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Author: Subject:  Karmann Ghia rebuild
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posted on January 27th, 2020 at 07:28 PM
Karmann Ghia rebuild


I bought this car about 18 years ago from a Sydney damaged vehicle auction.
I have no history of it, perhaps someone out there knows more about it.
It was stripped by another person soon after I got it and some repairs were started by them which were below standard for me.
The stripped car and parts were gathered back and have been in my shed ever since.

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posted on January 27th, 2020 at 07:29 PM



This is how it has sat for years
Time to get it ready for the VW spectacular 2020 which is featuring Karmann Ghias.

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posted on January 28th, 2020 at 09:31 AM



Never seen that one before

good if you can get going before August




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posted on January 28th, 2020 at 10:51 AM



Nice work



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posted on January 28th, 2020 at 05:46 PM



Ok, out of the storage shed and rolled into the workshop

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posted on January 28th, 2020 at 05:54 PM



Empty it of parts and start to unbolt the body off the chassis

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posted on January 28th, 2020 at 05:55 PM



Homemade overhead gantry helps every time

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posted on January 28th, 2020 at 05:55 PM



Now, 2 things to work on.

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posted on January 28th, 2020 at 07:24 PM



Fitted it to the rotisserie

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posted on January 28th, 2020 at 07:25 PM



Rolled it outside for about 2 hours of high pressure hot water cleaning.
Amazing what comes out of it and off it.

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posted on January 28th, 2020 at 07:27 PM



Found out that it had been at least pink, blue and red after the original ''Aluminium'' colour that it was born with.

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posted on January 28th, 2020 at 07:30 PM



The primer came off from everywhere as it had been sprayed on poorly or unprepared surfaces.

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posted on January 28th, 2020 at 07:32 PM



Hours later, back in the shed ready for the next stage of fabrication and welding rusty areas.
That was a good days work.
Looks unusual like this, doesn't it.

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posted on January 29th, 2020 at 07:32 PM



The chassis appears to be quite newish as in probably 25 years old, not nearly 60 years old.
Were or are they available brand new complete?
They are not just new pans, the whole chassis is newish.
Also, the chassis number in the pic is the only one and indicates something.
Your thoughts?

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posted on January 29th, 2020 at 07:52 PM



There is so much and too much paint on the old girl.
So, out with the paint stripper.
I'll do it panel by panel, otherwise it is too much too bear in one go.
Roof first.

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posted on January 29th, 2020 at 07:55 PM



Smooth as a baby's bum.
Then etch primer.

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posted on January 29th, 2020 at 07:58 PM



Both doors stripped and etch primed today.
Surprisingly, they are both rust free.

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posted on January 29th, 2020 at 08:00 PM



Diagonal braces welded in just in case the body flex on the rotisserie.

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posted on January 29th, 2020 at 08:03 PM



Started the bog chase, it is everywhere.
So, out with it all and see what we can do.

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posted on January 29th, 2020 at 08:05 PM



But wait, there's more.

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posted on January 29th, 2020 at 08:08 PM



Bog and rust, what a combination.

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posted on January 29th, 2020 at 08:13 PM



So, new lower nose panel, new sills, new rear lower quarter panels and engine bay centre panel ordered today.
That will give us a bit to keep going with and see what it then needs.
Cheers

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posted on January 29th, 2020 at 08:48 PM



Wow. Great progress but soooooooooooo much bog. It will be great to see another Ghia restored properly this time
Cheers
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posted on January 29th, 2020 at 09:05 PM



Typical Ghia rust and typical bog repair - you're lucky you can do the rust repairs yourself. Mine was a bog sculpture.:lol:
No idea on that chassis no. definitely not Ghia




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posted on January 30th, 2020 at 05:59 AM



As said - so beautiful yet so tortured



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posted on January 30th, 2020 at 09:55 AM



I know this toad of a thing will turn into the prinesses coach with your team of devoted experienced experts..
talk soon, hpyvwyear..




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posted on January 30th, 2020 at 06:06 PM



Engine lid time.
Both sides done.
about 2 kilos of paint mixed with paint remover, came off.
Bright and shiny now.

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posted on January 30th, 2020 at 06:10 PM



Couldn't resist of photo of this gem under the rear guard.
This is someone's attempt at welding a rust repair piece in.
That's where the term 'bird shit' weld applies.

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posted on January 30th, 2020 at 06:14 PM



The guillotine, folder, tig and mig welder were in action today.
One underneath side of the heater channel finished now.

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posted on January 30th, 2020 at 06:19 PM



Bonnet underway but must work elsewhere for the next 3 days, manning reception at our motel in town.
Probably good for a bit of a physical rest on the old body. :)

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