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Thread: TiefGarage VW Karmann Ghia '68

  1. #1
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Arrow TiefGarage VW Karmann Ghia '68

    Hello stanceworks reader,

    about a year ago I was here, building a VW Passat 32b with my friends.

    Times gone by and now it is time do something fresh.

    I went to the states for vacation, and fell in love with an old german beauty.
    It's an Karmann Ghia Coupe. This car is more often to be seen in the US than in Germany.
    Here with the Krauts nearly nobody drives one. If you see one, you are in the museum or at a very rare vintage car meet.

    The moment I heard the lovely sound of the VW boxer engine, I created a huge need for the car.

    Somewhen later back in Germany that idea did not want to go away. You know? The incepetion thing. That thought to drive a Ghia through sunset in my beautiful region ,the OreMountains, was there and needs to be satisfied.

    I looked through a lot classified ads, till i found an "export" model dated late 68 in Frankfurt Germany. Car was said to be in a condition, where a restauration could be worthfully.

    Without any doubt I went there and bought that thing.










    I looked like this, was in driving state, could brake better, but well..now it is here. Time to get hands dirty.















    As I never owned an aircooled Volkwagen, I did not know how to seperate the baseplate. Until now. Learning by doing.
    Was not very hard and did it on some easy sunday morning.







    Good friend helped me with welding some kind of stand under it.





    Baseplate looks very used:





    Transmission seems to be ok:



    Engine as well:



    Front axle is good, but will be replaced from ball joint to link pin. Why? Later on that.



    I did not know what's under the paint. So i decided to torture it by some glass bead blasting:



    That went pretty fail. The blasting by the company was very good. They are said to be one of the best in Germany. Greets to Strahlwerk Deluxe.

    But the car showed its real face. She is no hot virgin. She is an abused old hooker.
    The rear fenders are gone. The tops where held together with about 20kg of filling compound.
    Shame on the guys who did that.













    So at the moment I am looking for fenders for the rear car.

    If you have any questions please feel free to ask me.

    Updates will arive soon. They will show some news on axles and motorwork.

    Bye Tommy
    Last edited by wcstein; 02-28-2017 at 03:19 PM.

  2. #2
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Default axle arrived

    Bagged front axle arrived. It is a used one but shows no obvious traces of use.



    Should be able to drop the ghia to the limit. Which is by the way : highes priority.
    I am aiming for the slammed look.

    Axle : Dogback Beam Performance 4'' narrowed

  3. #3
    Join Date
    Feb 2012
    Location
    Temecula, CA
    Posts
    3,104

    Default

    im so excited for this!

    Instagram: @half_lung


  4. #4
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Default axle parts arrived #2

    Today was good.
    The postman surprised me with a package of axle parts.

    It included :
    • dropped spindles
    • torsion arms
    • the link between them( i do not know the english word for)






    Screws, bolts and everything to tighten it together are included.

    Due to my inducement to build a very reliable car I will give those parts for blasting and powder coating.
    Hope they get back as like new and give them a second life.

  5. #5
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Default some engine work

    When I got the car, about a good year ago, the engine worked well.



    But as you could see in earlier posts about the paint work, I was kind of sceptical.
    I took the decision to have a look into it.

    I've never done it earlier. With huge excitement I took off screw by screw. Removed the aircooling system, the oilcooler, the oilpump, the fuel pump and ignition stuff.

    Pulled off the heads, cylinders and pistons. I let the rods sit on the crankshaft.

    So actually the case should open now. It did not. It felt like glued together.
    After some rattle here and shaking there ,it finally opened.









    On the first sight all parts look well. The crancshaft's bearing shells show some scratches
    but now that the case is open they will be replaced like all other bearings.

    Crankshaft and camshaft look in good condition. So I will go with the crankshaft as it is but replace the camshaft with a Schleicher one. This will add a little more power and a little more sound. More engine tuning is set back a year from now.

    Pistons and cylinders will be replaced next two weeks. I hope to see you there.

  6. #6
    Join Date
    Dec 2013
    Location
    Dunwoody Georgia
    Posts
    48

    Default

    Looks awesome! I have a 62 that I'm building myself right now. What are your plans with the engine?

  7. #7
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Default

    Quote Originally Posted by thatbeetleguy View Post
    Looks awesome! I have a 62 that I'm building myself right now. What are your plans with the engine?
    Thanks.
    I will just replace all wear parts with new ones. The camshaft is replaced by a Schleicher one. That's it for engine tuning in 2017. I would like to build 2.0+ litre motor in 2018, but this season it will just stay stock except the camshaft.

  8. #8
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Lightbulb parts packed for blasting and powder coating

    Hi,

    after some morning snowboard action I put some parts onto a pallet.

    All axle parts will be blasted and powder coated.
    Engine and gearbox just receive a dry ice blast.





    The bearings in front of the axletubes went off very hardly. I wanted to use my own pullers but they did not grip well.
    So I visited a good friend who helped me out with some nice big pullers and a hot acetylene oxigen mixture.
    That helped the bearings to slip off.

    Next step will be motor assembly. I will start immediatly when it arrives from blasting.

  9. #9
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Lightbulb bad fenders

    As you might know from upper posts : the rear fenders are gone.
    So what to do? Buy new ones from someone who hoards them for unfair prices?

    Nope. Let's get a full rear car in good condition and prep it up for the Ghia.
    My coachbuilder found one in central Germany and we decided to buy it.

    So the thing which is shown in the next pictures will be the replacement for my old rotten fenders.









