a hose to the engine for vacuum.
Bit hard to see but pump mounted in rubber mount between the beam and frame head.
(https://lh3.googleusercontent.com/-Te5XZ4jqVXE/VbRxxSvwzoI/AAAAAAAAB2k/PI-8WAcqMQM/s800-Ic42/P1020305.JPG)
(https://lh3.googleusercontent.com/-QBt6S30R4mE/VbRxqu6rBsI/AAAAAAAAB2c/443xw6WqB_k/s800-Ic42/P1020306.JPG)
Decided to put the fuel filter at the rear mounted off one of the subframe mounting points on a custom bracket, easy to get at and well enough protected from everything.
Motor build is looming even though I'm not feeling it, anyone keen to come over and build it for me??
(https://lh3.googleusercontent.com/-ZEwz-ee4-MU/VbRx0zRNKoI/AAAAAAAAB2s/_xdlE7VSmr4/s800-Ic42/P1020307.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 09, 2015, 06:33:35 pm
Wiring on old cars is funny compared to modern stuff, just shows how far automotive design has come.
A couple of stumbling blocks getting things working but mostly was just bad earths on a body which has had every square cm painted and not something the factory did very well so plenty of bare metal left exposed.
Good to see lights on and various things working after being sitting dormant and in pieces for 5+ years.

The 6V horn relay didn't like 12V going through it so I replaced it with a horn relay from a MK6 Golf, amazingly still the same pin outs on the Golf part 50 years after the Ghia was built.
The horn gave me a good run for my money though, 6V wiring differs from 12V so after changing that it still didn't work properly and I ended up taking the entire colum apart to figure out why, cut a long story short it was an epic fail on my part when I installed the colum the bolts were too long which touched the speedo housing in turn grounding the colum to the body.
Took me a while to find that but now that those are shortened it works like it was supposed to.

Good thing about taking the colum apart I painted the steering wheel boss black to match the colum.

Wipers will be next, I'm installing a variable rheostat between the fuse box and wiper push button so that I can regulate that to 6V give or take meaning that as far as the push button and wiper motor are concerned the system is being supplied 6V instead of 12V so there shouldn't be any harm done to the variable speed switch.
Some pics with the lights on, been a long time coming.
 (https://lh3.googleusercontent.com/-YU_fO863WAk/Vcbi53T08kI/AAAAAAAAB3k/hOXpfxP0M9c/s800-Ic42/P1020336.JPG)
(https://lh3.googleusercontent.com/-ga8wG5sFyZ0/Vcbiv5RXkcI/AAAAAAAAB3c/J150WaM4UWk/s800-Ic42/P1020337.JPG)
(https://lh3.googleusercontent.com/-usI1u7lBl0g/Vcbip9cxbBI/AAAAAAAAB3U/MFWU0P1tmNI/s800-Ic42/P1020338.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on October 23, 2015, 10:53:50 am
Hows it coming together John?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 31, 2015, 05:05:25 pm
Quite slowly but making progress every week, bought new stainless steel bumpers instead of repairing / chroming my old ones as they are pretty tired.
Interior is completely done bar upholstering the seats, the exterior is now 95% complete as well with the last wheel being polished and clear powdercoated.  The 16x6 Fuchs wheels were a bit of a fail as I didn't realise there are 2 kinds and I had 3 of one type and 1 of the other which I couldn't live with so found the correct one but this needed polishing and clear coating.
Bonus being that I'll have a Fuchs as a spare as well if it actually fits on the front.

Bled the brakes today so once the wheel is done they can go on, found the tyres I needed for the front to be able to run the car fairly low.
Engine has been pre assembled and checked, rotating assembly now with engine balancer to do his bit before the long block goes together, loose plan right now is to be building the header / exhaust in the hollidays.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on February 11, 2016, 03:26:17 pm
Any updates available on this?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 28, 2016, 04:54:55 pm
I'll try and catch up updating this thread when I can but the reality is that I've not taken many pictures as I've gone along since the point where this thread was left.
These days it seems like forums are no longer the place for build threads but to try and help revive the forum I can do my bit in the hope others will also post their projects no matter how big or small they may be.
I completely gave up updating Thesamba thread due to getting stonewalled constantly when I needed help because a lot of people with the knowledge just won't help you if you are "modifying" a T34 as I am so I decided I'll just do it for me, my way with or without any help.

I finished this thread on the bumpers and I'd been quoted $3k just to re chrome both bumpers but most of the parts needed repairs as well so when I heard of a company in Vietnam starting to make stainless steel ones I found there was a group order being done by a KG club in the UK. An email later I was on the group order list with mine being shipped direct to NZ from Vietnam.
A few months later brand new hand made bumpers showed up for less than half the cost of chroming my originals and these will never rust again.
Other than a couple of pre production sets going to the UK for test fits and adjustments I was the first to actually recieve my bumpers which was very cool.
Obviously being pretty keen to see that was what I fitted the rear bumper that night which fitted like a glove and looked fantastic, the following night the front bumper was not so good........... :'( the shape seemed ok but sat far to close to the ridges in the nose even though the irons were pulled right out.
I was about to start grinding material off the back edge to create a bigger more acceptable gap when I emailed the guy who organized the group buy in the UK who was quick to point out that i check the bumper irons first.
I had straightened  / repaired all of the irons before powder coat and in doing so had made them "too" straight, the ends where they meet the bumper were supposed to point down a little which meant that the bumper sat on the body lower making the gap exactly what it should be so the front is now also perfect.
In all these Harrington bumpers are fantastic quality and great value for money considering the cost of chrome these days.
(https://lh3.googleusercontent.com/-aU2Ve71A1l8/VvioXQjiD5I/AAAAAAAAB8c/qi4OFKHv-kERhHv89gkbiNbkMioZ-BICACCo/s912-Ic42/20151019_110244.jpg)
(https://lh3.googleusercontent.com/-AENEE7QGqRQ/VviolOa5w9I/AAAAAAAAB8s/QkSrzRtkc1UxnMIYAmFuUHu03P80nyj4ACCo/s912-Ic42/20151019_181157.jpg)
(https://lh3.googleusercontent.com/-z6gBeOKM8cc/VviomeGsS2I/AAAAAAAAB8s/2siWHNVP3fMutghApN65Jzf3a7_zf-lXgCCo/s912-Ic42/20151019_182201.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on March 28, 2016, 05:40:21 pm
That does look good
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on March 28, 2016, 05:52:38 pm
I'd forgotten how frustrating it can be updating these threads, you've just typed out your novel and poof all of it disapears!!!
Start again.......... ::)

Way way back I'd found a supplier for a particular vinyl which was a 99% match to what VW used for their front and rear trunk liners in Type 3 and Type 34 VW's and even though I wouldn't need it for years to come I bought some quick smart. When restoring a T34 you buy parts / materials when they are available, not when you need them.
True enoug this stuff was just about a perfect match and with the exterior nearing completion I spent a few weeks making new templates for the front and rear compartment sides / floors.
The insulation pad in the rear above the engine was completely destroyed on my car like everything else and this is something you can't buy anywhere so I looked at all sorts of materials coming up with a solution by combining 2 types of materials to do the job and this was painted to match the colour of the original pad.
The "open / closed"  logos were embossed on the original so having a stencil cut which I used to paint the logo in black was as close as I could get.
More to follow........
(https://lh3.googleusercontent.com/-wbNyucTmmZY/Vvi25cHOYjI/AAAAAAAAB94/VBVTdZJp-5kpqDu6tXAKGfhkuO_bfWMVACCo/s800-Ic42/P1000032.JPG)
(https://lh3.googleusercontent.com/-BCq1HQMjEHw/Vvi24EGq5QI/AAAAAAAAB94/JT5Az7HuojIs1mfUp7x_H_lta9MwF92HwCCo/s800-Ic42/P1000042.JPG)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on March 28, 2016, 07:20:44 pm
great to have this back John, the bumpers do look excellent
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Lee on March 28, 2016, 08:02:34 pm
Thank you John....Really appreciate this build....
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: mark2 golf on March 28, 2016, 09:58:21 pm
Those bumpers look amazing. Thanks
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: GolfJon on March 29, 2016, 09:43:57 am
A great build thread and glad its been revived, love reading about this.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on March 29, 2016, 11:03:51 am
Quote
I'd forgotten how frustrating it can be updating these threads, you've just typed out your novel and poof all of it disapears!!!
It is appreciated John! When writing long entries it can be worthwhile using a text editor/word processor and then pasting into the thread so as to have your work saved if it all goes pear shaped.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 10, 2016, 09:54:38 am
So late last year I got all of the engine components back from Bob Mead the engine balancer meaning the long block could finally be put together with the new turbo cam I'd got for it.
We also installed some piston oil squirters from a VR6 engine as these are about the smallest I came across reducing the amount of material removed when the main bearing saddles were drilled for them.
Set the compression fairly low due to turbo charging but in saying that I'm not looking to make epic power just a reliable driver with plenty of torque, probably run around 10psi boost max.
(https://lh3.googleusercontent.com/-JvENVF67o9s/Vvio6bG4tkI/AAAAAAAAB9E/NIvhWmEje40UxGT5qGIvpddHjxkC6-ZoACCo/s912-Ic42/20151213_161727.jpg)
Long block together I made plans to make the exhaust system over the Christmas holidays which sort of worked out, starting from scratch and making every single thing from stainless really took a lot of time but I'm sick of rusty exhausts on old cars and even HPC type coatings don't seem to last so stainless is the only way.
Managed to get a few laser cut head flanges but not enough to do the job so made the rest myself as well as the mounting flange for the turbo and turbo outlet flange.
The turbo i'm using is a K24/26 from an Audi 5 pot so keeping it in the family, I had Steve Murch rebuild it for me so no doubt it will be done right and it was actually him who suggested using this turbo for this car.
Test fit in the car with the header and turbo in place, worked out great as I'm able to remove the whole engine with header and turbo on the engine which makes it hugely easier.
Still have a W/G to plumb in somewhere as the turbo is not internally gated and space is very tight for this but where there's a will there's a way.
(https://lh3.googleusercontent.com/-Zxv0tcNXxX4/VvipAdHw4cI/AAAAAAAAB9Q/xphg0oP9YaIjtfhVdft8C6QG1YvRWmOUQCCo/s912-Ic42/20160115_152636.jpg)
Motor back out again and back on the bench this time to make mounts to support the turbo, oil supply and drain lines etc.
Test fitted all of the engine cooling tin and fan shroud also realizing that all of the internal flaps and thermostat were missing which were fun to find!  Luckily I found about 90% of it locally and just made the rest of the pieces needed but unfortunately it all eats valuable time.
Over the years many people binned all of these components thinking they are not needed yet now everyone wants them again as they realize the factory engineers were right after all!  ::)
Decided to use a V band on the muffler side as i wasn't sure if the muffler would need to be removed for engine removal so rather than having to undo the whole thing at the turbo a V band makes this a snap, dropping the whole muffler / tailpipe in one go.
As I said not as many pictures but you get the idea anyway.
(https://lh3.googleusercontent.com/-Rw7-K9wWsC0/VvipFlnBFfI/AAAAAAAAB9Q/RURhq4HI6I4o9ND8AKgvIeJLFDOcZXttQCCo/s912-Ic42/20160206_134520.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on April 10, 2016, 10:39:48 am
What type of external wastegate are you going to use John?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 10, 2016, 10:42:33 am
Probably a Tial or Precision 38mm
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on April 10, 2016, 11:40:41 am
That exhaust is a piece of art.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: gti vr6 on April 15, 2016, 04:26:22 pm
Really exceptional work John. 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on April 15, 2016, 04:42:52 pm
x2. Can wait to see it belch flame on overrun...cos its vert
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 00quattro00 on April 15, 2016, 08:47:00 pm
Probably a Tial or Precision 38mm

