69 Ghia project in UK

VW underneath a classic Italian body design.
carl4x4
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69 Ghia project in UK

Post by carl4x4 »

I thought I better introduce myself and car properly, I've been browsing this forum for a while now it seems to have a lot of great information. In fact some of the articles posted by FJCamper were what finally gave me the courage to buy a Karmann Ghia! I've been competing in UK motorsport for a good few years but in more modern equipment in AutoSolos, Sprints and hillclimbs, and have always wondered about running a classic VW, so that's the aim...

I picked the car up a few weeks ago, it's a '69 coupe, it's a factory right hand drive UK car of which there are only a handful left here (most Karmann Ghias in the UK are imports from California or South Africa) its been off the road for 5 years. I'm in the process of stripping the interior and mechanical parts to prepare for some sill, heater channel, door bottoms, rear inner arches and spare wheel well repair. it has come with no engine, bumpers or front screen, engine is being built hopefully for about 3 months time, just need to find the time to do the bodywork. It's an early '69 so has the 4stud wheels & disk brakes, but still has swing axle rear suspension.


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The pans don't appear to be in too bad a shape, with only a couple of small holes at the lowest point of the passenger floorpan. There have been some repairs around the rear shock mounts which someone has done the classic welding over the rust rather than bother cutting it out. I spent an afternoon grinding away the old rust underneath to reveal solid metal, I've got a beetle repair panel for this and will need to fabricate something to join the boot floor to the arch.

The passenger side has some similar rust starting although no quite as bad as the drivers side.

I'm having the sills done professionally as they are on the outside you can see them!

On the bright side, it looks like like the engine compartment is OK, including the battery tray and it appears the back of the rear arches have had new bottom(s) put in at some point which means they are also good.

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The old repair ground back to remove the rust it was patching up, in some points the patches were 3 deep! I stripped off the rest of the paint from the inner arch to make sure there were no more horrors lurking !

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Front footwells seem ok, can anyone tell me what the three holes are for in the dash? Also I suspect the black VDO clock isn't the original unit.

Thanks,

Carl.
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FJCamper
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Re: 69 Ghia project in UK

Post by FJCamper »

Hi Carl4x4,

The 1969 right-hand drive Ghia dash is obviously not just the mirror image of a left-hand drive, as one might suspect, but it appears the holes you refer to (under the clock and fuel gauge) are the right size for VW knobs and switches. We (USA, left-hand drive) did not get our switches clustered as you have on the extreme right of your dash. I believe I recognize the emergency flasher and windshield washer/wiper switches in that group.

That is an aftermarket VDO clock, of course.

The good news is a Porsche 356 tach will fit right into that central speedometer hole, and you can flank it with a small aftermarket VDO speedo (direct fit) and stock fuel gauge.

European Ghias and VW sedans kept the swing axle past 1969, where VW put the double-jointed rear axles on all US models to counter bad Ralph Nader safety publicity -- his book "Unsafe At Any Speed" killed our Chevrolet Corvair and caused VW to give up swing axles for US export.

You should have a Z-bar or at the least the holes and studs where a Z-bar was once mounted above your rear axles. You may know the Z-bar is a very efficient arrangment and can be shimmed to act all the time instead of the comfort-conscious factory assembly with built-in reaction slack.

Anyway, I'm glad to see a good Ghia get a home with a deserving master.

Good luck, and don't hesitate to ask questions.

FJC
carl4x4
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Re: 69 Ghia project in UK

Post by carl4x4 »

Thanks for the reply, I was wondering about the Z-bar as it is still in place at the back of the car, but the rubber bushes and the rods that drop down are corroded and perished so will need to be replaced. I was wondering if it's worthwhile keeping the Z bar if I'm going to fit a camper compensator, or if it's better to run with both of them.
Also some advice as to which make camber compensator is a good one to get would be great thanks

Carl.
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FJCamper
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Re: 69 Ghia project in UK

Post by FJCamper »

Hi Carl,

The factory Z-bar, even shimmed, is a bit weak for spirited driving. When we talk about the superiority of the Z-bar, we're really talking about its design and function. A racing design, with a much heavier crossbar, is used by Formula V cars.

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Original Porsche "compensating spring"

Probably better that you use a camber compensator. There are two basic types, the original design that attaches directly to the axle ends by bolt or strap, and the more recent Sway-A-Way transverse spring that acts as a cradle.

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Sway-A-Way spring with shop mods to connect ends to axles -- we use this ourselves.

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The two types of compensators.

