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a.wilson Samba Member
Joined: January 11, 2007 Posts: 2033 Location: Georgia
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Posted: Wed Apr 08, 2015 10:31 pm Post subject: |
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Turned out nice! Good seeing someone taking time to refinish their original Gemi clamps.
Plain old nickel plating. Did you have a shop to plate them.. or was it from a Do it Yourself kit?
I was thinking about redoing some of mine.. either with some sort of medium or dark tough paint or plating. (but haven't gotten around to it yet). |
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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Posted: Thu Apr 09, 2015 1:17 am Post subject: |
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Hi Mr Wilson,
I'm glad you appreciate the Genni clamps. I'm trying to work out how to orient them on the engine so the logos face towards the back where they can be seen. In most cases the screw head is opposite to the markings and screw heads will end up facing towards the best access thus putting the markings out of sight.
I had considered those DIY kits but I don't have the means to deal with disposal of waste materials. I live within 20 meters of a creek that drains into Sydney Harbour 1 kilometre down stream. These days the water is quite clean and if the fish go belly up on account of something I did, the authorities could easily find me and the penalties are quite onerous.
I used an electroplating shop that's been around for 50 years near the Bankstown airport. They are good for nickel on small non decorative parts. For proper display pieces, like bumpers, hubcaps, mirrors, dash trims and stuff visible all the time, I use another shop in another town 360 kilometres away. I collect batches of work and drive them down when I'm passing by for other reasons. He makes more effort preparing the metal so it shines better. I can see the difference in his work. He also understands restoration work is different to production work.
Nicholas _________________ '66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery! |
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paul_round Samba Member
Joined: October 17, 2014 Posts: 502 Location: UK
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Posted: Thu Apr 09, 2015 9:28 am Post subject: |
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Awesome, awesome build diary Nicholas.
I'm particularly impressed with the fact that you did your own RHD conversion, as this is something i am considering, (UK).
Did you come across any major issues? |
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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a.wilson Samba Member
Joined: January 11, 2007 Posts: 2033 Location: Georgia
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Posted: Sun Apr 12, 2015 9:44 am Post subject: |
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sputnick60 wrote: |
Hi Mr Wilson,
I'm glad you appreciate the Genni clamps. I'm trying to work out how to orient them on the engine so the logos face towards the back where they can be seen. In most cases the screw head is opposite to the markings and screw heads will end up facing towards the best access thus putting the markings out of sight.
I had considered those DIY kits but I don't have the means to deal with disposal of waste materials. I live within 20 meters of a creek that drains into Sydney Harbour 1 kilometre down stream. These days the water is quite clean and if the fish go belly up on account of something I did, the authorities could easily find me and the penalties are quite onerous.
I used an electroplating shop that's been around for 50 years near the Bankstown airport. They are good for nickel on small non decorative parts. For proper display pieces, like bumpers, hubcaps, mirrors, dash trims and stuff visible all the time, I use another shop in another town 360 kilometres away. I collect batches of work and drive them down when I'm passing by for other reasons. He makes more effort preparing the metal so it shines better. I can see the difference in his work. He also understands restoration work is different to production work.
Nicholas |
Hmm.. that makes sense. Think I may do the same when I get around to redoing mine. (pay the plating pros to do them rather than wind up creating a huge mess at home, lol). |
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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Posted: Sun Apr 19, 2015 8:21 am Post subject: |
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Stepping backwards before moving forwards..
All the headlining work has been removed and we are starting again.
I wasn't 100% happy with the seal on the body bow. Even though I had put a thin piece of neoprene on the back of all the wood as seen here, I decided to go one better.
This stuff is a really good weather seal. I've been using if for years on outdoor cable and waveguides in the Satcom installation projects I do.
A length goes on the inside lip at the top of the panel.
And then some is applied to the mating side on the wooden bow
The surfaces will squeeze together create a seal
Its all back together and now we are where we were almost a year ago.
The next few weekends are being dedicated to the car. Unless something else comes up.
Nicholas _________________ '66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery!
Last edited by sputnick60 on Sun Apr 19, 2015 2:06 pm; edited 1 time in total |
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CiderGuy Samba Member
Joined: December 23, 2013 Posts: 1351 Location: Bucks County, Pa
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Posted: Sun Apr 19, 2015 9:27 am Post subject: |
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Thanks for this detailed thread. I've used Butyl rubber tape on the port holes of my ocean going sailboat, works fantastic. _________________ ----------------------
Cars Currently Owned:
1970 Karmann Ghia Coupe
1973 Karmann Ghia Coupe - Project car for sale
1970 Karmann Ghia Convertible (Body off restoration)
Timing is everything |
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easy e Samba Member
Joined: May 28, 2008 Posts: 3931 Location: 1 hr north of Santa Barbara
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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WooleyNelson Samba Member
Joined: July 13, 2012 Posts: 191 Location: Kokomo Indiana
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Posted: Tue Sep 22, 2015 7:37 am Post subject: |
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So... Ghia restoration *IS* the equivalent of rocket science!!! |
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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Posted: Sat Sep 26, 2015 8:57 am Post subject: |
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OK so I was chastised for not getting much done on this project of late and rightly so. The day job has been taking up so much time this year but this weekend, despite all the other demands on my time, I was able to insist on getting down to some assembly of the engine. I enjoyed the task.
The nicely cleaned and polished thermostat.
It was first washed in a solvent to clean the years of grime then sat in a lathe with a heat gun over it. This made it expand and I was able to clean it with more solvents and metal polish. It looks brand new and tested properly measured in a hot water bath with a thermometer.