I think ive got a spare kkk one if you want it to match
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 17, 2016, 10:19:36 am
In with the motor for another test fit and to finalise the muffler and tail pipe, I'm only using one resonator all be it quite a big one at 500mm long and can only hope that it will be sufficient to quieten it down enough but the turbo should also help as it cuts up the sound quite a bit as well so here's hoping because I don't exactly have a lot of room left for all the other gubbins which has to go under the car.
The whole exhaust has worked out really well with hardly any of it visible from the back, one of my pet hates is to see the exhaust hanging down for all to see which in most cases ruins the look.
I should be able to remove the motor complete but the Vband makes it cery easy to drop the muffler out first shoud that be needed.
The next job is going to be to drop the motor and get it ready for its first start, I decided to do this on a test stand rather than in the car and also its first run to break in the cam will be done on carbs due to having to start it and get it up to 2500rpm right away so don't really have time to stuff around getting the injection sorted first.

Once the initial 20 min break in is done on carbs the motor is essentially ready to go in and stay in, I can than set up the fuel injection and get it running on that making its first test drive a very close reality.
I'm having a crack at using all MK4 GTI ECU and sensors on this engine, few issues to work around but don't really see any reason for it not to work. Best part of it is most of it is free and the ecu is pretty tuneable.
(https://lh3.googleusercontent.com/-2LPfnz4iQsc/VxK3l9T7GDI/AAAAAAAAB-8/LxheCE65pxUAnQfR2xinzqCpHY1lDJZmgCCo/s912-Ic42/20160417_095710.jpg)
(https://lh3.googleusercontent.com/-Gxl2UTloKcc/VxK3meDc9DI/AAAAAAAAB-8/MD0hA9dmStM3q7TSwFf0wogPK0X-wsOlgCCo/s912-Ic42/20160417_095739.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on April 17, 2016, 10:43:58 am
That is pretty snug under the rear but looks absolutely fantastic
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: kiwihigh on April 17, 2016, 11:11:23 am
awesome  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 01, 2016, 11:18:44 am
Having done all of the interior work to date myself I didn't feel the need to learn how to sew and also potentially mess up the original repro material I had sourced for the seats.
There's so much potential for it all to turn to custard and the seats being a pocal point it needs to be 100% right so I've again called on Ian Goodwin Car upholstery to do the seats for me.
I've used the same guy for 20 years and have always got what i expected from him be it seats or headliners etc, started out with the rear jump seat which I made a new base and backrest for as the old ones were...........you guessed it, completely rotten!
Marine ply cut to match which was originaly covered in horse hair but we've ditched that in fabour of modern foams which just makes much more sense, back seat complete and in pretty much how it would have been in 63.
(https://lh3.googleusercontent.com/-GK-cbOrYm14/VvipMMpOnvI/AAAAAAAAB9c/OsdCbTKISQIz_vNXPyxz62cuIvynBiOYACCo/s912/20160213_091605.jpg)
The front seats were torn apart a long time ago and I've had the frames sandblasted and powder coated which as the next things being done right now, had a hard time finding replacement knobs as a couple were broken and they are not reproduced.
One in particular is only produced for a couple of years but got one in the end so I have everything ready to go now once the seats are done which will pretty much finish the interior.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 08, 2016, 09:17:07 am
This post sort of brings me up to the point of where I picked this thread up again, doesn't seem like a lot has happened looking at it but there's a bunch more stuff I just haven't taken pictures of. With most of the underbody stuff sorted out I had quite a few weekends of "what am I doing today" with the net result of little or nothing getting done at all so i thought it prudent to make a "to do" list.
Now I can just glance at the list and pick what I'm going to tick off which is usually a case of cross one line off and add 3-4 more things back on  ;D You know, one step forward, three back kind of thing.

With the motor back in for its 2nd test fit to make the muffler part of the exhaust it seemed like the perfect time to test where the wheels and tyres are at, 3 different sizes on the front have finally resulted in the tyre I'll run, not a lot of choice in 16's but I ended up with a 195/50/16 in the back and a 175/60/16 in the front.
I don't much like the little front / big rear tyre look so wanted something as close as possible to the same rolling dia front and rear and a 195 just isn't going to fit on the front at all.
Fitted the front wheels and lowered the front end down only to have a whole lot of brake fluid come out of the chassis at the front which can only mean one thing, leaking master cylinder.  Damn Porsche parts!!  ;D
Anyway, took that out and apart to find some corrosion around the front seal which luckily was easily cleaned up and put back together. Re bled the brakes and all seems fine so far.
Front and rear wheels on the car goes back on all fours the first time in many years and I really like what I see, fair bit of rolling forward and back to get it to settle as much as possible but I'm diggin the ride height, front is a little high but a tank of gas will solve that.
(https://lh3.googleusercontent.com/-M21Fusa4RHA/VvipZXLuRPI/AAAAAAAAB9g/aE_gSS-gi0wPYfCXvG9BPHl0sQV0XHHmACCo/s912/20160312_151712.jpg)
(https://lh3.googleusercontent.com/-_ZBfAdXhvTw/VvipeAMr-eI/AAAAAAAAB9g/0ildP2mVcH4KTzRQ8Ch_iqUv-IgBk43jQCCo/s912/20160312_164122%25281%2529.jpg)
(https://lh3.googleusercontent.com/-ucVhAZoo6RQ/VvipRRC_x4I/AAAAAAAAB9g/A8fqFqNisMAeRoy_tEEKfYDzcqD916VfACCo/s912/20160312_114526.jpg)
The more I looked at the wheels I felt something was missing then my wife suggested they needed some black, of course if I detailed them then the black would tie in with the black roof.................
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RobClubley on May 08, 2016, 09:34:06 am
Sitting on its wheels at last. Looks so good!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on May 08, 2016, 10:08:20 am
Looks superb
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Worms on May 08, 2016, 07:26:24 pm
It'll be ready to come out of it's little bedroom soon!

Awesome work. Keep it up :-)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 09, 2016, 04:53:29 pm
All jokes aside its been bloody awesome putting it together in that room, the perfect storage spot.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Worms on May 12, 2016, 10:12:10 pm
Agree! Not taking the piss.

Assembling something in mugarage, would involve lots of stuff falling on it, dust, fuss from the clothes dryer, people seeing, who you don't want to see it, etc etc etc.

You can hide away in yours, and get stuff done!

I wish I had more space... but my attic is a bit awkward to get cars into  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 21, 2016, 10:04:43 pm
The next instalment of this on going saga to resurrect this old pile of junk involves wheels, when I started this I decided on 16" Porsche Fuchs right from the get go and thought fully polished was the way to go so I had the set fully polished and since Im far to lazy to polish wheels had them clear powder coated at Pro Coat. In all a saga by itself but then found out that there's 2 types of 16" Fuchs...................of course as luck would have it I had 3 of one type and 2 of the other  :P ( I had a set of 5)
I did have 2 other "correct" wheels but I'd already cut them up to make 3 piece wheels for the Porsche  :(
You'd only see it if you knew what to look for................which I do so that irritated me, hunt was on to find replacement wheels!
By pure fluke I found another VW nutter down country who had a set of 16"s on his car and he also didn't know about the difference but as it turned out his car had 2 of one type and 2 of the other and lucky for us both we needed each others wheels to make our sets "correct" pretty cool really.
Anyway where I was going with this before I went off on a tangent was that once fully polished and on the car I couldn't help but think something was missing and even my wife suggested they needed some black so I thought maybe detail them like the 15"s were done originally which would also tie in with the black roof.

Now I've detailed my share of Porsche wheels over the years and never a fun job or easy to get right, difficult to get the line right which breaks the polish / black.
So with these ones I made a cutter which mounts to the center bore of the rim and once the masking tape is in place the cutter then cuts a straight line right around the perimeter of the petals leaving you a clean line to mask to.
(https://lh3.googleusercontent.com/-oGURywTjdko/V0AtEWS3U8I/AAAAAAAAB_c/SYuzjIi-7uMbKK7zPSx9sRGiA9tFBsWPACCo/s800/20160416_112314.jpg)
(https://lh3.googleusercontent.com/-agbn5x1Jwdw/V0AtE4I3kmI/AAAAAAAAB_c/g2J4nNwHhj0xDnr4vSJndwwLC9UJKVpOgCCo/s800/20160416_115055.jpg)
In all still crap loads of work and still not perfect but if I were to do it again I'd use line tape instead of masking tape so that there's a cleaner masking line but hey they are wheels after all which will get chipped  and scratched so....
3 done, one to go, well and truly sick of masking by now and with the day coming to an end I shouldn't have done the primer stage at this point, I should have done primer the next day and painted the black while the primer was still wet (what they call wet on wet)
I didn't and primed them then ran out of day and enthusiasm so left them till the next day, primer had dried so had to sand each wheel and once painted black it was quite difficult to remove the masking tape without lifting the primer in places, the things you learn!
(https://lh3.googleusercontent.com/-xXi0urQc_TE/V0AtGT6e9fI/AAAAAAAAB_c/ykbZMRpZvN4HN-ccvLvkn06BuudNtvALwCCo/s800/20160416_155756.jpg)
(https://lh3.googleusercontent.com/-KvSiX0ufick/V0AtPogH-HI/AAAAAAAAB_c/O-H8I_ZuX2A0SSk-prIQPVDPXJM-Yq1YgCCo/s800/20160416_174246.jpg)
Still, I think they'll be ok for my old pile  ;D
In all a huge pain in the ass but well worth the time.
(https://lh3.googleusercontent.com/-llZvqoCXShI/V0AtOqJfBLI/AAAAAAAAB_c/dCQ_9YIjso4i9KmtpYF_4rfV8bIpE1xCQCCo/s800/20160419_093416.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on May 22, 2016, 02:23:48 pm
absolutely well worth it!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: brian on May 22, 2016, 03:58:52 pm
absolutely well worth it!

