DSC01724 Date: 06/27/2011 Overall the car is in good shape. Its had some collision damage over the years but the Ghia has no major rust. It has been refinished at least once.
DSC01723 Date: 06/27/2011
DSC01725 Date: 06/27/2011
DSC01726 Date: 06/27/2011
DSC01727 Date: 06/27/2011
DSC02083 Date: 10/03/2011
DSC01732 Date: 06/27/2011 Actual mileage is not know as the speedo doesn't work.
DSC01735 Date: 06/27/2011 The owner told me that the interior had never been replaced except for the door panels and the top. After disassembling the interior I was able to look at the bottom of the front and back seats, and the carpet and they are the originals.
DSC01731 Date: 06/27/2011
DSC01734 Date: 06/27/2011
DSC01736 Date: 06/27/2011
DSC01737 Date: 06/27/2011
DSC01728 Date: 06/27/2011 The engine is a little tired and definitely in need of some maintenance.
DSC01741 Date: 06/27/2011 With the battery looking this bad. You know its not going to be pretty under it!
downsized_0928111422 Date: 01/16/2012 So I knew the car had some prior collision damage in the left front and the left rear sections of the car. The front fender had been replaced but the structual damage was not repaired correctly leaving the inner structure pushed back. The front also had some broken welds in the inner wheel well and bumper mount that allowed the bumper to move up and down 1/4 of an inch. I decided to take care of these areas before disassembling the car.
downsized_0928111422a Date: 01/16/2012 Pushed it forward and welded the bumper mount.
downsized_0928111340a Date: 01/16/2012 Left rear had also been pushed forward and had not been repaired properly leaving some buckles in the inner wheel well.
downsized_0928111340 Date: 01/16/2012
downsized_0928111346 Date: 01/16/2012
downsized_0928111342a Date: 01/16/2012 Pushing the left rear back out.
DSC02098 Date: 10/04/2011 The fender had been replaced and when reinstalled it had been overlapped on the original fender 2 inches. The overlap was not sealed underneath and there was rust developing between the two pieces of metal.
Since that was a problem the only good way to correct it and repair the inner structual damage was to remove the fender.
DSC02099 Date: 10/04/2011
DSC02100 Date: 10/04/2011 Damage to the nose was not repaired properly.
DSC02103 Date: 10/04/2011
DSC02102 Date: 10/04/2011
DSC02101 Date: 10/04/2011 The brass colored spots is where the fender was spotted on using a brass rod. This will cause the filler to bubble over time.
Just above the grille opening note the filler in the rust holes.
DSC02110 Date: 10/06/2011 Rust holes above the grille opening.
DSC02112 Date: 10/06/2011
DSC02116 Date: 10/06/2011 The only real way to repair the previous damage correctly was to remove the fender.
DSC02124 Date: 10/06/2011 2 inch overlapp above and to the fleft of the headlight bucket.
DSC02123 Date: 10/06/2011 Red area is the 2 inch overlap. Black section is the replacement fender that was never refinished on the inside.
DSC02122 Date: 10/06/2011 Front left grille/air box opening.
DSC02127 Date: 10/06/2011 Damage left behind.
DSC02117 Date: 10/06/2011 Air box damage that was left unrepaired from the previous collision.
DSC02118 Date: 10/06/2011
downsized_1006111607 Date: 01/16/2012
DSC02125 Date: 10/06/2011 Drilled the spot welds and cut the side cover off to access the air box.
downsized_1006111951 Date: 01/16/2012 Cut the air box open to allow access to repair the grille opening and the air box.
DSC02131 Date: 10/06/2011 Straightened up.
DSC02126 Date: 10/06/2011 Before
DSC02130 Date: 10/06/2011 After
DSC02129 Date: 10/06/2011 After straightening.
DSC02139 Date: 10/07/2011
DSC02156 Date: 10/12/2011
DSC02157 Date: 10/12/2011 Self etch primer.
DSC02120 Date: 10/06/2011 Damaged bumper mount.
downsized_1006111609 Date: 01/16/2012 Bumper mount that was left pushed in.
DSC02119 Date: 10/06/2011
downsized_1006111953 Date: 01/16/2012 Cut it off and straightened it.
DSC02155 Date: 10/12/2011 After.
downsized_1013111539 Date: 01/16/2012 When the car was repaired before the fender was not pulled forward enough to clear the drivers door causing it to rub. If it had been pulled before the original fender was cut off it would have taken care of this.
downsized_1013111608 Date: 01/16/2012 A relief cut was made in the fender from top to bottom. Then jack the gap closed and welded back. This opened up the door gap.
DSC02163 Date: 10/13/2011 Tacked and checked the door gap before welding solid.
downsized_1014111551 Date: 01/16/2012
DSC02134 Date: 10/07/2011 Rust hole cut out.
DSC02141 Date: 10/07/2011 After.
DSC02143 Date: 10/07/2011 Just to the left of the air box opening there was prior damage and holes left from a dent puller. Welded them up and smoothed out the nose more.
DSC02136 Date: 10/07/2011
DSC02144 Date: 10/10/2011 Rust holes that had been filled over. Cut it out and welded in a patch.
