I have a low-mileage (52k) '63 model Karmann Ghia coupe which after some 8 or 9 years ownership I am finally aiming to restore.

My dilemma is whether to remove the body from the pan. This is probably the best way to be certain there are no nasty surprises down the track. As I have no intention of selling her any time this century, I'd like to find any issues, so this is the way I am leaning for now.

The only real concern I have is whether there is a risk it won't go back together as well as from the factory. I have owned a scary number of VWs over the years, and this together with an old '54 beetle sedan I had years ago are the tightest ones I have ever driven - I don't want to lose that feel.

I've never done this before, so I'm not sure if my fears are well-grounded or just fear of something I haven't done previously. Not worried about the mechanics of the process, that seems fairly straightforward. But even if I take all precautions, can I stuff-up a really good car?

There is very little rust evident, although with a ghia you can never quite tell - which I guess is why I am leaning to removing it to make sure.

Any comments/experience from someone who has done it before would be welcome.

Thanks, Angus

gday angus, its up to you how fussy you will be with the car, if you dont find any rust in the outer sills or floor pan then there is no real need to split them but if you do then you may as well, as long as the floors and sills are replaced properly then there should not be a problem bolting back together, be sure to spray wd 40 or something on the bolts and turn them slowly in and out to avoid bolts snapping off as that would create a bit of work for you otherwise

Hey Angus, good to hear you are getting stuck into one of your resto's. Let me know if I can be of any help.
As steve says above, providing any repairs are done (if required - sills/floors) precicely and with care to maintain gaps and alignment there should be no loss of that perceived 'tightness'. It would certainly be peace of mind to do the resto to a body off extent but ultimately it depends on how far you want to go.
All the best
Al

I feel a KG is best prepped split from the pan as the area outboard of the body bolts is a primo spot for rust due to the double/triple panels that drop down just outside of the body bolts. This area needs body off to see and repair as necessary. Spend the time in prep and proceedure and use a GOOD quality pan seal and putting body back on the pan is definately not a problem.

Thanks for the replies. This is one I'd like to do once and not have to touch again so listening to the above I think it's going to get split. You guys have done this once or twice before so value the feedback.

Matt, you'd probably remember the '54 I'm talking about above - this ghia actually drives a little better than that, really nice. A pity the sons of the previous owner all decided to learn spray-painting on Dads old car under the house, the paint is just s**t.

Thanks again, Angus