+1
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on May 29, 2016, 12:04:51 pm
Getting the motor going was the next item on the list to focus on, need to do the required 20 minute break in of the cam and lifters @ 2000rpm which just isn't going to work well while I faff around trying to get my fuel injection working so it was decided to do the break in on carbs then switch over to FI later.
In order to do the break in I really needed to finish the exhaust and the rest of the engine to a point where some carbs could be slapped on and run, The turbo I'm using is not internally gated so an external gate would be needed and with packaging limits as they are under the car space is at a premium already.
I didn't want the gate hanging out underneath somewhere in full view so that presented a few challenges of its own but in the end there was really only one place which made sense by coming off the collector at an angle with a pipe going upwards so that the outlet side of the gate can dump back in to the exhaust after the turbo.
(https://lh3.googleusercontent.com/-HhYnn02Tgc4/V0A93k9Y87I/AAAAAAAAB_0/VyMZpBbFMVsJgNw20vTNQy7bQr35xkc0QCCo/s800/20160507_161535.jpg)
(https://lh3.googleusercontent.com/-8TfywbOP8ws/V0A93m5FKjI/AAAAAAAAB_0/Fugm5g3g4GYq93mxwHtJGtqafDWwBTY-QCCo/s800/20160507_184428.jpg)
Took the spring out of the gate so that it bypasses as much as possible since the turbo boost side won't be connected during break in while on carbs, also finished off the fan housing and all the other related cooling tins etc at the same time.
We'll be running it up on a test stand to make things easier and it also takes out any risk of damage to paint and body work.
This next week will be the telling tale of how that all works out.........or not!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 06, 2016, 10:15:31 am
My posts are catching up with where I'm currently at which can only mean I'm working too slow!
Since the motor is out again to be run on a test stand seemed a like a great time to start on wiring the fuel injection.
As I've mentioned before I'm going to attempt to adapt a Bosch motronic ME7.5 from a late MK4 Golf gti to run things, mainly because its free and highly tuneable.
Having wrecked plenty of these cars I've kept looms, all sensors, TB, injectors etc etc. My motor being a 2.0 and turbo is close enough to hopefully get things running and tweak it from there.
First thing was to start separating the wiring I need to retain and then look at building the ecu in to a stand alone type of deal where I just need grounds and power to run it so I made everything bolt on to the original ecu cradle which now houses all of the relays and fuses I need to run things.
Weeding out the un needed sensors and emissions stuff has reduced the wiring quite lot but there's still plenty to contend with.
(https://lh3.googleusercontent.com/-nA3JKQhPkm8/V1P0CHQ1ijI/AAAAAAAACAw/lVrh5qF5CWgp9IZXFGeFb6qom1CukYXLgCCo/s800/20160526_191950.jpg)
The relay / fuse panel is also salvaged from the VW loom, might as well use it. Attached the diagnostic port to it as well keeping the whole thing neat and tidy.
I'm not running heaters in this car so I was able to run the wiring out through one of the heater tubes meaning once again no cutting or modification of the body needed.
The engine side of the harness will need extensive modification as locations on the engine are completely different but again its just a case of cutting to length and soldering.
Again a bunch of stuff deleted here which won't be used, I'll have to get a bunch of codes removed from the ecu but main focus first is to see if it will even run.
(https://lh3.googleusercontent.com/-ftEu8FvOZ5k/V1P0Ao5qeKI/AAAAAAAACAw/CmLDCIZ9jxMTui-OlE8usiFO_XPvpG49QCCo/s800/20160528_153924.jpg)
Mounted the ecu under the rear seat opposite the battery which seems like the ideal spot for it, don't know where my water tank for the water injection is going to live now but i'll have to deal with that later!
(https://lh3.googleusercontent.com/-2VvwCH7aImI/V1P0LeAKSvI/AAAAAAAACAw/8IZF8PV1ZdAP8w3P34XX7h3eq-hQ4zKzACCo/s800/20160528_164701.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Filx on June 06, 2016, 04:31:56 pm
Can't wait to see if this works - might open up a whole new world of cheap / free tuning opportunities.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on June 06, 2016, 07:24:26 pm
Agreed. A new world for flat 4 engines.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on June 06, 2016, 08:40:29 pm
Do you use that EuroDyne tuning package?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 07, 2016, 07:32:21 am
Not sure yet Jon, Eurodyne is one option or I just have a tuner make the changes needed. My main focus is to see if it will even run with what I have first and then go from there.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 09, 2016, 08:45:58 pm
The 2008cc turbo flat four lives!! much excite  >:D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Worms on June 09, 2016, 09:08:54 pm
NICE! Where's the vid???  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on June 10, 2016, 06:23:06 am
Yay!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 10, 2016, 07:16:13 am
NICE! Where's the vid???  8)