DSC02149 Date: 10/10/2011 Weld pins for straightening dented area.
DSC02151 Date: 10/10/2011
DSC02151 Date: 10/10/2011
DSC02153 Date: 10/10/2011 Inside spare tire well left side. Rusty spot from prior picture.
DSC02160 Date: 10/12/2011 Rust repaired and finished off smooth.
DSC02370 Date: 01/05/2012 Rusty package shelf.
DSC02406 Date: 01/07/2012 Removing the engine.
DSC02395 Date: 01/07/2012 Mount for fuel canister in the engine compartment needs to be welded. Cracked on each side.
DSC02398 Date: 01/07/2012
DSC02413 Date: 01/08/2012 Body removed from the pan and on the dolly.
DSC02415 Date: 01/08/2012
DSC02416 Date: 01/08/2012
DSC02417 Date: 01/08/2012 Door opening braces were welded in on both sides to keep the alignment of the body so the door gaps stay looking good.
DSC02414 Date: 01/08/2012 Pan will get pressure washed, and get sand blasted. Both floors will be replaced, suspension parts replaced, and tranmission rebuilt.
DSC02459 Date: 01/10/2012 There was some leaking fuel hoses!
DSC02461 Date: 01/10/2012 Removed the factory undercoating.
DSC02465 Date: 01/10/2012 Brake reservoir was leaking causing the fluid to eat the paint away from the mounting bracket and around the dash. This will get cleaned and blasted.
DSC02470 Date: 01/12/2012 Pressure washed the car completely to remove years of dirt and grease.
DSC02471 Date: 01/12/2012 Engine compartment has some minor rust that will get blasted and also replace the left side where the battery sits.
DSC02473 Date: 01/12/2012 Package shelf looks better after the cleaning.
DSC02475 Date: 01/12/2012 Wiring harness in the car is in good shape. There is a few add ons that will have to be straightened up.
DSC02477 Date: 01/12/2012 All the undercoating is gone!
DSC02478 Date: 01/12/2012 Right rear fender well. Heater outlets, fuel breather line, and wiring will be removed before painting.
DSC02479 Date: 01/12/2012
DSC02481 Date: 01/12/2012 Under the package shelf.
DSC02482 Date: 01/12/2012 Left rear fender well showing the previous collision damage. (right of the picture)
DSC02483 Date: 01/12/2012 No Rust!
DSC02484 Date: 01/12/2012 Left front fender well will get some work, then some color to protect the replaced fender.
DSC02485 Date: 01/12/2012 Bottom of the hood. OG paint!
DSC02486 Date: 01/12/2012 Rear lid had some sound deadener that was coming loose so it was removed and will have some added before paint.

More OG paint!
DSC02487 Date: 01/12/2012
DSC02489 Date: 01/12/2012
DSC02498 Date: 01/14/2012 Dusting over with the blaster to get some flash rust off after the pressure wash.
DSC02515 Date: 01/14/2012
DSC02514 Date: 01/14/2012 Blasted the grille openings and lower section of the nose.
DSC02494 Date: 01/12/2012
DSC02492 Date: 01/12/2012 Did some spot blasting.
DSC02506 Date: 01/14/2012
DSC02507 Date: 01/14/2012 Blasted the bottom of the rocker panel to remove surface rust.
DSC02509 Date: 01/14/2012 Blasted the bottom of the rocker panel to remove surface rust.
DSC02499 Date: 01/14/2012 Blasted the package shelf found a few pin holes that will need welding.
DSC02504 Date: 01/14/2012
DSC02510 Date: 01/14/2012 Brake reservoir area after blasting.
DSC02511 Date: 01/14/2012 Left rear firewall to fender well spot welds were broken loose from the prior collision and will get welded.
DSC02501 Date: 01/14/2012
DSC02512 Date: 01/14/2012 The entire car will be stripped to the bare metal.
DSC02552 Date: 01/31/2012 Drivers side quarter had a small det that need to be repaired. Weld pins are for pulling the dent.
DSC02553 Date: 01/31/2012
DSC02541 Date: 01/23/2012
DSC02554 Date: 01/31/2012 Right side quarter had a crease that needed to be repaired.
DSC02556 Date: 01/31/2012 The rockers are in really good shape. There was a few small pin holes that needed welding.
DSC02555 Date: 01/31/2012 Lower right front fender with no rust issues.
DSC02566 Date: 01/31/2012 Right rocker panel with a few small dents.
DSC02567 Date: 01/31/2012 Left rocker panel had some small dents.
DSC02565 Date: 01/31/2012 Stripping the paint.
0119121501 Date: 02/04/2012
Date: 01/31/2012
DSC02572 Date: 02/03/2012 Quarter needed some repairs.
DSC02573 Date: 02/03/2012 Several places on the fender needed repairs.
DSC02589 Date: 02/05/2012 Fiberglass repair material was used to fill the weld area.
DSC02594 Date: 02/08/2012 Sanded the fiberglass even and then a coat of filler will be used to finish it off.
