The resurrection of my 1960 karmann ghia

[Antoine_P]

You guys are way too nice as usually ☺️

Thanks a lot for the support!

So, before I continue with the metal work, a small part update, as I removed my door hinges:


3 of them are really good, with no play, one has a light play and will need new bushings. And all of them need a cosmetic restoration ����

Then back in the right back corner, I luckily have more to show ��

In this seal channel we have also some rust issues:


So let's build a patch (only for the right part, I will take care of the apron later as one part) :


First bendings:


And then giving the right form:




And here we are:








This will be a great welding/assembly session: ����


And then the other side of this corner:


Tried the flexible shape pattern:


And let's go:






First look close to the car:


And then hammering, wheeling, fitting, hammering, wheeling, fitting,... ☺️��


Looking better:


And here we go:






I will weld all this corner when every patches will be ready and the car will be on the rotisserie to have a great access everywhere ��

Which leads to my next plan: I want to have it strong enough for the rotisserie, so next work will be heater channel, in order to have a robust body in the rotisserie and then I will weld all this corner.. Stay tuned !

Antoine

[dwmh]

That lower quarter panel patch came out well. Good job.

[Pehr]

Really nice work on the panel

[Antoine_P]

Thanks a lot
So, as I said before, plan is now to do the heater channels in order to be able to finish the pan parallel to working on the body (I don't want to paint/assemble the pan before using it as a jig for my heater channel :wink: )

So, I started on the right side:


and soon enough found some rust




I put the ghia on the lift and worked my way further:






it takes time but I try to remove everything without damaging something else, so removing every weld point separately like here:


my heater channels will be welded on the body while screwed on the pan to ensure that it works together:


and at the end of the day, I did in fact got a lot of rusted metal together again:


Cheers

Antoine

[Jaroslav]

Antonie. Good job - great determination. Looks like only you will be the manufacturer of this car. You make more than 2/3 of a car. Mark it with your logo - made by Antonie.

The barn could tell its stories. Too bad the houses can not tell the stories of the owners. What was in that building and how time changed the purpose of use and will change further. 100 years means nothing to the house.

[onya]

Great Work Antoine,

I've said it before - that Garage of yours is awesome.

[Jack 1957]

Originally Posted by onya

Great Work Antoine,

I've said it before - that Garage of yours is awesome.

X2. The shop is as cool as the project.

[Antoine_P]

Thanks so much guys!!

So, time for a new update..been working further on the right heater channel and it's connexions to the body

My stock of rusted metal grow again:


and I discovered a hole I didn't knew :roll:




the reason is this opening behind that let the humidity there:


so I cut up to good metal, cleaned everything, put some primer, made a patch and welded it:




Then I remade this closing panel:






and welded:


then it was time for some test fit:




and then some welding:




already looks better, a short before/after: :twisted:



and then again some test fit:




looks quite good:


but before welding there, I need to fix the A-Pillar, then test fit it on the pan,... and before all of that, I enjoy the better access to take care of the holes and accident-traces from the past:




Now we are up to date, need to work to bring you the next update ops:

Cheers

Antoine

[123pugsy]

Good stuff Antoine. You have a lot of patience.

[Antoine_P]

Thanks mate, yes, patience is a must here as family doesn't let me work so much hours on it but every bits get it closer !
Some more small steps done:
-here I found some more rust :


Yes here:


So I made a patch:




Adjusting:


And welded:


And onto the A pillar. I want to save as much original metal as possible so let's fix this part:


Adjusting:


And welded:


Next step is the bottom of the "flat part" of the A pillar, final adjust of the heater channel, to weld it in place and then finish the A pillar 👍

Cheers, Antoine