I'll take a vid this weekend, pretty stoked actually.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: deedub on June 10, 2016, 07:21:44 pm
Awesome! So it started and ran on the stock map? Very interesting....
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 10, 2016, 07:52:25 pm
Started on carbs
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on June 22, 2016, 08:50:44 pm
ECU mounted its time to complete the car side of the wiring harness, this thing literally has ONE switched power in the whole car ! ONE.......I need 4 switched powers for the ECU and relays alone!
To solve this I modified a MK4 Golf battery top fuse box by making half of it for constant power feed and the other half switched feeds, lucky for me the switched feed I needed is under the back seat at the voltage regulator so I used it to trigger a 40A relay which powers my switched feeds for the ECU.
Great thing is the battery fuse box also has in line fuses which I can use as well, everything wrapped and installed VCDS seems to talk to it just fine.
(https://lh3.googleusercontent.com/-uVNPFpuqgmE/V2pJLZAsFSI/AAAAAAAACCY/Wgx3ee6dfcwvlieDyCAEeyCnNafeb5lywCCo/s800/20160606_153654.jpg)
My ign and door keys were the originals from new and were completely worn out so something had to be done, NOS ones are around but at 50 usd a pop I wasn't so keen. I did some research and found out what series keys they were and got part numbers in the hope of finding a cheaper solution.
Ebay Germany was the place, NOS key blanks made by the same manufacturer as my originals for 17 euro a pair! Bought those quick smart.
Next problem, how to cut keys when your originals are far too worn to be of any use, while at Armstrong locksmiths in Greenlane I asked them if they would have my key codes on file (original keys had codes stamped on them) They did!!
In the end we decided to cut a couple of their generic blanks with my codes so that I could first try them before cutting my NOS ones, well they did work so Armstrong then cut my new ones. Quite a faff by the time its all said and done but I'm real happy with their service and work.
Original style keys are really cool with the large VW logo in them, another item crossed from the list.
(https://lh3.googleusercontent.com/-4hNEhiS-YUY/V2pJLFhYQJI/AAAAAAAACCY/HihMtTITTksRRNMS_akWlHL1C-PPtOiDgCCo/s800/20160608_135939.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on June 22, 2016, 09:43:43 pm
Nothing left to chance. Great stuff.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 02, 2016, 09:22:19 pm
Time for the serious work to start, fuel injection!!
I want to use as many factory components as I can and that includes coil packs from the 1.8T, problem is they are 20-30mm too long........there must be a way to shorten them yes??
Thought I'd give it a go and pulled one apart, sure enough the brass connector between the coil and the spark plug was able to be machined down on the lathe to give me the 20mm I needed.
Cut the rubber insulator down and also the earth shields which sort of hold the whole thing together, if they don't work I'll have to come up with a new plan but until then I'm running with this.
(https://lh3.googleusercontent.com/-EJaymcdlg7M/V2pI0K43KYI/AAAAAAAACCU/Kvwg1u3D4RYCuVbtQ9FDnEbqzdkYoJYbwCCo/s512/20160614_165951.jpg)
(https://lh3.googleusercontent.com/-RERYS-ifnvs/V2pI1An8bWI/AAAAAAAACCU/8uRE7XrMTzMHvCpDjsQ3fDfwXwM5dAnpwCCo/s800/20160614_170012.jpg)
The inlet manifold was always going to be a huge challenge and after looking at countless options it was evident I'd have to make my own system so that it all fits neatly under the rear deck.
I don't know why but decided to make it from stainless, what a huge pain in the you know what!!
Started with making the inlet pipes for each cylinder and then adding injector bosses to that, cleaning up the welds by hand as I went.
Cut up the 1.8T fuel rail and modified each section to suit the flat 4 layout, head flanges were going to take an age so I'm really glad I chose to get those lazer cut by One Stop Cut shop who also cut an aluminium throttle body flange at the same time.
Starting to weld things together here figuring out problems as they arise.
(https://lh3.googleusercontent.com/-rPkklu3i3WI/V3eFjmjup4I/AAAAAAAACDQ/qXRtgCUeZ1AHUV24V4uI21CMur_xZHDxgCCo/s800/20160624_165858.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RS ZWEI on July 04, 2016, 11:53:04 am
Awesome work John.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 16, 2016, 10:12:59 am
Had to think outside the box on the intake plenum for this engine as space is tight under the lid, armed with laser cut flanges I welded the intake tubes on to them so that they could be mounted to the head.  From there one was able to make some sore of plan where to put the s throttle body and intake pipe.
So far all i'm using is 1.8T Golf parts, cut the fuel rail to size and tig back together and so on. With the manifold in place I decided to route the intake pipe at the back of the engine and found the only place for the throttle body to be about the middle of the engine case and even then had to put it on a 45 deg angle to clear everything.
(https://lh3.googleusercontent.com/-iexKdodiD7w/V3eFlgbMpjI/AAAAAAAACDQ/pUy2RfDukbgE5xoeROQtfTYbb-h2C720wCCo/s912/20160701_142629.jpg)
Doing all of this in stainless has really been the wrong move as its just such a difficult material to work with but there's no turning back now.
Intake pipe on the end manifolds is 2" which steps up to 2.5" as its comes in to the collector for the sthottle body.
Made attachement points for the fuel rails so that they can be easily removed as the intake needs to come off to drop or install the engine.
Having to custom making everything yourself really slows down progress but each step is a step closer.
(https://lh3.googleusercontent.com/-X_mmMIicQCw/V3eFoGK0QSI/AAAAAAAACDQ/BfaVndaFCz8rZLC5LRSUzpOmfTUxmrJUwCCo/s912/20160702_104506.jpg)
Cobbling it all together with small bits salvaged here and there from other jobs  ;D  Getting there!
(https://lh3.googleusercontent.com/-L1Sz5KbERbM/V3eFu0zpWEI/AAAAAAAACDQ/jC2aLAoyaYoGvZApYgfJlTlubQeFXZdqwCCo/s912/20160702_174631.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 24, 2016, 06:31:45 pm
Placing the DBW throttle body was another one of those "find a spot for it" in amongst everything else, only really one place to put it where it will still fit under the engine cover.
With that decision made finishing the intake manifold didn't present any further problems and also added the intake air temp sensor at the same time.
Made up a braided fuel hose to connect the two fuel rails as well, still to remove the blue and red anodising so that it blends in better and looks more OEM.
(https://lh3.googleusercontent.com/-8mNBFo0mIvo/V5RbiV85DBI/AAAAAAAACEQ/BD5qmNTXyaw_nnoCgOVeDlSbkMOJzo-2gCCo/s800/20160709_173817.jpg)
When I had some flanges cut at One stop I'd asked about cutting a 60-2 trigger wheel as well but for some reason it seemed too difficult so that didn't happen, after that I ended up at Gilbert Sheet metals who also do laser cutting.........WELL what a shambels that was!
Nearly 1 1/2 weeks of waiting for them to come up with a price which after a few reminders was soo astronomical I thought f%ck it I'll just make one. I guess they weren't interested from the start but then say so instead of wasting all this time f@cking around.
In any case the 1.8T Golf one was too small so I had a larger disc cut out of 8mm plate steel which I then cleaned and trued in the lathe. Next in to the rotary table on the mill to drill 60 holes 6 degrees apart.
Once all the holes were drilled I cut the center out to the size I needed to fit over the engine fan, with that size determined the outside could be machined down in the lathe cutting in to the drilled holes about half way leaving pick up points for the crank sensor.
(https://lh3.googleusercontent.com/-JFujH7jhtMY/V5RaK85-Y2I/AAAAAAAACEA/OEa7tCysqrUq-FjMKi-nKmx5RBCWjemhQCCo/s800/20160712_152010.jpg)
(https://lh3.googleusercontent.com/-M7DQ3x23FlU/V5RaNgXTVLI/AAAAAAAACEA/cIZnG3RGIu0hBY2D8WB3FOKd2fyElUWhACCo/s800/20160713_120008.jpg)
As luck would have it a blown 1.8T short block landed at my feet just at the right time which I used to determine exactly where the crank sensor had to be in relation to the trigger wheel, checking rotation etc was correct I made a mount for the crank sensor and then placed the trigger wheel where I needed it bolting it in place. The 3 mounting holes are slotted a little allowing for fine adjustment / tuning.
(https://lh3.googleusercontent.com/-wqbU63KPUZU/V5RaKAyvs_I/AAAAAAAACEA/qgXyLH-BLhwFk7fRG6mA6bcOPmQrAm7hwCCo/s800/20160714_090449.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Trofeo on July 24, 2016, 07:48:15 pm
So the hole spacing is measured individually? So a few calcs,  work out the spacing, and off you go.. Just amazed at what can be achieved in your workshop. Simply mindblowing!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 24, 2016, 08:25:13 pm
Yes, a 60-2 trigger wheel is just 60 teeth with 2 removed. This is how the crank sensor knows where TDC is.
Sooo the rest is very simple, 360 : 60 = 6 degrees per tooth and from there its quite easy on a rotary table, index 6 deg drill hole, index 12 deg drill hole and so on.
To make things as accurate as possible I simply calculated the ratio I was enlarging the trigger wheel and thus made the drilled holes larger by that formula also meaning it should in theory be scaled up fairly evenly.
The crank sensor is magnetic so all it is doing is counting the spaces between the teeth and firing at pre determined locations.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 30, 2016, 10:06:41 pm
The next instalment of the engine is the cam position sensor, not sure if anyone is still following what I'm doing but don't blame you of you've all gone to sleep!  >:D
Of course there's no way to add the 1.8T cam sensor to the end of the cam as on the watercooled engine since the cam is enclosed in the engine case and already drives the oil pump. The distributor of course is driven 2:1 off the crank so this would be perfect for what I need since I don't require it for ignition so the first job was to strip a brand new 009 distributor and throw 80% of it in the bin  ;D
Fortunately I had a big enough chunk of aluminium bar 2 random holes drilled in it to machine the adaptor from which would hold the cam sensor to the dizzy body, once I had the round adaptor made I thought it didn't look factory enough so with it mounted in the rotary table I machined the sides down so that it matched the cam sensor and dizzy body. Quite a lot more work but looks way better.
With the sensor mounted on the housing I could then measure the height for the inside bushing to locate the sensor wheel on the distributor shaft, fine tuning is able to be done via turning the dizzy housing in the engine case to perfectly time the sensor to the crank position.
(https://lh3.googleusercontent.com/-7roCfGviqi0/V5RaduWDifI/AAAAAAAACEE/-CRlHas8LvMeKVpwHGEP3kLQIU7rjPQnQCCo/s800/20160716_105152.jpg)
(https://lh3.googleusercontent.com/-wloV3DYkU_Y/V5RaeGRYvhI/AAAAAAAACEE/tTuXLOeLws4LQq7TZCjpOtNq5a0SJ8a8gCCo/s800/20160716_154913.jpg)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RobClubley on July 31, 2016, 07:57:52 am
Very much still watching with great interest. I just don't want to clutter up your thread too much with comments. Love your work, attention to detail and dedication.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: John Stone on July 31, 2016, 08:24:22 am
What he said - thanks for sharing it Vert
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on July 31, 2016, 09:25:59 am
As above, watching with interest!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on July 31, 2016, 11:08:35 am
+1
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: kiwihigh on July 31, 2016, 12:31:40 pm
Same as above.. i read every update  8)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on July 31, 2016, 01:20:30 pm
Cheers guys, it's taking quite a bit of effort to keep going.....Other projects are an easy distraction.
However I have found room for an intercooler. .......super tight fit but details later.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: mark2 golf on July 31, 2016, 09:11:41 pm
Very clean john. Love it.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: dubstar on August 01, 2016, 01:53:04 pm
Cool solution for the cam sensor
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Worms on August 01, 2016, 07:07:26 pm
I'm VERY much following too!

This place needs a like button, so we can show interest, but not fill your thread with drivel (like this  ;D)

4 cylinder Engine fell out of the Touran on the weekend, too  ;)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 01, 2016, 10:32:07 pm
About time you got that miserable 4 pot out of there lol
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: VW'n on August 02, 2016, 04:33:53 pm
Do you have an estimated power figure?
There can't be many orginal air cooled motors converted to fuel ejection?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on August 31, 2016, 01:41:36 pm
It was never about making epic power, really have no idea but it's something I've always wanted to try and it seemed like a great idea at the time  ;D
Maybe 150-160hp really don't know what to expect, only going to run low boost 8-10psi but getting it running will be a feat in itself and looking forward to that.