DSC02577 Date: 02/03/2012 Just started to get into the left quarter and below the tailight to see whats behind all of the body filler. It wasen't looking good.
DSC02578 Date: 02/03/2012 The slot for the bumper bracket was in poor shape. I welded some tears and the slot opening around the edges. Made a pattern from the right side then shaped it back to the original shape.
DSC02579 Date: 02/03/2012 Right side has some damage but nothing major. It still needed some work.
DSC02583 Date: 02/03/2012 After the shaping.
DSC02570 Date: 01/31/2012 Rear apron had some damage that needed repair.
DSC02584 Date: 02/05/2012
DSC02585 Date: 02/05/2012 Body work to right quarter.
DSC02587 Date: 02/05/2012 Body work to right fender.
0126121622 Date: 02/08/2012
DSC02581 Date: 02/03/2012 New headlight bucket came in bare metal and needed to be primed with self-etch primer before installing.
DSC02590 Date: 02/08/2012 Welded it in and ground the welds.
DSC02592 Date: 02/08/2012 Test fit left side.
DSC02593 Date: 02/08/2012 Test fit left side.
DSC02591 Date: 02/08/2012 Test fit right side.
DSC02603 Date: 02/09/2012 Spare tire well right side. The triangle piece seen at the top, was rusted away on the left side.
DSC02604 Date: 02/09/2012 Some rust repair was done to the lower section. Triangle piece had to be fabbed to replace the rusted original.
DSC02605 Date: 02/09/2012
DSC02607 Date: 02/09/2012 Rusty one and new one.
DSC02606 Date: 02/09/2012 Checking the fit.
DSC02625 Date: 02/13/2012 Triangle plate welded in and the new nose rubber seal installed.
DSC02626 Date: 02/13/2012 The bottom of the spare tire well had some rusty areas that was sand blasted, self-etch applied and the primer surfacer.
DSC02627 Date: 02/13/2012 Driver side apron inside the trunk area had some damage that had to be bodyworked.
DSC02628 Date: 02/13/2012 Welded up a hole under the dash that the aftermarket radio wires ran through.
DSC02629 Date: 02/13/2012 Bottom of the dash, radio wire hole.
DSC02632 Date: 02/13/2012
DSC02631 Date: 02/13/2012 There was a weird split in the bottom of the dash that had to be welded up.
DSC02630 Date: 02/13/2012
DSC02637 Date: 02/13/2012
DSC02638 Date: 02/13/2012
DSC02645 Date: 02/14/2012 Center of the nose had some prior damage that needed repair.
DSC02667 Test fitting the bumper. Date: 03/05/2012 Test fitting the bumper.
DSC02691 Date: 03/22/2012 Started blasting the floor pan to see what is needed to be replaced.
DSC02692 Date: 03/22/2012 Looks like the pans only need repalcing from the seat tracks to the rear.
DSC02694 Date: 03/22/2012
DSC02695 Date: 03/22/2012
DSC02696 Date: 03/22/2012
DSC02697 Date: 03/26/2012
DSC02698 Date: 03/26/2012
DSC02699 Date: 03/26/2012
DSC02700 Date: 03/26/2012
DSC02701 Date: 03/26/2012
DSC02702 Date: 03/26/2012
DSC02707 Date: 03/26/2012 Bottom side of the pan.
DSC02706 Date: 03/26/2012 Botton side of pan.
DSC02708 Date: 03/28/2012 Straightened up the fender that was removed earlier and started the filler process.
DSC02709 Date: 03/28/2012 The fender is skimmed with filler so that once its cut down it will only have a thin coat applied to the panel. This helps so that if there are any ripples or small dents that were not seen it will take care of them.
DSC02710 Date: 03/31/2012
DSC02711 Date: 03/31/2012
DSC02596 Date: 02/09/2012 The filler in the quarter was at least 1/2 inch thick.
DSC02595 Date: 02/09/2012 Stripped the paint off the left quarter, found a ton of filler and alot of dented metal. Picture was taken after most of the filler was stripped.
DSC02599 Date: 02/09/2012 Welded up the holes left from prior dent removal.
DSC02601 Date: 02/09/2012
DSC02712 Date: 03/31/2012 The rear quarter panel was damage before and not straightened very well. All of the filler was removed and pins were welded to remove the damage.
DSC02716 Date: 03/31/2012 There was about 200 pins used to remove the damage.
DSC02718 Date: 03/31/2012
DSC02720 Date: 04/02/2012 Once the damage is pulled out the pins were cut and ground off.
DSC02721 Date: 04/02/2012
DSC02719 Date: 04/02/2012 Panel came out great and will take less filler now.
DSC02728 Date: 04/03/2012 Rear quarter was wiped with the filler then blocked down straight.
DSC02730 Date: 04/03/2012
DSC02729 Date: 04/03/2012
DSC02731 Date: 04/03/2012 Wiping the entire panel with the filler and blocking it down will only leave what is needed to fill low areas and take care of any ripples in the metal.
DSC02733 Date: 04/03/2012 It may look like alot of filler but when applying it thickness is what matters. There is alot less on the panel now that the metal was straightened correctly.