FJC
carl4x4
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Re: 69 Ghia project in UK

Post by carl4x4 »

Thanks, so as the z bar needs a load of new parts, I'm probably better off removing it and replacing with the camber compensator. Any view as to which is better? how does the one with the red pads stay in touch with the axles? is it just pushing up all the time? the CB performance one seems to have loops to hold it in place.
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FJCamper
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Re: 69 Ghia project in UK

Post by FJCamper »

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Hi Carl,

The CB Performance spring has loops to hold it in place. But kind of loose-fitting.

The Sway-A-Way is a genuine cradle and just pushes up, which works very well.

We have modified our Sway-A-Way with U-bolt end clamps, making the spring work both up and down, keeping the axles more even and under control.

FJC
carl4x4
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Re: 69 Ghia project in UK

Post by carl4x4 »

That looks good, are you sure that's a Volkswagen? where's all the oil under the car ;-)

Do you run stiffer torsion bars at the back?
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FJCamper
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Re: 69 Ghia project in UK

Post by FJCamper »

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Topside of 261 -- given this number as it was the first number issued a VW in the Carrera Panamericana in the early 1950's.

Hi Carl,

That's the underside of our Carrera Panamericana Ghia, a 1965. It's on tow tires for movement this weekend to a local slalom/autocross.

We run standard front and rear torsion bars. The originals, incidentially. The rears have been adjusted once to compensate for wear. And they have nice Prothane urethane bushings at the outer torsion bar end.

In the previous post photo, you see a stronger transmission crossbrace, no heater boxes (VW industrial engine sheet metal), and a dished aluminum (a-lum-min-num this side of the ocean) engine oil plate covering a special oil suction pickup and windage tray. No deep sump, as it would get damaged on a Mexican tope.

FJC

PS: If you havn't heard it, our own Ghia (our other 1970 #53 car) song as performed by the surviving Beach boys

http://www.youtube.com/watch?v=g-nxYy6HEX0
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galazkiewicz
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Re: 69 Ghia project in UK

Post by galazkiewicz »

carl4x4 wrote:...
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Front footwells seem ok, can anyone tell me what the three holes are for in the dash?
The D shaped holes are part of the raw dash stamping, there should be extra holes that are never used. One D hole is used in the US spec brake circuit warning light, the rest are covered by the wood grain vinyl.
carl4x4
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Re: 69 Ghia project in UK

Post by carl4x4 »

FJCamper wrote: PS: If you havn't heard it, our own Ghia (our other 1970 #53 car) song as performed by the surviving Beach boys
http://www.youtube.com/watch?v=g-nxYy6HEX0
You've got a KG song, that's fantastic :-)

Good to see the Karmann Ghia being Autocrossed in the US, There is one Ghia that competes in AutoSolos in the UK that I know of (like Autocross in the US)
Ian Godfrey
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Re: 69 Ghia project in UK

Post by Ian Godfrey »

My RHD 69 dash holes left to right were as follows... wipers, blank (covered by vinyl mask),blank , headlight, emergency flashers.
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carl4x4
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Re: 69 Ghia project in UK

Post by carl4x4 »

Thanks for the replies on the dash, it looks like I'm only missing the wiper switch which I presume is the same as a beetle? Not sure what the green switch on my dash does, must take a closer look at where it goes.
Ian Godfrey
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Re: 69 Ghia project in UK

Post by Ian Godfrey »

yes wiper switch is the same as a beetle
carl4x4
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Re: 69 Ghia project in UK

Post by carl4x4 »

Bit of a long post, but I thought it was about time I put an update on the forum, I admitted defeat and decided to get a professional to do the welding (there were just too many complex joins & corners for a novice welder like myself!)

Hooked the Ghia up to our Camper and away we went...

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First pics of the rear arch repair, he's fabricated a new piece to replace the boot floor section that has rotted through, and used a Beetle body mount arch section which is a very good fit considering you can't buy that section for the Ghia any more.

Before:
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The Beetle section offered up, plus a new fabricated part to match the Beetle part with the Ghia:
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After:
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The sills have revealed some predictable horrors, the heater channels crumbled away when the outer sills were removed...


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What was left...

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Some repairs to the floorpan, plus new heater channels, sills, inner & outer rear wing repair panels

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New heater channels going back on offside
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plus new inner & outer rear wing panels

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(The doors will be addressed later)

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Very pleased with the end result on this side, the guy doing the welding has put a lot of work and thought into it, with a lot of new metal that should see off the rot for a good few more years :) A trial fit of the doors before the sills finally went on made sure all the gaps were correct :)



This week is the offside sills, which are predictably shocking, words fail me... :roll: :roll: :roll:

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FJCamper
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Re: 69 Ghia project in UK

Post by FJCamper »

Hi Carl,

Impressive and skillful work. Expensive as well, I'd imagine. But now you have a solid Ghia, and one that gets more valuable by the year.

You've really saved one, Carl. Thanks.

FJC
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