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halbug
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Joined: March 09, 2006
Posts: 463
Location: Germany
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Evil_Fiz
Samba Member
Joined: May 06, 2011
Posts: 1056
Location: Jacksonville, FL
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 Posted: Sun Mar 31, 2024 5:04 pm Post subject: Re: Ghia coming home |
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| halbug wrote: |
Emil, all right - I will find more custom brackets to be made  thanks man!
How about your project, are you still working on it?
Cheers halbug |
yes I am. I have been prepping the body for epoxy. I have spent A REALLY LONG TIME researching, learning, and undoing mistakes. If all goes well my wife will epoxy the doors, hood, and engine cover next weekend. With luck, the entire car will be epoxied the following weekend. She has to do the paintwork because my eyesight has degraded too much for me to do it. Look for a lengthy and detailed post in my thread in the near future.
If you haven't already, check out "Project Binky" on YouTube. Those two guys are the British version of you and Antoine (TRS63).
Cheers,
Emil
_________________
It's not just about what's interesting. It's also about what's helpful, and it's helpful even if it helps just one other guy working on a Ghia.
kiwighia68
See my build on TheSamba at:
The K_R_A_K_E_N_N : a 70 Ghia Convertible reinterpreted |
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 1012
Location: Stuttgart - Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 463
Location: Germany
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1144
Location: Melbourne Australia
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| Posted: Tue Apr 02, 2024 1:41 pm Post subject: Re: Ghia coming home |
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That looks really good, no warping either  |
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halbug
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Joined: March 09, 2006
Posts: 463
Location: Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 463
Location: Germany
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| Posted: Sat Apr 06, 2024 5:40 am Post subject: Re: Ghia coming home |
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Did you ever notice that VW has been using tapers to fit together the fuel filler neck?
I cut the top piece off and turned the access material away, creating back the original 5 deg. taper. Than shortened the neck by the amount the tank gets taller.
I made a little stretching tool with the same taper and pounded it into the remaining tube on the tank.
It worked actually without heat, very easy. It's all about the right tools, right?
The two pieces fit perfectly into each other. Looks like VW did it 
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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TRS63
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Joined: December 17, 2017
Posts: 1012
Location: Stuttgart - Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 463
Location: Germany
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| Posted: Sat Apr 13, 2024 9:15 am Post subject: Re: Ghia coming home |
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Thank you Antoine!
Today I finished the top before closing the tank next. Sorry Ian, I stole another idea from you. Jep! Phantom in-tank pump and return from Aeromotive. I just couldn't find space for the swirlpot.
I wanted to mount it to a flat so I took out the ribs from the tank top partially. After some trails on the old tank I decided to make some cuts and heat to minimize warping. It worked! CUSI welding is very different. The filler needs a lot of cleaning...
Here are some pics.
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1144
Location: Melbourne Australia
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| Posted: Sat Apr 13, 2024 2:51 pm Post subject: Re: Ghia coming home |
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| you're welcome. You have done it very neatly reshaping the top of the tank like that. excellent work |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 463
Location: Germany
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| Posted: Thu Apr 18, 2024 10:04 pm Post subject: Re: Ghia coming home |
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Thank you Ian!
After many rounds of grinding off the CuSi and re-welding I finally got the filler leak proof. The thing with Cusi is, that it wants much more power than what my welding machine is recommending. That is something I had to figure out the hard way. At least it's easier to grind off CuSi than steel
If there is not enough welding power the CuSi just drips on the metal creating build up and holes in the weld material. More power and it started to melt and flow evenly onto the metal. Exactly how I wanted it to seal the tank joints. They are next.
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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halbug
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Joined: March 09, 2006
Posts: 463
Location: Germany
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1144
Location: Melbourne Australia
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| Posted: Sun Apr 28, 2024 2:41 am Post subject: Re: Ghia coming home |
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My experience is it takes a number of days to get 'your hand in' on any type of welding, so I still think it is going very well. It is very exciting to see the halves of this tank finally going together.
Brazing with Si Bronze needs the steel to be super clean, I imagine Si Copper is the same. It can be good to finish sanding with 'glass paper', the light brown sand paper for timber that is made from crushed glass. Any left over glass fragments (silca) will melt into the weld where all other types of paper can leave a residue that spoils the weld. The other way to finish is with a stainless steel wire brush which also leaves a clean finish. Then after sanding or wire brushing, clean thoroughly with acetone. 'Cleanliness is next to Godliness' in welding.
I hope it goes well for you |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 463
Location: Germany
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| Posted: Mon Apr 29, 2024 2:04 am Post subject: Re: Ghia coming home |
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Hi Ian, thanks. Cleanliness is not the issue here. I have tried on fresh sheets of metal and had excellent results. It seems to be the inconsitency of the seam, because of the spot-welding on the back side. When it comes to having spots of thicker metals (spot welds) mixed with 0.8mm sheets and stretched metal portions things get messy. It is such a thin line between getting the metal warm enough for the CuSi to melt onto it and to burn holes...
Once you have a first seam of CuSi on the metal and try to weld again things get really bad, because the CuSi-seam takes heat away and in order to re-melt the existing seam you will definitely burn the surround metal.
Welding the top to the bottom I will have a consistent metal to metal condition, so fingers crossed the CuSi welding will give me less of a headache.
Cheers halbug
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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TRS63
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Joined: December 17, 2017
Posts: 1012
Location: Stuttgart - Germany
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Era Vulgaris
Samba Member
Joined: August 22, 2012
Posts: 1704
Location: Raleigh, NC
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| Posted: Mon Apr 29, 2024 1:47 pm Post subject: Re: Ghia coming home |
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Every time I look back on this thread, I see you doing the most incredible work. I haven't really commented simply because I don't know what to say. Alot of the work is so far beyond my skill level. Just amazing! I really can't wait to see this when it's done. You're going to have one of the best performing Ghias that's ever existed.
I will say that I love what you did with the steering column. If I do another Ghia after my current build, I'm contemplating either a Mendeola or Ihmor front/rear suspension, but I've never liked how you have to re-route the steering column with both of those kits. Your solution to keep it looking stock inside the cabin is brilliant!
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Currently own:
66 Karmann Ghia, L390 Gulf Blue, under construction, here: www.thesamba.com/vw/forum/viewtopic.php?t=760505&highlight=
99 Mazda MX-5 10AE, Sapphire Blue Mica, 6 speed, LSD
Previously owned:
98 Porsche Boxster, silver, 2.5L -- 67 Karmann Ghia, Black, 1500sp -- 98 BMW Z3, Atlanta Blue Metallic, 2.8L I6 -- 75 Porsche 914, Laguna Blue, 2270cc -- 72 Porsche 914, Signal Orange, 1.7 FI -- 74 Karmann Ghia, Black, 1600dp -- 74 Triumph TR6 with O.D., sapphire blue |
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halbug
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Posts: 463
Location: Germany
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halbug
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Posts: 463
Location: Germany
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TRS63
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Joined: December 17, 2017
Posts: 1012
Location: Stuttgart - Germany
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halbug
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