DSC02732 Date: 04/03/2012
DSC02535 Date: 01/21/2012 Battery tray cut out.
DSC02536 Date: 01/21/2012 Underneath shot.
DSC02538 Date: 01/21/2012 Rusty battery tray.
DSC02539 Date: 01/23/2012 Area of the rear apron was rusty and needed a patch.
DSC02540 Date: 01/23/2012 Cut out.
DSC02569 Date: 01/31/2012 Patch finished.
DSC02723 Date: 04/03/2012 The replacement panel for the battery area was not exactly like the original one. Notice that the channel that holds the engine seal slopes down on the right side on the original section.
DSC02724 Date: 04/03/2012 It was a little over 1/2 inch angled down from the top edge.
DSC02725 Date: 04/03/2012 On the new panel the spot welds were drilled out and the channel moved down to match the original one.
DSC02726 Date: 04/03/2012
DSC02727 Date: 04/03/2012 Moving it down will make the engine seal line up with the engine tin better when reinstalled.
DSC02747 Date: 04/04/2012 The channel for the seal on the new panel was 1/2 inch too short and didn't match up with the existing original channel.
DSC02750 Date: 04/04/2012 This is how it should line up. Passenger side.
DSC02752 Date: 04/04/2012 I cut a section of the channel off of the old panel and grafted it to the new one making up the difference.
DSC02756 Date: 04/05/2012 Battery tray section welded in.
DSC02758 Date: 04/05/2012 Some body work was needed to starighten up some ripples and where the patch was added.
DSC02760 Date: 04/05/2012 There are still a couple of hold down brackets that need to be welded on for the battery.
downsized_0518122013 Date: 05/18/2012 Brackets for the battery welded in.
DSC02761 Date: 04/05/2012 Inner wheel well that had some damage from prior collision. Also the welds for the battery section where there.
DSC02734 Date: 04/04/2012 Reinstalled the deck lid to check the fit with the rear body panels.
DSC02735 Date: 04/04/2012
DSC02738 Date: 04/04/2012
DSC02739 Date: 04/04/2012
DSC02740 Date: 04/04/2012
DSC02743 Date: 04/04/2012
DSC02893 Date: 04/17/2012 Floor pan replacement right side.
DSC02895 Date: 04/17/2012 Seat track was removed and the x bracing was added to keep it square so when welded back the seat will work correctly.
DSC02896 Date: 04/17/2012
DSC02897 Date: 04/17/2012 New replacement panel.
DSC02901 Date: 04/17/2012
DSC02903 Date: 04/21/2012 Panel welded in and the seat track back on.
DSC02907 Date: 04/25/2012 X bracing removed and welds ground.
DSC02899 Date: 04/17/2012 Bracket that was transfered to the new panel.
DSC02898 Date: 04/17/2012
DSC02904 Date: 04/24/2012 Left side panel all welded in.
DSC02905 Date: 04/25/2012 Seat track back on.
DSC02906 Date: 04/25/2012 All finished up.
DSC02929 Date: 04/30/2012 This was the bad side that wasen't fixed correctly.
DSC02930 Date: 04/30/2012 Got it shaped up. Not nearly as much filler in it as before. Also got the bumper mount hole shaped up nicely too.
DSC02942 Date: 05/03/2012 The rear panel had a lot of waves in the metal. Mostly because of where the panel is welded to each quarter panel.
DSC02944 Date: 05/04/2012 Got it shaped up! Top of the right quarter panel had a few places that needed attention too.
DSC02974 Date: 05/07/2012 Checking hood gaps.
DSC02975 Date: 05/07/2012
DSC02978 Date: 05/07/2012
DSC02979 Date: 05/07/2012 Driver side gap needed some attention.
DSC02981 Date: 05/07/2012 Center nose at hood gap needed some work too.
DSC02972 Date: 05/07/2012 Disassembled the door and marked all the dents.
DSC02994 Date: 05/09/2012 Had to do some more filler work to get the door to fender alinment looking better.
DSC02995 Date: 05/09/2012
downsized_0518122010 Date: 05/18/2012
downsized_0518122008 Date: 05/18/2012
DSC02993 Date: 05/09/2012 Bolted up and aligned the doors to check the fits again before getting on to the bodywork.
downsized_0518122006 Date: 05/18/2012
DSC02953 Date: 05/07/2012 Inside edge of the door was pushed in. Looked like it may have been backed into something.
DSC02954 Date: 05/07/2012
downsized_0518122012 Date: 05/18/2012 Damage repaired.
0518122011 Date: 05/18/2012 There was some surface rust around the inside edge of the door so I blasted all of the inside.
I left some of the OG red color to do a color match.
DSC03141 Date: 05/31/2012
DSC03139 Date: 05/23/2012
DSC03153 Date: 05/31/2012
DSC03152 Date: 05/31/2012 Blasted the backside of the decklid. There was some rust along the bottm edge and some corrosion from the battery acid.
DSC03160 Date: 05/31/2012
DSC03145 Date: 05/31/2012
DSC03154 Date: 05/31/2012
DSC03142 Date: 05/31/2012 Blasted the inside ofthe doors. There was some minor surface rust.