I wasn't going to bother with an intercooler due to the low boost but in the end after weighing up all the options I decided it a good idea if one would fit, there's barely any room left under the car but I realised that a MK4 GTI intercooler might fit if one of the inlets was changed but being plastic that would be a pain.
Looking at it some more it was obvious I could just remove one of the end tanks and swap it out with one from a 2nd donor intercooler.
Having something which looked like it might work I managed to find a spot under the car and made mounts to position it in the air flow as much as possible, Once finished I'll make some sort of duct to funnel air to it.
(https://lh3.googleusercontent.com/xhZ6G4bAV3uE9LWAwmVOs2ZCZgaKKsNwXl4CyCULS8sFEkS6c0voq2iZFKXdIZ2qeg2eUf0dYcBWJkS1-03K3x8IEvqYrEpo_smGXxQR4a4DWV83nRprwbtRNH4JuUl5HMNZZuFt319OWaRPsGQ-jDrxyY99slxUdJ4E_Tg7sk_-lRKY6zB433lGhTp0UknAGbYArZnSt7uIWTLenHFkTMOzsuouE_NkCv07U_Yn4TD_zs6_LLdoQKUotPV9IS7BpR-OQTrqcBRcYvMzNi0aSdn31K4q2AD22U0GjP5hlpchqyZxsTnjynoXSR7axxus1zj268TkO-N-TnqDXvxBR5ixmMizqAzzJVuVfc3pNijwmoEqyYd_j0RJ-DJsjkL7wTkW_D5GLBWnmww3KddZWdoqVT-4zTE-wQgl_QRk8Ity9ZoT2b0ajP_4P2CrNHb9Qt5RW2kpyRdbQ3SlUIlMVbfiYpRZLQ9xFjsnqYn7vEwBXVXmRGEJMV1S-oJQ16OmA-72ssjpW5N-Tz6siNOdqidgcO5QluabechcXv6hu0mM60gFCoBiLkVh7Dtrl_gftnQEDPshhKpM4VSXlB2Qg433GLltq-vybOvZthj7HRdRRc-j=w1091-h614-no)
The biggest feat would be the intercooler piping due to no space so some outside the box thinking would be required, I started with a bunch of generic aluminium bends which I cut up as required.
Having run out of gas for the tig welder before I went overseas I just duct taped the pieces together meaning the whole thing could at least be test fit. I'm having to use every conceivable space in order to fit them and look like they are meant to be there.
I've still to make the rest of the turbo intake and place the filter before everything can be welded, once that's done hopefully I can find a good spot for the diverter valve and associated plumbing.
(https://lh3.googleusercontent.com/fe878xh02xpn1P9g7y75VxFYTiUnqWgYMW5omDThzI3edpxY9sZKHF4bUojGO5UFA7bFpYvax2E4m6V9aXWuYliKyCIe9DX2P56lc2Dj1AydmbstKyJ_dXtu4VsxXHA9ZO68jQpFKk7ONgzEMmxTzvafDh41v6BCJ0VIBqzvSFPxFtPnJUyuT1KkWZqt6hAhqZjKRquOrccWATUeB-7RCcrIJMMYlKPDxFS8ANyGQJkMbJbHAyodGVN18m-5jITQRhLjUkUZ7XYR1TMSDy3ZH4qkDsTVbrE7_aoZrXEiB59ZKUz_K_2fmLhhSLnE3fPMj7NkqIhMWv7lzE_bbQ2s7AAh9lj9Kmq7VRROsm95QtprGeaVP3hjnSPau_7A-7mxxY8eMynjHaDWOPrmMihyT2qThjqxbXPe_-LxWuJJJRfyjfUzieWFjDJPgJdilf-Carm0R1JC32V5z4U1jMwFlbbRoMM6AS_n1Uj29l24lg4dMtKOGt-OX87-dUxcp8sqGRdGln2xXFj8lN17Pr6en_6kV-uqmYXVYTvexODgmmKbYI5x6Xbgml5cze0Utzrj0_0RbaG7kL2FXTiPc0kHltIsibedpFM7qy1Zb8U66ZtlHmCf=w1091-h614-no)
(https://lh3.googleusercontent.com/kBHTLzuxQBBdHgsMK5LzL5M0ORe2oA5GYh8tRcwrZA28IJXoqNQg54wWkaY21mkK6PunVFiDIhuAvgYji0JCsoWiRVH8fqK1P5MsmyInGH9c6FVbPS1ThCZWW68HXeadiFfzTB1X2ZrTL0tfwDikemJZM8B7LBtPYzaXzYefEtOCYssn-A2tkNJKmGLoN5Lll7XQ68WrQbt4pNYSwtqfVo4m3QKdYPXo_HvMtczFRIISePRUIPHSClgZ_JnCgKkXRfTKl_d_jypY8xcaohdjYARCmD5_M1rfsdq-MP6OAanls7-jg2hw0IIXT_vU9r9ix4TUYqqc9HLXN9qD6jUTL1l0YzvwvB-pbR4IrwOz3C8N09XHbp6imo_7WyphGLqvTe6gXxkl9P25Qtja90hFbr43oouEEqvuk0m1UKHVkffJQVHqeBgCm9r39alLtWSfu7bNlSIUpjqY5SHPeaOO_nomjPyQNRbn7Km956pFce848SnS3rLgd4MbNZQ8ZOWyze9lN1UpiMGpsY3jKJwYP4mBUFCzux14DjX74QCVys4_9iXrYAUpqLTHKBiBU4xfbQ8wMU8oktaE3HWNnvCZAJLxxIIvgURONQRoFdgGmy-G6wSX=w1091-h614-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: BB on October 11, 2016, 05:10:28 pm
Your still the best Vert.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on October 12, 2016, 10:50:26 pm
I generally check each Sunday afternoon for the next installment of air-cooled goodness, but somehow missed this one

is it just me or do the first two pictures not work?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 13, 2016, 03:29:19 am
They all seem to work for me....
I'll be picking this up again next week, need to get it finished.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Worms on October 13, 2016, 07:03:55 am
They all seem to work for me....

Not for us though :-(

I love seeing the progress on this too.

I'm not patient enough to ever complete a project like that!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on October 23, 2016, 11:40:15 am
Back in NZ and back to finishing this thing, before I left I'd made most of the intercooler piping but as I'd run out of Argon I wasn't able to weld any of it. Armed with a new bottle of gas quite a bit was achieved yesterday welding aluminium, had to trim a few of the joints for a better fit and also installed each piece with hose clamps to seat everything properly.
It's becoming quite awkward to work under there as there's hardly any room to even get your hand in to tighten things.
Made a mounting block for the boost map sensor and welded that on as well.
I went and saw a tuner in the UK and showed him what I was doing and he seemed impressed and at the same time left him asking why, his advice was to get it running first and then send him some logs to see what needs changing and go from there.
There's no guarantee this is going to work but they to offer a stand alone ecu which plugs directly in to the factory harness and uses all of the factory sensors which is nice to know that back up is there.
(https://lh3.googleusercontent.com/5knmiYz7wgkOKGziKhBsWvzDpbrtjEzeFHTgsjz7myq-ZqQ13HhGdTyHStHPt-V3zrBvT7TNQnhJcw=w1599-h898-no)
(https://lh3.googleusercontent.com/yaTbOfN7GKLM-WKvGzzI-m4_wayn1lYnTeIGPw0Rld70vRXZtPLYzdqa9rfCNJzoEu8OFGBBV6Dbww=w1599-h898-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: le mans on October 23, 2016, 11:59:35 am
Cool. If you don't mind sharing who is the tuner and which aftermarket ECU are the peddling?
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on October 24, 2016, 02:47:38 pm
Room much!! :o :o
all that's space under there finally has a use!!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 02, 2016, 02:34:15 pm
Cool. If you don't mind sharing who is the tuner and which aftermarket ECU are the peddling?

Storm Developments, was great to meet their head tuner while I visited them.
Can't remember ECU brand but hopefully I won't need it, really want to try and make this set up work.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: robh on November 02, 2016, 03:48:25 pm
Looks like they are using Syvecs http://www.syvecs.co.uk/
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 06, 2016, 11:12:15 am
Finished off the intercooler piping last weekend welding on the last needed fittings and brackets, redesigned the fuel system by making a little surge tank which now houses a MK4 GTI pump. How I thought what I had there before was going to work is beyond me, obviously not thinking it though I guess.
Making the surge tank and giving it a suitable home was difficult without drilling any holes or modifying the car itself which has been the story of my life through out this project but the cool thing is should someone in the future want to return it to 100% stock they can by just unbolting everything................which won't be me!!
Intercooler piping done that was off to Tim at Pro Coat who as usual does a great job and collected it Friday so I had plenty to do yesterday.
(https://lh3.googleusercontent.com/BM5NJ48yoXBAHvWhuGCK9j2o6CEBi-6LRNh1lAiMHaHavfvHgHsUcok0i8rVSmN-LxXDMIc3CLO5P4m6zFdzHGfXONSbWmUxe5PV0P0edwDIgPm-13B1zCLRBlIDlhg24cI7EkKwasiyAFN1dY19pNyOyoQYIGBDv0QxosxcG77ja0HudQnpruGtHmNVO7KZbzAq_WCPJS-sJZAyV6Hs_3nhzK8tvCb7Cr2lyom0paOhf-JO47j890qtNUIKDPbYrmXrypaXq3jAxW7ah0KD_zZXbuHWitdxQ_jQLltjHPXoer2TGTaUfDsZ7fDSGxPdNzHwpTfKLR3LtfrUXke3jInUbQWYn8d3QzD5SALvjxMjqo2LhEk-zmPR4ChZEhnAdhhKTcEjTOfqJekjUtSWfT8PKzC082ydwsULvXtvPDAMIf1slxIuywAvX-BhAk52FLV1CaVFOSw6VmgbhZSAY83LkPGOp3mSiYtLZIimAeK7E1yqs1sk8RAz-w24P1i3jUPVQYYBTvtjdxkyy2-eGNXxo38LqDG7FdwghL1GoIEQ0tApmVPR3m2DJbLSGWCjK4HJDgRRvoO0P6Eak4xH-714Ob4NScXXV9gFfQtLI_TKu0Ua=w1091-h614-no)
Started fitting the fuel pump and sorting out the lines, first hurdle was making two trips to the parts store for the correct fittings and by now 11am with nothing achieved.
Pump finally in place the new fittings could be lockitited in to the tank so that could also go back in at the same time.
Trying to get the front end completed was a headache as every turn I took seemed to fight me which has been the way lately and even small things seem to take an age.
(https://lh3.googleusercontent.com/VqqvDQfZqou7QXMc0MITnT3zObBTbKYDq6mVwsYzVnXqq5Ck5a2PbPBq9SkN-auZgralQdNBTI2SCIYiZOhLFzf454rF_iDeNAd6miwjJKovJDIdQ29KX8JvkitiMriPbZkQzeN1lfr0GvmaFmqscgZgy8UU4TBIA16ycuMrxwJFh5upYzZj_hfJyQjXeJYfy0a5XxO4mK-jXK5rU-RlNilX0Jeoo_VKfMU32rxk_eEf4mWwNgoJaFo0CzCQp4-dcn2ELTY-CyqC341QzFEb5N4oWWHfUkWLqhVW8cwNkc74XNNrfCK9pZ5_MILCRlKWj1ocJ-4edmVTCcZeuQkvbIaxT9vjr6u7CAJYPlgsI_JQ7KhFrR8ElMocDmGw0kzcTQyxfkn--1P-3EXaTHpPr7Oa3h43pXDk4LgWcFKhRjC7gSU6qLCx3_qEM4uFeorZiPSZ_lenWKxXgqxYmz2FKbRX332P47oW1QwxsnXZc7OQ8nCoQStg58sC50uao4FGjw9Yu6JWMAJ3oyu-lDsjunztTe0L8Zi49Drd_Zxyk17HX8ltjiewuG8ExpHH1CVKQcX3lyMR9qrIKBaT19W7yiTIqOcxheSccOfJPTCC1rwkk8Ia=w1091-h614-no)
Fuel system hopefully sorted for now the engine could be finished off, fuel rails and injectors in and intercooler piping fitted.
Final shot of the finished for now engine bay bar some kind of breather system yet to be designed and some vacuum hoses to be finished.
(https://lh3.googleusercontent.com/xxv0Yl1tKDQBl_qBkP-Uv3BbO_DFbyaGLyT62oF3OeSkeipMMaKsU2D1fI9iiH0UbfCEXRfx-dmNZKKqi--nSN7CYE-gNSobcx-iLnZo_TuI9s5SAQ2rTegK0MrHhVnATfnAXT06WH7XepBCes8AFB1ab20bcJhDshmbgaxW-3lw3nX0-zdQONkx5BZh-RKknuA-SYgjljXNzfRZbpzSp69niHA9Yrp6ALeBDSHF2Jaeo0qHIKgv-P91ZU2jdN2SawwyFJH5nkkR2zM3MIkI8qMBP9zfBA0OKH_8GwLX177iU2teeYrivtpvYTpMDNKddNo3PGEa9D77G7tfFwK-e_0Pakl3i10DhfsafB0oImhPVH3cT2FNGH5J2JgPPzZy4TB56W4Zi-2rltqo3J6oE5WoUJ7htCuamX5YOfc3ih_1dTut31E5NmLkgLcRJWnoatisTuKRcqaTCupWO58M0LGl101Ex4v2VGIvbF6v0iuOUork0eoFh8ZBNdHI56wr0ogXNs9H60MqpjCgCi8bOHrMVSl4vkhKSCOSe5b78DLoWMPU8x52sIHyTxx3XBBn8-R5ZePlLHQz6UovGvqMJ-b20kKES_L3qBTq21eoJyr5r9yz=w1091-h614-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on November 06, 2016, 01:09:16 pm
great work! looking forward to the video of the grumbly idle
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: McDoof on November 07, 2016, 01:10:51 pm
That Engine bay:
(http://i1033.photobucket.com/albums/a418/nschlabitz/toight_zpspxxj7c7f.png)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 13, 2016, 11:26:57 am
Yesterday was a fail with a capital F, been working towards putting fuel in it to pressurise the system so that I can check for leaks and yesterday was to be that day but when you pour gasoline in and it comes right back out again you know you're not going to have a great day  >:(
Thankfully I only put a few litres in but it still made a big mess and the whole place stinks of gas now, looking at where it was leaking its become evident that the MK4 pump has a breather hole in it which is where the fuel is leaking from.