The fan shroud took a while to get right on account of the Generator not being properly assembled. I did it last night and didn't have the bushes quite right. It just needed reversing of a few steps and making sure the Fan at one end and the Pulley at the other end has the right spacers.
The view from underneath showing the tin work
The view from the back showing the bulk of the goodies mounted up.This is as far as I managed this week. The Carburettor is waiting to go on as is the coil and the HT and LV wires. I will use the Vintage Speed muffler system similar to the one John Moxon uses . Boris at Vintage Vee Dub is working with them to redesign the Type 1 exhaust for the Ghia. The new design will tuck the muffler higher under the rear valance to create more clearance for cars that have been lowered. I have the original VW heater boxes to go on and these have been ceramic coated.
Steady as she goes.
Nicholas _________________ '66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery! |
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Tonyorlo Samba Member
Joined: June 03, 2013 Posts: 182 Location: Glen dale wv
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Posted: Sat Sep 26, 2015 3:45 pm Post subject: |
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This is a great build! You have a very impressive attention to detail. |
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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Posted: Sat Oct 10, 2015 6:22 am Post subject: |
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Some good news today. The engine was started for the first time on the test stand. Normally I'd have photos for you but since, on an interim basis, an old Monza style exhaust is bolted on, I refuse to dignify it with any published image. You'll just have to wait a while.
We learned that that flywheel on this car is actually a 12V flywheel, so somewhere in its past things got altered and this discovery will reveal an impact later with the gearbox's bell housing and of course the starter motor bush. How odd is that given the car was 6 Volts when I got it. I've never heard of a 12volt flywheel and 12 starter made to run on a 6 volt car. It explains why an easy start relay was on the motor.
For now the motor runs fine but won't idle properly. Checking points to a problem in the carb. The plan is to swap it out with a known good one and see if that proves to be the root cause.
Another minor problem is the oil leaking out of the NPT plugs. It turns out I had forgotten to properly tighten them. The ones at the back responded to a few more turns to tighten them up but we'll have to get the flywheel off to get at the front ones. But this is why the test stand is important and saves discoveries in the engine bay.
Nicholas _________________ '66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery! |
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Rich62ghia Samba Member
Joined: September 01, 2012 Posts: 147 Location: Wollongong, Australia
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Posted: Sat Oct 10, 2015 4:24 pm Post subject: |
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Excellent progress on the build Nicholas car is looking awsome and congrats on getting the engine running. Having fired up mine recently for the first time I know how big a milestone it is. Good idea on bench testing first makes any re-work to fix much less painful. Did you do the test with the induction improver installed or is that after the engine is in the car?? |
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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Posted: Sun Oct 11, 2015 12:58 am Post subject: |
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Rich62ghia wrote: |
Did you do the test with the induction improver installed or is that after the engine is in the car?? |
I'm told the "induction improver" is sitting in Spain at the moment. I hope to pick it up next month. The car needs to run in for a few thousand kilometres before it can be installed. I wish it was paid for when the Aussie dollar was on a high.
Nicholas _________________ '66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery! |
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John Moxon Samba Moderator
Joined: March 07, 2004 Posts: 13952 Location: Southampton U.K.
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Posted: Sun Oct 11, 2015 1:18 am Post subject: |
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sputnick60 wrote: |
Rich62ghia wrote: |
Did you do the test with the induction improver installed or is that after the engine is in the car?? |
I'm told the "induction improver" is sitting in Spain at the moment. I hope to pick it up next month. The car needs to run in for a few thousand kilometres before it can be installed. I wish it was paid for when the Aussie dollar was on a high.
Nicholas |
I haven't asked about the "induction improver" recently Nicholas as I've been embarrassed at the "glacial" progress my friend has been showing. It sounds like Spain is undergoing some recent "Global Warming" _________________ John.
Judson Supercharger Information on The Samba
My 1958 Shorrock Supercharged Karmann Ghia
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sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3915 Location: In Molinya Orbit
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Posted: Tue Oct 20, 2015 5:30 am Post subject: |
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I took the engine for a little test run on a borrowed Beetle chassis. It runs like a clock. Not very powerful but smooth and torquey enough. It starts first crank without any added throttle. You can't ask for better than that!
We fixed the idling problem with a new idle solenoid. Just the next size up which happens to match the original 6 Volt. Obvious if you think about it.
So I managed to get it home finally and parked in behind the car. Its ready to go in.
I have to prep up the thrust bearing and a few things in the engine bay concerning the battery cables and other wiring matters.
Nicholas. _________________ '66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery! |
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Mr.Duncan Samba Member
Joined: May 12, 2012 Posts: 3542 Location: Houston, TX
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Posted: Tue Oct 20, 2015 7:41 am Post subject: |
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sputnick60 wrote: |
The nicely cleaned and polished thermostat.
It was first washed in a solvent to clean the years of grime then sat in a lathe with a heat gun over it. This made it expand and I was able to clean it with more solvents and metal polish. It looks brand new and tested properly measured in a hot water bath with a thermometer.
Nicholas |
Great looking engine! Remember to adjust your thermostat correctly (i'm sure you did)
https://www.youtube.com/watch?v=HlooE4EdRqc _________________ (Owner) www.vintagecarleds.com
Red 1971 Squareback Thread
Red 1966 Beetle Thread
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1971 Green Super Beetle (sold)
1966 Ghia (sold)
1971 Blue Super Beetle (sold)
1966 Java Green Std Beetle (sold)
1971 Red Squareback (sold)
1966 Red Beetle |
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c21darrel Samba Member
Joined: January 22, 2009 Posts: 8211 Location: San Dimas
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