DSC03155 Date: 05/31/2012 Epoxy primed the inside.
DSC03150 Date: 05/31/2012
DSC03157 Date: 05/31/2012
DSC03146 Date: 05/31/2012
DSC03156 Date: 05/31/2012
photo4 Date: 06/01/2012
photo2 Date: 06/01/2012
photo3 Date: 06/01/2012
DSC03181 Date: 06/07/2012 Rusty area from brake reservior leaking fluid.
DSC03188 Date: 06/07/2012
DSC03182 Date: 06/07/2012 Minor dent on the hood lock support.
DSC03183 Date: 06/07/2012 Package tray had surface rust.
DSC03193 Date: 06/07/2012
DSC03191 Date: 06/07/2012 Lilly approved.
DSC03190 Date: 06/07/2012
DSC03201 Date: 06/07/2012
DSC03192 Date: 06/07/2012
DSC03199 Date: 06/07/2012
DSC03200 Date: 06/07/2012
DSC03346 Date: 06/13/2012 Got it to first prime! 2 coats of epoxy was applied then 2 coats of 2K urethane primer.
DSC03345 Date: 06/13/2012
DSC03347 Date: 06/13/2012
DSC03350 Date: 06/13/2012
DSC03349 Date: 06/13/2012
DSC03348 Date: 06/13/2012
DSC03351 Date: 06/13/2012
DSC03352 Date: 06/13/2012
DSC03481 Date: 06/26/2012
DSC03483 Date: 06/29/2012 Got the hood stripped and bodyworked. It was interesting to see some file marks from body work done at the factory before the car was refinished.
DSC03495 Date: 06/29/2012 Hood was epoxy primed and then 2K primed.
DSC03485 Date: 06/29/2012 Tag lite housing had been replaced at some point. Cut all of the red off and found OG orange.
DSC03488 Date: 06/29/2012 Had some ripples in the housing so it needed bodywork.
DSC03496 Date: 06/29/2012 Self etch primer on the housing.
DSC03542 Date: 07/26/2012 Bottom of the floor pans were bodyworked where they were sectioned together.
DSC03543 Date: 07/26/2012
downsized_0804121434a Date: 08/04/2012 Floor pan was reblasted, sealed the seams top and bottom then self-etch, and black applied.
downsized_0804121434 Date: 08/04/2012 Floor pan was blasted, self-etch primer , then colored.
downsized_0804121320 Date: 08/04/2012
downsized_0804121319a Date: 08/04/2012 Floor pan was blasted, self-etch primer , then colored.
downsized_0804122125 Date: 08/04/2012
downsized_0804122126 Date: 08/04/2012
downsized_0804122127 Date: 08/04/2012
downsized_0804121319 Date: 08/04/2012 Front suspension (beam) was blasted, self-etch primer , then colored.
downsized_0804122119 Date: 08/04/2012 Painted beam.
downsized_0804122119b Date: 08/04/2012 Steering box was cleaned and painted.
downsized_0804122119c Date: 08/04/2012 Rear trans mount.
downsized_0815121927 Date: 08/15/2012 New front shocks, new rubber bushings, and original dust covers.
DSC03546 Date: 08/22/2012 Rear axle shaft with new inner and outer bearings.
DSC03545 Date: 08/22/2012 New left and right axle bearings inner and outer.
DSC03558 Date: 08/24/2012
DSC03559 Date: 08/24/2012 Brake rotors, drums, backing plates, and spindles were blasted before painting and resurfacing.
DSC03562 Date: 08/24/2012 Back sides.
DSC03556 Date: 08/23/2012 Front wheel bearings were in good condition. Cleaned up, regreased and reinstalled.
DSC03590 Date: 08/31/2012 Right rear. New rear shoes, wheel cylinders, blasted and painted hardware.
DSC03594 Date: 08/31/2012 Left rear.
DSC03595 Date: 08/31/2012 Resurfaced rear drums.
DSC03563 Date: 08/24/2012
DSC03624 Date: 09/07/2012 New upper and lower balljoints, and control arm seals.

New front shocks and new rubber kit for the shock covers.
DSC03625 Date: 09/07/2012
DSC03626 Date: 09/07/2012 New tierod ends and steering dampner.
DSC03598 Date: 09/07/2012 The front disc brake calipers had been previously replaced and were in good working order before the car was disassembled so they were reused.
DSC03600 Date: 09/07/2012 Cleaned up and sprayed with stainless steel paint and new pads installed.
DSC03620 Date: 09/07/2012 Disc brake caliper installed.
DSC03601 Date: 09/07/2012 Resurfaced rotors.
DSC03618 Date: 09/07/2012 Resurfaced brake rotor.
DSC03623 Date: 09/07/2012
DSC03602 Date: 09/07/2012
DSC03605 Date: 09/07/2012
DSC03606 Date: 09/07/2012
DSC03617 Date: 09/07/2012 New brake master cylinder.
New metal brake lines.
New brake light switches.
DSC03621 Date: 09/07/2012
DSC03619 Date: 09/07/2012 Front rubber brake hoses.