Looking at it more its pretty clear that the MK4 pump is designed solely as an in tank pump and to be submerged in fuel at all times so by me placing it on its side with the outlet outside the surge tank = problem.
Where to from here, my original Walbro pump I had is an external pump but as luck or lack of would have it a different diameter to the Golf one.
Of course I'd custom made the surge tank to fit the Golf pump which all seemed to be wasted now but not to be outdone a solution had to be found, fortunately the Walbro is a smaller diameter so I could machine a step up ring for it.
The pump body wasn't very smooth so first I machined a tiny bit off the pump body to clean up the roughness and then made an aluminium ring slightly smaller than the pump body.
With the ring made I heated it with a gas torch which allowed it to easily slip over the pump, cooled down its there to stay for good.
Loctite between them will help seal the two parts together, with the ring in place the standard o ring idea I had should seal it to the surge tank.
That's what you get for trying something new, must say I'm getting rather tired of taking steps backwards.
(https://lh3.googleusercontent.com/4aOBzYZcD8xHfnhGxWlHNYrwuqom5T9dAJzK84WNPgUs00zXOIiHlqc85o66FJFPR6iQHsuE_lEkJnRnzoVuSIxK_dVTKL5R2kB12VPBcrQwmGCkqsmVeqWoEm6L74DV6QY6gR0FQRkh1GAd_Zx9E4zomlPEcjvL0Hc44JoppQw1Fb9MENhSagbLBl8-lZmdOO0C-NPT4ku1Xm2RvlILZdABHkCsX1zKzatuPEdi54Ar6zgLrf-B_m5Oz6vw0zdy1rTtXGdzjhPXdjwNAY-gVvHZSQyqNLbXT9BJLZQljHaL2pPKRiuY7lw67t4nky1v8RvPx6BzREeotJ00LxJAkisxkptjyK3e2z1YN-uQo0O-uZeo1qfV8KpsUYnxAnPn8GBUtnVDgd8zL38oq8u3JSIDNi7urO8rvfHuY8XYV-qL4AQgeV9NdoH58VC56Dk1eFLuPrxGRBakA9rx9g98t8evcEXy9fpsbgNyk8ue30uDD-DabUC102flpL0HjysAMCllj2HBjreGfl5S6dCbIv_GUJX6MC_km1zBCIvaiM2JXGBUckf0qEApoA-TdJVDZc-mDOSXl8cey27YAhihJnDSmCMRnzDvky73uJazSgSWeduj=w1091-h614-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: spooln on November 13, 2016, 11:39:58 am
Issue averted.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 20, 2016, 05:57:32 pm
No need for a lot of drivel this week other than IT RUNS on Bosch Motronic!!!!!  >:D

Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: VW'n on November 20, 2016, 11:10:42 pm
Bit the drivel is the best part!.
Great that it runs that should keep the build motivated.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: rambo_005 on November 20, 2016, 11:57:06 pm
Well done John, quite an achievement!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: GLIDN on November 21, 2016, 03:57:35 pm
Storm Developments, was great to meet their head tuner while I visited them.
Can't remember ECU brand but hopefully I won't need it, really want to try and make this set up work.

He is good
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 25, 2016, 08:03:02 pm
Bit more done during the week, main problem was i couldn't run it for long where its parked so some aluminium home heating pipe made a great fume extractor to dump the fumes out the window.
It was quite a flaky starter at the beginning and wouldn't start at all with the cam position sensor connected so that was the first thing to try and fix. I started looking at the timing of the trigger wheel which all seemed to be in the right place and confirmed the firing order was what it should be as water and air cooled firing orders differ. The problem was the old distributor which I converted in to a cam position sensor turned out to be 180 deg out of phase.
A simple remove the drive cog and flip over fixed that and she now starts first turn of the key, even my home made tach works a charm.

Fuel trims were also not working but the donor motor all this F. I stuff came off had VVT which I have no need for, a resistor here to fool the ecu for now got the adaptations working, as we go the VVT will be coded out but for now this will do.
From cold it idles a bit higher as it should, gradualy coming down to around 800rpm as it warms up.
I'm confident enough with progress that I can carry on finishing the remaining things under the car to make it driveable.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: mark2 golf on November 26, 2016, 08:46:37 pm
Very cool john.
You will have to start pulling some walls out.
Cant be far off a road test.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on November 26, 2016, 08:58:17 pm
you'll have to change the name of this thread John, rustbucket no more!
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 27, 2016, 11:57:13 am
Very cool john.
You will have to start pulling some walls out.
Cant be far off a road test.

Thanks Mark, yep removing a wall is only weeks away rather than months.
Still lots of small things to finish but I'll do those once on the hoist, I've probably gotten up off the floor a 1000 times but I'm really tiring of that.
Here's a picture of the fume extractor, works a charm and was invaluable for testing purposes.
(https://lh3.googleusercontent.com/wUP8bFUXvSkmOwYjBr1bX4GNqOsHNZa05rqUh-X8CumeuAU-nOVfDXB8d8knkpEQw_-hq1Cqu3t8w1eh2Lh3_AdxyjVmts2PUcwoEaxjER5RLjzjk4RmzdYW8huanKE5CgZr3lo02C7cG4cJraVHJEzR4zv-6_fWULwmoAGwA7ZOLaO7GDcidcdwhJkm-9KuBsJjyk2wdlbZYgDzkd4bubtYwhkfG56Fr9gnKwl7dLkN_SvSwd3fA3I7dDehwgSV0fv5-OROA8YAVC6qsbdrN2dhUDipEUjdyzywxPNgG5GHfArQ85vfs3s8NBqo9CSOaISgkhIkyJ0UJku3Wqd_Fk1U0-3pqBaidvXmD6PYEr5acnEKqNF0uvkklY4DFFoiryYcsQgRD_Y1P7gP4T1amDp5dAhvxSht32whGwl5SEYukn2njxtTQqvqUB-Gsv5DGxpIxCSXnOnh4n9lZKYQ-igdAFn70eLtAprDjPSAL5cdqR3nFaDrGSS1EUmNpggzjtNqnkOKqh4jFTvXDqtlunw8H8OEtESotrHIhiWIw_jWOL7CoPFqyiG95Rrk99ES0vcAbFYOLiEJN4LWzcLvP2hL25R5btby1WcMYBJP3M2Rzl2j=w1091-h614-no)
A few things left to finish underneath like the charcoal canister which I decided to use running the vent line from the tank to it, these old vw's always stink of gas with the tank in front of you so hopefully this should solve that issue.
Since the original fuel line wasn't being used I've just utilised that for the vent system mounting the charcoal can at the back.
Finished the wiring for the oil cooler fan and thermo switch, there's less and less things hanging down under there so progress must be being made.
Last major thing to do is the DBW pedal and with an intercooler, oil cooler, charcoal can and air intake under there its very very tight with the only spot left on top of the gearbox.
Way too difficult to work under there so I borrowed and trans case which allows me to make the needed mountings on the bench, hopefully its all fits.
I'll use the original throttle cable cut to length to pull on the DBW pedal, made a mount with a series of holes so that it can be fine tuned for the right feel.
(https://lh3.googleusercontent.com/v8AOzG92WPui1gnZHl0hsxyVc7BgEfVCR1PGE8axTI9LyRf10FrSyusPyXipx1QvJa2I7usOus-Yb0Id_I7XjXGSv5pJFxA_Y_4HgV2-Sgk9c3YIDdyeRJWRP22vLDEOlag4EDq4lqXgrl5MfQ1JnstFWcXkVcdQFyiQ-hPvHScp6SDwdXEE0EPZlSr4AzKEJJ8hMpMvQUstJ36cuiSEJFav1c07ecw5Ceqi_WJKU8aEYB5pCY9qqiRIkopq3pT1jEGEqjhnhUHxK2TqQBM4BMlzo2wO___RCZwY9btjlyVTh31hkrhIKJ1ps4p4rmntFcBjEr2_Z1igu2FPJw0CTIv4hJ_OuGb3GTKiZlSXqdFTpKWuxnrEqHoJ3pcxv657x6SvblZrNwGVYWa67axuXjQncKa_tP0oPmQH0Dwg6tGowRtksHahphwcDLEivHQapGeN0ZW3U-Ai940znWLPYJC5EX2vBy22HAs4j4gC1Cwk3zQOtZF7ICKPUQoT8CH6GMYcSY4MNl8HUJOdgd3o29obozHDRnmSO-K39CiLWyPrDD6A0EZnHCYaStRIQU0G1uwYu6MYR-hr6R2cgyvGf4rU9T5Ze0g2W8Q780blegVj-44Q=w1091-h614-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: RobClubley on November 30, 2016, 11:47:24 am
Type 34 on Petrolicious

https://www.youtube.com/watch?v=hzpjFVN5Yfg
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: schattenblau on November 30, 2016, 12:32:05 pm
you beat me to it rob

;D

nice video
early 911 steering wheel ?