    From the beginning I was not satisfied with pumping fuel through the fender.
    I liked the look of the lowlights with gas filling under the front hood way more.
    So I decided to let the gas port be cleaned:



    This weekend I am going to measure all bearings for the engine.
    So after that, I will order the engine parts and show the rebuild process.

  10. #10

    Default

    very excited to see where this goes!

  11. #11
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Talking Accuair vu4 clean

    Time ago I had an Audi A3 bagged and slammed to ground by an Accuair System.

    I want to use the solenoid unit with the Ghia and so thought it would be better to clean things up.

    While looking into the air holes I saw rusty coating from former wet air.
    Could only be good to get the system clean. So, let's go:


    Full solenoid unit


    Cover and magnets removed


    Valves have some custom mounting. Tried to open with pliers - just tried...
    So to get out the valves I built a tool myself. Just went into DIY market and bought a long 11mm nut. Cut off edges and grinded some sharp tooths into it.
    Tool opened the valves safely.


    Everything is apart. Now I clean everything and put it together with a little spatter of oil.

  12. #12
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Lightbulb

    Accuair VU4 was successfully put together.

    Now it is time to get hands on engine.
    I wanted to start with preparing the crankshaft. The gears for cam and ignition wont come off,
    so I need a puller.

    I found one in local mechanical store, and will try to use it on weekend.



    US imported crankshaft gear puller. Hope this will help me with removing the gears.

  13. #13
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Wink rear axle arrived

    Postman rang again.
    He brought a huge package with a decent weight.

    So let's look what we got:

    Rear suspension and dropplates from Aircooled Suspension :


    Rear suspension frame and parts


    I was very surprised by how short the rear shocks are.

    Engine parts are on the way but did not land yet. Let's hope they arrive soon.

  14. #14
    Join Date
    Jan 2012
    Location
    Los Angeles
    Posts
    5,777

    Default

    Can't wait to see this on the floor!
    IG: @sebastienaudeon
    1974 Porsche 911S

    Quote Originally Posted by TRaNz View Post
    *pats Sebs head*
    there there.
    keep calm, go mash your face on a car window.

  15. #15
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Talking

    Found a small piece of fun from early days and want to share it with you.



    It features me cutting off the seat slides.

  16. #16
    Join Date
    Apr 2014
    Location
    Aachen, Germany
    Posts
    61

    Default

    Really looking forward to this, great work so far!

    Gre aus der Eifel

  17. #17
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Arrow compartment parts arrived

    Engine housing got blasted and powdered black.
    Halfes where dry-iced and are clean now. I am going to rebuild the engine this weekend.
    Keep fingers crossed that it will run next week.







  18. #18
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Smile engine nearly done

    Welcome back,

    engine rebuilt took a little longer. Encountered some trouble with my other cars.

    Engine case glued together




    Many parts replaced


    Put together


    What has been done?
    Split case halves have been cleaned properly. Installed new bushings to crank- and camshaft.
    Oil pump has been replaced by a reinforced one. New pistons and cylinders from Mahle have been installed.

    I reused heads and valves because they seem to be in good condition.
    Oil cooler was just cleaned and installed with new sealing. Oh, I said sealing? EVERY sealing and bearing was replaced by
    new MadeInGermany ones...
    Fuel pump is new inclusive the rod which empowers it.

    Carburator is old but you may guess it: cleaned with new sealings.
    Put everything together and now waiting for electric parts: Bosch ignition coil and cables.
    New spark-plugs are available. Hope to show you some engine fire by end of the week.

    PS:
    Chassis is done with bodywork and waits now for some fresh paint.
    Final color has been chosen. No hints...you will see by some pictures in near future.

  19. #19
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Exclamation rear replaced

    Oh I forget to mention the incredible bodywork done by:
    CLASSIC CONSTRUCTIONS

    Made a split Ghia


    Put it together


    These guys are awesome. They work incredible precise. I envy them a lot for their skills but same moment
    I am proud to have my chassis built by them.
    It's quality that matters.

  20. #20
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    Jan 2012
    Location
    Los Angeles
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    Default

    Quote Originally Posted by wcstein View Post
    Made a split Ghia
    That sneaky not bad Obama though.

    This is awesome work to say the least, glad to see the Ghia coming together!
    IG: @sebastienaudeon
    1974 Porsche 911S

    Quote Originally Posted by TRaNz View Post
    *pats Sebs head*
    there there.
    keep calm, go mash your face on a car window.

  21. #21
    Join Date
    Sep 2014
    Location
    Germany
    Posts
    45

    Default

    Your passat looked great so I assume this is going to kick ass as well


    Gre aus Bayern

  22. #22
    Join Date
    Jan 2013
    Location
    Chemnitz, Germany
    Posts
    34

    Default

    oh look. Two years went by, my keyboard broke but not the wrenches. The car is nearly finished. I'll update some steps day by day.

  23. #23
    Join Date
    Aug 2016
    Location
    N.Ireland (Norn Iron)
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    278

    Default

    Thread revivial!!! Awesome man, look forward to the updates
    My BMW E36 318ti Steel Blue Compact build thread -
    http://www.stanceworks.com/forums/sh...ad.php?t=88271

  24. #24
    Join Date
    Aug 2014
    Location
    Atlanta, GA
    Posts
    46

    Default

    Heck yes! I love Karmann Ghias and I cannot wait to see the updates.



    Bagged 2016 Shadow Black Focus ST1
    B U D D Y

    Static 1986 Guards Red NA Porsche 944
    P O R S C H E P A I ~

    @kenznotmercedes

  25. #25
    Join Date
    May 2019
    Location
    Austria
    Posts
    18

    Default

    Awesome. I'm looking forward to the result

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