DSC03622 Date: 09/07/2012
DSC03551 Date: 08/22/2012 Brakes Ts cleaned up and new center line installed.
DSC03566 Date: 08/24/2012 Rebuilt transaxle. Painted with Stainless steel paint. New mounts installed.
downsized_0815121833 Date: 08/15/2012 The Original shocks were a brownish red color with a black plastic dust cover. The new shocks are black with a metal dust cover. The OG pastic dust covers wouldn't fit without cutting the metal dust cover off. So instead of cutting it I custom mixed some color to match the OG shocks and painted the shocks except for the dust cover leaving it black making it look like the OG shock.
Next pic shows the finished outcome.
downsized_0815121913 Date: 08/15/2012 Just like original!
DSC03610 Date: 09/07/2012
DSC03611 Date: 09/07/2012 New rear shocks.
DSC03612 Date: 09/07/2012 New rear rubber brake hoses left and right.
DSC03613 Date: 09/07/2012
DSC03609 Date: 09/07/2012
DSC03608 Date: 09/07/2012
downsized_0815121929 Date: 08/15/2012 Detailed the heat lever knobs.
DSC03628 Date: 09/07/2012 Resprayed and detailed the heater control knobs.
DSC03753 Date: 10/28/2012 Back on the body! Did some trim out on the insides.
DSC03754 Date: 10/28/2012
DSC03755 Date: 10/28/2012
DSC03756 Date: 10/28/2012 The wiring harness in the ghia is in good shape so everything was moved around and covered to keep the red overspray off.
DSC03757 Date: 10/28/2012
DSC03757 Date: 10/28/2012
DSC03774 Date: 10/28/2012
DSC03769 Date: 10/28/2012
DSC03759 Date: 10/28/2012
DSC03760 Date: 10/28/2012
DSC03761 Date: 10/28/2012
DSC03762 Date: 10/28/2012
DSC03766 Date: 10/28/2012
DSC03770 Date: 10/28/2012
DSC03763 Date: 10/28/2012 The driverside wheelwell had to be reprayed with the chip guard since the fender had been replaced and never coated.

To keep the textures the same as the left front the other 3 wheelwells were recoated.
DSC03764 Date: 10/28/2012
DSC03768 Date: 10/28/2012
DSC03767 Date: 10/28/2012
DSC03765 Date: 10/28/2012
DSC03772 Date: 10/28/2012
DSC03782 Date: 11/03/2012 Got the main body trimmed and started onthe removeables.
DSC03781 Date: 11/03/2012
DSC03788 Date: 11/03/2012
DSC03783 Date: 11/03/2012
DSC03780 Date: 11/03/2012 Recoated the rear deck lid with sound deadner like the factorydid it.
DSC03784 Date: 11/03/2012
DSC03785 Date: 11/03/2012
DSC03789 Date: 11/03/2012
DSC03786 Date: 11/03/2012
DSC03787 Date: 11/03/2012 Shiny reflection!
DSC04168 Date: 02/12/2013 The car was wet sanded with P600 then washed.

Time to move to the spraybooth.
DSC04170 Date: 02/12/2013
DSC04169 Date: 02/12/2013
DSC04171 Date: 02/12/2013
DSC04174 Date: 02/12/2013
DSC04173 Date: 02/12/2013
DSC04178 Date: 02/14/2013 Masking everything that was trimmed out.
DSC04176 Date: 02/14/2013
DSC04177 Date: 02/14/2013 Bottom of the dash was masked to keep overspray off. Door jambs were masked too later. The lower area is going to be covered with carpet later so overspray isn't a problem.
DSC04182 Date: 02/14/2013 Any openings had to be masked to keep overspray off.
DSC04183 Date: 02/14/2013
DSC04184 Date: 02/15/2013 Did a little edging before the topcoat goes on.
DSC04185 Date: 02/15/2013
DSC04188 Date: 02/15/2013
DSC04189 Date: 02/15/2013
DSC04187 Date: 02/15/2013
DSC04186 Date: 02/15/2013
DSC04192 Date: 02/15/2013 2 coats of clear applied.
DSC04193 Date: 02/15/2013
DSC04194 Date: 02/15/2013
DSC04195 Date: 02/15/2013
DSC04196 Date: 02/15/2013
DSC04197 Date: 02/15/2013
DSC04200 Date: 02/15/2013
downsized_0225131733 Date: 03/18/2013 After the refinish work was done, the paint was left to cure for a week then it was color sanded. This process eliminates any imperfections in the finish. It was first wet sanded with 1500, then 3000, then polished.
DSC04333 Date: 03/18/2013
DSC04334 Date: 03/18/2013
DSC04329 Date: 03/18/2013
DSC04331 Date: 03/18/2013
downsized_0227131801 Date: 03/18/2013 Reflection of my truck in the parking lot.
DSC04337 Date: 03/18/2013 This is the fender that was removed because of poorly repaired prior damage.
DSC04328 Date: 03/18/2013 23 window bus reflection.
DSC04327 Date: 03/18/2013
downsized_0227131757 Date: 03/18/2013 Fuel lid.