 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on November 30, 2016, 01:28:37 pm
Needs lowering and Porsche wheels  >:D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 04, 2016, 10:53:59 am
One of the last parts to make is a catch can for my various engine vent lines and stops the oil being routed back to the intake. One small spot in the engine bay remains which would perfectly suit a small catch tank.
I made one from cardboard first playing around with the shape so that it can be installed and removed in one piece, the place where it fits is quite an odd shape with no real straight lines so just this little tank took more than a whole day to make.
Finally had the shape which would work and clears the fan housing without needing to remove it so traced it on to Aluminium sheet, I tried to minimise the amount to pieces to weld and in the end made the whole tank from only 2 main parts which were folded in the correct shape and welded together.
A separator plate inside drilled with a bunch of holes should help to stop the oil getting as far as the filter, add a couple of hose fittings job done ready for a coat of paint.
(https://lh3.googleusercontent.com/wA0wzmgnwgIPRhRKXgU11wSw9YiuP9Fgv9aHu8EBOyuRjCvWQ8NIPdLlYdCoiBXWr_hnCx5h0IkfqYpVvDWy4u6wIsOo-2Xh_WNtbVLLTUh9l6LVtnpszLEehqfKvy0WwFwUTM1D47jOY3DCqQ_TuQBiRC3iMTIJAINLWLVpV2VIabAqmD-MU5zY6WJtZ6QWSydxGB1gURymNWg5CeFzSvwDVE5WEgMNAgLKS2KOH_xrDsdH0G0o91yOcQm8qwqxdoulaRG4yg4UieRCgXZPXvHDEBjP7Rd0SHqSmX8DynNQhijAbPcOmmneVbWRXNaeWfOzQAhtcrkyShNboCA7H7RZ14YBx7Ln0bHCKCoHfLwxyWipJGEBeP7WRBbcP3m6sxhwdFZzRk6FXqLKtMmVMVLQlbDTjxqtRg6IPZIEbb8W2MVd4FxecCKzaytY71EZzEXDUAZFE7IViok8bwfrgLEz6Z5W2JAAcuqQBeju9rA4JRdxkJJzEv4TT1dMfW4Dm9dOl1U0Ex6YQiqNjn7iXDxSW1qyDXS2HkgCyIU5Q3z_7Ng-H63P1OBzJQhsRNhy9kjFysgNWc246-oMWMgykfZgg4orc9kdAFhcpnaRai-qOvOv=w1092-h614-no)
(https://lh3.googleusercontent.com/5rrowguPbZfTgkof9BhGBdpUVmbJyTGyvWoW0Bv8AzxczN7gUhCmYOWV_TfgkwiqiATHC8F_F3Wm5JBpjXGro3HMjnd4zT38IoywBxQ0fJ1oQ_Ln1C15lRUloO4s8BcM9sGS7OVahQaULvODc8aTlxN_Y9C5SAdgEBAykjOtd9a0ZT9lAQqS1FCfbqXUZQz3z1p7XlFPt0JQfdO_reb0fENs5LDLI3fn-9T8gCTZXMqzSpScV8XE-1i7O-kyZWGZz4LlCSbZn_nl0E5-luEyJIc0fQrE-RETOKQzeNmPk8kdzzJ9CexeFhmGhy08BJ9HMmWhyZZZhLPdzEwJ-DlVM3kGRwJni7s_ZuRx55U62SjyoXPthx6d9dDvRnxnSM31tlWhkZ1X_tybXH2bCaSA2gJfkUoneAAzryUIlQV5tc00Z2zHJ5cLOTv0Q0DfJnLBNnmdjLnIDeoQAtL8tgCxW2pg1VsopiupoFnm6jeV6BnpnsPJpQc9D0XxX6rsI78Ww3OyHwGub2FgTOuT_FnypU2Tx3m3RmkM0gQtrx0qudTkHtE5rRRHmwLs95eBMXIJhfcWd-vYXDDaOWUAuFMKM_MkCgd1GWrT-AbqJYA83OQxwAcL=w1092-h614-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on December 04, 2016, 06:06:38 pm
it'll soon be time to get it out to enjoy the weather John, great work
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 11, 2016, 10:10:54 am
With the holidays approaching fast and a clear hoist for a few weeks the wall had to come down to get the car out of its storage area, it was well worth the effort to put it in there a couple of years ago as its been a brilliant spot to work in but its gotten to the point where I need it out of there so....
Remove the wall and drag it out, If I wasn't doing work to the building in that area in the new year I would probably put the Porsche in there to work on but that doesn't really work at this stage.
(https://lh3.googleusercontent.com/BJiboZpyrRenYoNRgwux-ooD3xRvsVvlUepgOJ3VdpK4B5znzheil7xWMuCJ-v4aad7QAAYkDErfVMHc63QbHf5oLTdRGS9BNTnWzs2KYxCWCZ9ZWM1v206CkSt7d-w0UX5DIqkvaZVcP4xeITDXxOWe-EUWRzSS9SdBnxgmiwdTDv4L-MRCT3W6lpq7KcAhAS0Up4AUivw5TPKnNFNf5IPBq-ZAKpjf5_UwuIVO9IWLfmyleYSFxhSvp8acimK8t1w3VORQ-LMxRtlCLgbt03853AQHfxOUEnWR9fKoRGhEeXbOsB20O8sj7xrW6XgfXjaq_gr7xlyIfQO_6ehuTdH_R3c17G0wAEMlEb7Tdt4yl4FAiHP6VPSuedBdVbg77P95zt2sQ4Qyc-slaS5RZsANYHUlZb2dQfZC87n4IEKUWeUJjCO4_Yv6tbCil8UjPT2ul_NgbA717UBKwbhYBJS4pyPDL1uNobGVkj1TveJpmXl872QcxOoQcImhrMygYJtpJcsj8U6yQm9OMW_yz0aJjF_FtxjK8usmmidxebt9jAkB55Exnqxl5TQrAbs7mesvLbhxdLpqN9QTHPdEMSAg-lMB4xwSomhPk7TM2LAjoy7MfRqX=w543-h306-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on December 24, 2016, 06:22:03 pm
Still more progress on the ole rustbucket, one of the last major pieces came together today namely the seats!
Been a long time coming......read a year! yes that's correct I gave the trimmer my frames exactly one year ago but then great results are worth waiting for and its not like I needed them before it was actually driveable.
The guy is great at what he does and been doing it forever so I'd rather wait and know what I'm going to get even if it takes some time.
Finished putting them together this morning cleaning up the old hardware which could be salvaged.
(https://lh3.googleusercontent.com/RNuPYMhHvcRcjw1POtlCkXpNIKWIokM-5PW9gfDmzWS9rXflQRI85vDtPyJ-EwQXZpKSOls7AQq7_PLDSLA8aow0HCzFRFaYNKm_EtGpx5xZPGcdaagYzaca9bRch3LXuumm7D_6Hx3sTmQkZUFXwdQJ-Zu5nUucs8cg1EC_jkf0fSP-uuN99cVnohw74KyLABinYThAAzZ22d1bxMa3gZeDR53IoVUXrH63TBLJRPaC161EQ6_eUVpoMn-GxPMBPDNq15xy1wD26zScgGSopzIlhZadykbRPPsGzomzyRSj5yuA998YXMVPRsnyWKpu7XeXDA526aQOHbgl5PBBeL-T-75Hl1_upFSmMHZMIGC-a5zDrhl32YYNjB-q4k5oYamrV-AJO8jKuNEtNAlYkPT38J7e3QR3tGnhprgVG5yvzNA3QRberZqxkT2mdRA-I6U5VTKTdGZdv2KJEo6OFwGPyegkywr7xPjnLY5-JeBxDfG0_Jey0JZxw-OjvN2DamAVgSsbZ-okuOJMWhjpkgvzYql-nIcYzA4egYF-RlN1JAYFpcyqOMvGBcPS9JVCPABVmWLqBDz1OgX5NqkxXYrY-9FgIkY3qLn35bo4A5txxA-HFhOH=w1091-h614-no)
Passenger seat fitment was fine but the drivers side was too loose so had to remove and spread the runners a little with a block of wood and the knock o meter.
Re installed and all good, finally have something to sit on once that first test drive happens.
I have the car on the hoist now to fix a bunch of oil leaks and hopefully finish a bunch of small jobs underneath including some form of scoop to direct air to the intercooler.
(https://lh3.googleusercontent.com/F8HVG2mOmfDv4zdW4CtuaMunLe5dNndvWG1yqB0mNu_V4XaIyvpAo1LnJ9jwSuSPgJfdDOR67uPrO-PsOPSXoSqoRiyAYOoBBLzmSJXKaE_ImBjKSNj1q7_RgoH7dmOqW3UNhS76e0b--w_CHKP-h2oatVU5u29o2j7TlroQ8ykLFzf0J1LHVJquOB-OnrWYjTF2sPrPLkqMa-FlOpGBnFVjgTA8p6taxq-w2QTwGpwGJ5nt9A-ssJaCaYy9n36E4uGSfx4jIYw_b-Oqsm01Q5quOBlKCI9W0aw5WOuwtb_r6_tgZDj9scNB8XROiGX8fbaeedwqhBFYV-d3mznKx6lBt6NRqPtc_u-qzl2pCt88emFWm9uTILPFCd3ApfuM6Bxggsah2KiTVNv03CwqBf953AID26l3L792xi4IqdAWnEzn57p45QhSytMGyQ8rGhwMUdSSgmXmK0zCmJQMD3ZieH2UlahrpKlTLipZ-cJi9RbCGze-2-x5aOZ6BqvvHREFn7L2jkwb5q4J7qTXocViNS-ricqwRNdAxUb1htHnhVa_7ac2roRGLT2fpbr7CozMtnqoN7XHgNbkUY6YiE-00HrNdy4oQYDUixYaq1v7Fxevm5ej=w1091-h614-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on January 07, 2017, 09:04:45 pm
I had these big plans to do all this work on this thing over the holidays but none of it has really come to much, one thing though is that having it on the hoist has made life a 1000x easier.
Anyway a few bits and pieces here and there gets me a little further ahead at least, started on a scoop of some sort today to direct some air in to the intercooler under the car. Making the pieces from cardboard which I'll then trace on to aluminium.
(https://lh3.googleusercontent.com/cSXpw8KR0LAJupvewDPVvySb_dudkax5oPojueZO1EevS2m_QEejMMoFLWxt9AFXhzMamRqVouhOIzq7hwAGxjRboRG6DZ1XRbCenNvjEn-qqB-W5eb9c0X-JHwHnCiuMHrxVMh5P-KtJneK0nMTRVgpIpVMukvwFCBshGuTi9YyeZ-8F2xBNzfb6n_ywFA0G25mvBrZ0hABvcHtD221QcQpHndQKvBB-0h_1gW1vdt29akFZ0Wt3PmnjhShMnvpNKEENmhI2WLukmQA9G4l9nU7CQwf_QRD5ajKOCTUziYUZMeB--95aukMzINzNs-cviRrw7uvqDXQreyvEPRukBLlZOYGCQIRB54QItqUcGWmeZ_i9BxT8YEUgfuvQjskVXB_EP-yr8WPWKa4CaarDWyhwbEKmcP6QkbAJczupSR5UHAa0L51o8uQyYm5aSbFWVs7LIcXjFxNwiXEG9_Cv1FipSKavb6pk4o-pucbA6YlGSXQpU--EFS5Pous9jtWFRIdDQTK0QnTnsm16I_BMkdn2mEVpBa7Ok3jdFHjvPBfYGJ0vwaqSgWxg_LL7O-xMH2LkgWccSN5D19q9Xx9l4RuQm1nxNc5vy8cqOfLVgI3Ofx_fJuJ=w1091-h614-no)
Also couldn't resist taking the front end apart again to re index the torsion bars for another 20mm drop but unfortunately that meant the front was sitting on the bump stops so I took them off and cut them down giving me some travel back.
Annoyingly the fuel gauge didn't work so that wasted another 1/2 day, found the sender to be faulty....
the great thing about this old junk is that you can actually take stuff apart and repair it, as was the case with the sender.
Corrosion between the housing and copper element stopped it working however upon testing it the gauge would either read nothing or completely full.
Bit more fault finding done a bad ground on the back of the gauge was problem 2, now have the 6V gauge working on 12V lets see how long that lasts.
(https://lh3.googleusercontent.com/Vvy5x6yt-sAxldCGYgayGSVuFpJ1-3lPsfk5kZxdjsFbhNcibbPC-DKEOdPIPRtGUw1kI56iQxpA5HoMhnkO9NI1Q7VU3sFfeU1865Hnd9JaVwl-NU7CU7ZtqJjOJ4QEQf8c93j1Di5RxdLWL-MYzAkQnQDO8_Gdr9a8zaaRwlGX3tUTS2HVdv_skAdMEduC2Q2qWDpfRhl0mz1dkRJv-Rs2nAJ0gwMDcgB8py03RTuTHhqrFXIaNHBrZVFndPXjpQit14YR7Gm2BVafrDb2KNQ1zX-n_EjA4waoF9GAOqWEYuLZ2E9EHpGf9pvdHbuqoHmRa-x5sB-axRHhgm9Ie3uuhsy_HLVPFcfxGdo14m_fHsxsgJ6BeGkisU7BX1eAHD5xzcWdhbd6ZzMnuY9GPWc8baMflRiarSx0jASQbomCVA0wiQBRc9QcaXh_MUqi47xy4jYc-I7_GP79O2hnfDkjdQtLW8q-cSS2XxZeYLZLAIvkXta5EJEfO3BfaqdeTHZ9TNjjJ-jzIcWmP11drWqKB6WQssvfsdKYO4mjRfVbM4CPoAwbRRokXCbtCDt1KPKgyWioRUn8KdHIh_myHZvRrYQEU4IodUb67c0mW7-cCGbEH7tG=w1091-h614-no)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on February 12, 2017, 12:21:49 pm
Been a while since the last update and have had my fair share of issues to deal with, once all of the items I wanted to do over the holidays were completed the time came to actually drive it and considering its running a stock standard 1.8T ecu it actually runs and drives really well.
I was really surprised how well it drives and feels, not a lot of noise and seems pretty effortless. I don't think I'm making any boost for some reason but that's not a bad thing while the engine is bedding in.
A couple of trips down a very quiet road near work all seemed fine..................until the 3 mile mark..............a huge cloud of smoke coming back to work.
Cut a long story short it blew a hose clean off the oil cooler loosing around 5L of oil in an instant, oil over absolutely everything underneath. I've never had such an epic mess to clean up.
5 hours on the hoist degreasing and washing everything down, amazing where oil goes when sprayed under pressure!!
But why?
Fundamental mistake on my part, running an external filter and oil cooler both of these see unregulated oil pressure direct from the pump meaning it could be as high as 300psi pressure maybe more.
Normally you fit a pump cover with a relief valve but being a type 3 engine I don't have room, after looking at other options I settled on a Jaycee oil filter mount with a bypass valve built in which has a hose back to the sump.
Above 80psi it will send oil back to the sump doing the same job as the pump cover.
Very lucky that I'm running a deep sump as otherwise I think the engine would have been toast, with this deep sump I'm running more than double the original oil capacity.
(https://lh3.googleusercontent.com/BEZRQxHkO7kQpoWv3TwJo-qlpBTQiwNyQtKtv-ZXlLzMcHg3T-HrWgbkN3GMXfg3Wavj6GUM-02b0d1furQqzFSnvuq8iAVd2L6MtAf0Ex-uHTANbDxU_GpXtk5hsKIEeX40v6IZ2BEn4hQGhisKfksam2PAVo7t8GwrNyrY8C6iK0jrZJg_Ij5OXiE_zq23m4xnzMHh3kF1SD_0a76gXEZ3VbW4AGVne_Gk0g5Ef_tBsYcE7NzqmAVGZSC3dqm4Sk0ItPh1nuwGxIo4e9oaH9GjveuRhhw0OcPOSjG1dnAm7oyKJOlGNYX412rFBv8RJPOZS9weabvPavgRVu80qdUoQLgGf484l21h6PocV-TBxKIr4mpTr_LFFNWaYlsvbacQea2HDxd24x0pyy5kiz3M_YROI7uH5rDuOYjhYKTQvP-yUYw7oc6OPj_GZTPo85997-5aqWxBtau0r3RHY3bcpewYFziQw6VBiHn83IOhqD0eE0sDHHIY2LNvXLjWfiy422X-HLxDZia_Fyt4p0URkuRlol2m3iO5CoainMChkrSWi20aJc1bHjGbVabK8rXeo7oOm9picFmePRCztnvu3zgo4RdzTcVL2nJ_yXoGbRHNz6sq=w1091-h614-no)
Few weeks of waiting for parts to arrive yesterday I pulled the sump to drill and tap for the return line, changed the rubber hoses to the cooler for ss braided ones (probably not necessary but I'm not taking any more chances)
Ran the new hoses and buttoned everything up, primed oil pressure and all seems fine so far.
Hopefully this is it for a while and can now just concentrate on tuning the thing, this has by far been the most stubborn car ever as it seems it just doesn't want to be finished.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on February 14, 2017, 10:17:34 am
"I was really surprised how well it drives and feels, not a lot of noise and seems pretty effortless."

