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Texas65
Samba Member
Joined: May 09, 2016
Posts: 12
Location: Texas
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 Posted: Fri May 13, 2016 7:25 pm Post subject: 1965 convertible resurrection |
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Purchased a basket case 1965 convertible to mess around with. The car is a real project, from what I can tell most of the major components seem to be there. And of course it is rusty........
I am going to need some technical help with this one. Since I did not take it apart, I may need help identifying some items when the time comes.
I do have the Bentley repair manual, so that is helping for the mechanical stuff.
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John Moxon 
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Joined: March 07, 2004
Posts: 13957
Location: Southampton U.K.
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Texas65
Samba Member
Joined: May 09, 2016
Posts: 12
Location: Texas
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| Posted: Mon Jun 20, 2016 3:55 pm Post subject: Re: 1965 convertible resurrection |
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Finally ready to get started on this project. Took a little detour and built a rotisserie. After my last project, I swore I was never crawling around on the floor again (within reason).
I hope to be done with the floor plans in a week or so, it is easy to fit them up now.
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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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| Posted: Mon Jun 20, 2016 11:21 pm Post subject: Re: 1965 convertible resurrection |
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Nice work, if your body restoration skills are as good as your rotisserie building skills you will do well.
_________________
1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon) |
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Texas65
Samba Member
Joined: May 09, 2016
Posts: 12
Location: Texas
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| Posted: Tue Jun 21, 2016 3:07 pm Post subject: Re: 1965 convertible resurrection |
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| Mellow Yellow 74 wrote: |
| Nice work, if your body restoration skills are as good as your rotisserie building skills you will do well. |
Thanks, I am hopeful the project is a little less challenging than the 1970 Corvette I did.
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Texas65
Samba Member
Joined: May 09, 2016
Posts: 12
Location: Texas
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| Posted: Thu Jun 23, 2016 12:42 pm Post subject: Re: 1965 convertible resurrection |
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Need a little information. I have been fitting the replacement pans and have done about all I can do. When I purchased the car the original pans had already been cut out, so I have no measurements to to work off of. I did locate the below image in the sticky area of this forum. It is for a 1970, I am working on a 1965. So far I have discovered that the seat rails on the 1970 must be different. Anyway, using that sketch I am hitting around 593mm for the width from tunnel to inside the outer rail. The drawing shows 595mm. Measuring to the pre-stamped bump on the rail to the tunnel I have 610mm, the drawing has 612mm. If I slide the pans out, the front and rear edges no longer line up with the outer edges of the napolean hats.
My question is, what is the tolerance on the pan layout? Will plus or minus a few millimeters cause major issues when dropping the body back on or is there enough movement to compensate for some deviation?
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Evil_Fiz
Samba Member
Joined: May 06, 2011
Posts: 1049
Location: Jacksonville, FL
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| Posted: Thu Jun 23, 2016 3:22 pm Post subject: Re: 1965 convertible resurrection |
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When I took measurements during the creation of the drawing I found there were slight differences between the two pan halves. IIRC it was about 2mm so I averaged it out to the measurements you see. The holes in the pan rails have about 2-2.5mm tolerance in either direction so you will probably be OK. The measurements for the holes in the pan rails were consistent throughout at 15mm for round holes and 15x18-20mm for oval holes. Another inconsistency I found when removing the pans was the amount of spot welds. The driver side was almost 2:1 vs the PAX side.
Others with far more experience than myself will be along shortly to provide you with experienced information. I have not begun to install new pans so accept my comments as a moderately informed opinion.
BTW, I have subscribed to your thread. Good luck.
_________________
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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c21darrel
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Joined: January 22, 2009
Posts: 8211
Location: San Dimas
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Texas65
Samba Member
Joined: May 09, 2016
Posts: 12
Location: Texas
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| Posted: Sun Jun 26, 2016 7:52 pm Post subject: Re: 1965 convertible resurrection |
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Right or wrong, the floor pans are now permanent. I should have the remaining pieces attached (seat rails, accel. pedeal mount, and jack points) later this week. I need to do some repairs to the driver side seat rails.
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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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| Posted: Mon Jun 27, 2016 3:28 am Post subject: Re: 1965 convertible resurrection |
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Do you have any tips on doing the plug welds into the lip on the tunnel? I am doing this soon and am a bit unsure about the balance between getting good penetration into the relatively thick lip versus blowing through the relatively thin pan.
Also, It looks like you re-welded the two welds on the inside edge and the two welds on the rear of each pan? If so,was this because you had to make adjustments or just because the welds on the repro pans are not great quality?
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1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon) |
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Texas65
Samba Member
Joined: May 09, 2016
Posts: 12
Location: Texas
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| Posted: Mon Jun 27, 2016 6:53 am Post subject: Re: 1965 convertible resurrection |
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| Mellow Yellow 74 wrote: |
Do you have any tips on doing the plug welds into the lip on the tunnel? I am doing this soon and am a bit unsure about the balance between getting good penetration into the relatively thick lip versus blowing through the relatively thin pan.
Also, It looks like you re-welded the two welds on the inside edge and the two welds on the rear of each pan? If so,was this because you had to make adjustments or just because the welds on the repro pans are not great quality? |
I am no professional welder, so dismiss anything I say that sounds out of line.
I drilled 1/4" holes every 2 inches. I started the welding in the center of the hole on the tunnel material and spiraled out to the pan material. It is very easy to blow out the pan material, it happened a few times. I could not just lay on the welder, I had to take it in short blasts to keep from overheating the material.
As for the seams on the pans, there were splits in the pans along the corners and a couple along the back edge. They were never welded. Since the pans were purchased by the previous owner who had done a little trimming, I was not sure if he split them for fitment or if they came that way from the supplier. I just welded the seams up after all the plug welds were done.
I also did a few 1/2" long welds on the underside along the tunnel and around the foot box area of the pan. The plug welds are holding just fine, but I really don't want to fall through going down the road.........Plus, I believe I read in the Bentley manual that it should be welded underneath. I need to go back and confirm, I was on a roll and did not want stop and read the book. |
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Basketcase
Samba Member
Joined: August 10, 2011
Posts: 636
Location: Ohio
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| Posted: Sat Jul 02, 2016 10:41 am Post subject: Re: 1965 convertible resurrection |
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looks like you're doing a great job.
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'72 Karmann Ghia Coupe (the Boss's) |
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Texas65
Samba Member
Joined: May 09, 2016
Posts: 12
Location: Texas
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| Posted: Tue Jul 12, 2016 7:50 am Post subject: Re: 1965 convertible resurrection |
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Making a little more progress. Finished welding out the chassis, sandblasted, and painted with chassis saver.
Pulled the chassis off the rotisserie and mounted the body on it. If I could manage to get a little relief from the heat, more might get done. It has been over 100+ degrees F everyday for the last 2 weeks.
I guess it is time to start pulling off some of the rusted out panels and see just how much work is ahead.
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