DSC04340 Date: 03/18/2013 Drivers door.
DSC04344 Date: 03/18/2013 Passenger door.
DSC04339 Date: 03/18/2013
DSC04338 Date: 03/18/2013
DSC04347 Date: 03/18/2013
DSC04348 Date: 03/18/2013
DSC04349 Date: 03/18/2013
DSC04335 Date: 03/18/2013 Refinished the steering column.
DSC04336 Date: 03/18/2013
0302131842 Date: 03/18/2013
downsized_1030121556 Date: 03/19/2013 Bahia Red color for the 1972 Ghia Convertible.
DSC04362 Date: 04/04/2013 Heater outlet covers were rusty and paint peeling off. These are located just below the rear seat by the floor.
DSC04361 Date: 04/04/2013
DSC04406 Date: 04/25/2013 Blasted, primed and painted. They were a little pitted but useable.
DSC04370 Date: 04/19/2013 Headlight assemblies had paint on them from prior refinish jobs. Also some rust that needed blasting.
DSC04369 Date: 04/19/2013
DSC04373 Date: 04/19/2013
DSC04375 Date: 04/19/2013
DSC04376 Date: 04/19/2013 Both of the assemblies were disassembled, blasted and painted a factory gray color.
DSC04377 Date: 04/19/2013
DSC04404 Date: 04/25/2013 The chrome retaing rings for the bulbs were cleaned and polished. Then the units were reassembled with new Halogen bulbs.
DSC04405 Date: 04/25/2013 The adjusting screws and clips were in good shape just needed cleaning to remove paint and grime.
downsized_0408131657 Date: 04/28/2013 Left headlight wire repair from the prior collision was very poor. The next pic shows what was hiding under the electrical tape.
downsized_0408131700 Date: 04/28/2013 The wires had been cut and butt connectors had been used to connect them back together.
I took these apart and soldered them together, covered them with heat shrink, then covered them with electrical tape.
DSC04474 Date: 05/28/2013 Left headlight bucket. The headlight plug had to be replaced as it was damaged from the prior collision.
DSC04472 Date: 05/28/2013 New wiring boots and turn signal boot.
DSC04593 Date: 09/01/2013 Installed the rebuilt headlight assemblies and the trim ring gasket.
DSC04592 Date: 09/01/2013
DSC04392 Date: 04/23/2013 The inner fenderwell hinge covers were covered with undercoating but had some small rust issues.
DSC04394 Date: 04/23/2013
DSC04395 Date: 04/24/2013 Blasted both panels and repaired the rust.
DSC04396 Date: 04/24/2013
DSC04397 Date: 04/24/2013 Small patch fabbed. Didn't get any pics of it welded and finished off.
DSC04398 Date: 04/24/2013 Once the patch was welded the taller edge of the patch was cut down to match the original panel.
DSC04401 Date: 04/24/2013 After the rust repair they were sprayed with self-etch primer.
DSC04414 Date: 04/27/2013 A stone guard protector was applied before being painted black.
Also 2 new seals will be installed.
DSC04408 Date: 04/26/2013 Brake fluid reservoir and lines to master cylinder.
DSC04415 Date: 04/27/2013 The brake reservoir and metal lines were cleaned out and the lines recoated. New flexible brake hose will be added when installed.
DSC04381 Date: 04/19/2013 Rear tag light assemblies had red paint on the lenses, and wires from prior paint jobs.
They were disassembled, blasted the bulb holders because of some surface rust and recoated. Seals for the lenses will be replaced as will the bulbs.
DSC04420 Date: 04/29/2013
DSC04606 Date: 09/01/2013 The new tag light assembly.
DSC04605 Date: 09/01/2013
DSC04384 Date: 04/19/2013 Horn assembly was cleaned and refinished. They seem to work ok so no need to disassemble them.
These are finished just didn't get a pic of them completed.
DSC04417 Date: 04/29/2013 Fresh Horns!
DSC04601 Date: 09/01/2013 New horn boot.
DSC04598 Date: 09/01/2013 Horn assembly inside the trunk area.
DSC04418 Date: 04/29/2013 I didn't get before pics of the tailight assemblies. They were blasted and repainted. New gaskets and bulbs will be added.
DSC04419 Date: 04/29/2013 The tailight lenses are in good shape and are going to be reused. The left tailight is a before of cleaning and polishing the lens.
The right lens is an after a little polish. They will look great after they have been completely cleaned and polished.
DSC04594 Date: 09/01/2013 New bulbs installed.
DSC04596 Date: 09/01/2013 The picture doesn't show how nice the lenses turned out.
DSC04433 Date: 05/07/2013 The 2 pieces on the left are the door jamb wedge plates. The doors have rubber wedges that mate into these. They help with alignment and rattle issues .
The right 2 pieces are the antenna base and nut. The base was pitted and the nut had scar marks from someone removing or installing with pliers.
These pieces have been rechromed.
DSC04575 Date: 08/30/2013 Nice and shiny!
DSC04438 Date: 05/07/2013 I bought a replacement antenna but the quality was very poor. The look was nothing like the OG one and the fit was horrible so I decided to reuse the original.