that's just how a type 3 drives john! I've been telling people for years! ;D :o  :P
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on March 31, 2017, 02:07:45 pm
(https://scontent.fakl1-1.fna.fbcdn.net/v/t1.0-9/12391273_1235610626455065_1064416504904204993_n.jpg?oh=c284d33e73f24047137e478f84c88008&oe=595E7F81)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: wilco on April 01, 2017, 11:32:26 am
Looks like it's stuck...
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: gti vr6 on April 02, 2017, 01:10:09 am
Looks like it's stuck...

air cooled v-dubs don't get stuck that easily.
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: 80 Vert on April 09, 2017, 09:24:09 pm
Realised I never updated the oil pressure situation, after ordering a new filter mount with a built in pressure relief valve which has a line plumbed back to the sump seems to have worked wonders for the old girl.
Also had new braided oil lines made to the oil cooler so those should be trouble free as well from now on, started out driving very short distances around work gradually venturing a bit further, I have a whopping 52km on it now still on the stock 1.8T map which runs good enough.
I have reached a decision on tuning though which is going to be Eurodyne and that will happen over the next few months.
There's no major panic as it starts and runs good enough to break the motor in, seems to make some boost and gets along pretty well.
Fan on the oil cooler used to come on pretty quick but even that seems to have sorted itself out and by all accounts the motor temps seem fine as such but the proof will be longer trips I guess.
Only a few months to tune before winter at which time I'll pull all the glass and start putting right some of the stuff annoying me.
(https://lh3.googleusercontent.com/CivtKS4y7yO11DKFPfq4-HMheDazsSjfRFRqC0YP1bwVywprLyfSaeA-MBbtXBoRdFyuc6B09RC63w=w470-h265)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: the phantom on April 10, 2017, 12:29:33 pm
looking sweet
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: Fizz on April 10, 2017, 01:00:03 pm
mmm... so nice  :)
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: virus-zn on April 10, 2017, 05:10:19 pm
That pic does not do this car justice... the attention to detail and craftsmanship, especially in the engine bay is phenomenal...
 
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: badhabit on April 12, 2017, 10:34:31 am
i think you need to borrow my 1200 beetle "race car" HA! and i think you'd go WOW my ghia is quick!?!
you've been driving to many modern cars!  ;D ;D
Title: Re: Project car T34 Karmann Ghia a.k.a Rustbucket
Post by: coons on September 24, 2017, 05:24:59 pm
First time on here in a while. Car looks epic John - nice one  8)