The OG antenna had red paint on it from prior repairs and the mask was a little sticky. I didn't get a finished pic but it was cleaned, polished, and the mask lubed.
DSC04574 Date: 08/30/2013 The little things like this is what makes the finished job look so much better.
DSC04439 Date: 05/09/2013 I didn't like the quality of the aftermarket lenses so I did some part searching at shows to get some replacement turn signal assemblies. The ones on the car were in bad shape with mounting studs broken on the base or missing along with lens screw holes cracked or busted out.
DSC04440 Date: 05/09/2013 The replacements I found were in good shape just really dirty and dull.
I did a good soaking in some mild cleaner then polished them up. You can see them mounted and lit up a few pics down.
DSC04441 Date: 05/09/2013 Turn signal base.
DSC04442 Date: 05/09/2013 Blasted it and cleaned the bulb contacts.
DSC04443 Date: 05/10/2013 Applied self-etch primer to keep it from corroding again.
DSC04445 Date: 05/10/2013 Applied some good reflective silver.
DSC04446 Date: 05/10/2013 New gasket and bulb and they are like new again!
DSC04452 Date: 05/14/2013 Fuel filler neck that attaches to the tank.
DSC04455 Date: 05/17/2013 Cleaned the undercoating off, blasted and repainted it.
DSC04475 Date: 05/28/2013 Fuel tank was pretty dirty inside and out. After a good cleaning the results wasn't good.
I believe we will replace it.
DSC04478 Date: 05/28/2013
DSC04613 Date: 09/01/2013 Rust pits/holes is common in the bottom of these tanks. They are sometimes repairable. But there are other areas in the tank with holes so I believe the best thing is to replace it.
DSC04612 Date: 09/01/2013 Another rusted area.
DSC04492 Date: 07/09/2013 The tires and wheels we started with. They have seen their better days.
DSC04493 Date: 07/09/2013
DSC04490 Date: 07/09/2013 The chalked marked area on this rim was bent and had to be straightened.
DSC04494 Date: 07/09/2013 Several rims had damage that needed to be repaired.
DSC04497 Date: 07/09/2013 Before.
DSC04501 Date: 07/09/2013 After.
DSC04503 Date: 07/09/2013 After.
DSC04517 Date: 07/18/2013 Blasted all the rims.
DSC04518 Date: 07/19/2013 All 5 rims were wired up, 3 and 2. Bare metal ready for epoxy primer.
DSC04522 Date: 07/19/2013 Epoxy primer applied.
DSC04528 Date: 07/19/2013 I decided to do the backside of the rims black. I believe they were that way from the factory.
I think they will look better that way since the road grime won't show as bad.
DSC04532 Date: 07/20/2013 I wanted to do the wheels in base coat/clear coat but I didn't want them to be super shiny. So I found Silver base color that looked appropriate and also found a clear that when it dries it is dull.
The reason to clear them is so the color will last without wearing away after many washes.
The reason for wanting dull clear is that they didn't look correct shiny for the age of the car.
DSC04533 Date: 07/20/2013
DSC04624 Date: 09/01/2013 I didn't get a picture of the tires when they arrived but they were wrapped up nice to protect the whitewalls.
4 BF Goodrich Silvertown radials with 3/4 whitewalls.
1 Firestone F560 blackwall for the spare.
http://www.cokertire.com/
DSC04589 Date: 08/30/2013
DSC04585 Date: 08/30/2013 I bolted 2 up to see how it was going to look.
DSC04537 Date: 08/09/2013 These are the drain tubes for the rear glass. Someone has bee at it again with the electrical tape.
DSC04538 Date: 08/09/2013
DSC04539 Date: 08/09/2013
DSC04630 Date: 09/01/2013 New replacement hose along with the old.
DSC04614 Date: 09/01/2013 Right rear drain hose for the back glass.
DSC04616 Date: 09/01/2013 Left rear drain hose for the back glass.
DSC04506 Date: 07/09/2013 Body mounted back onto the pan assembly.
DSC04584 Date: 08/30/2013 Headlight trim rings, nose grilles, and VW badge.
DSC04505 Date: 07/09/2013 My new helper under the car.
DSC04507 Date: 07/09/2013 The side bars are for support while the body was removed from the pan. With a convertible since there is no hard top to help with support it is possible for the door openings to move out of alignment.
These will be removed.
DSC04583 Date: 08/30/2013 Dash face installed.
DSC04590 Date: 08/30/2013 Some of the OG sound absorber was in good shape so I reused it. The sliver face stuff is from Fatmat. I am going to use this in the passenger floor sections also.
All of this will be covered with carpet and won't be seen.
DSC04591 Date: 08/30/2013 The sound absorber on the left and right is made by Evercoat.I used this because it can be seen when the rear seat is out and it looks more like the original. The reason I didn't use this all over is its cost is much more than the Fatmat.
DSC04454 Date: 05/17/2013 Evercoat sound absorber.
DSC04453 Date: 05/17/2013 Evercoat sound absorber.
DSC04622 Date: 09/01/2013 Front shot of the bottom of the floor pan.
DSC04619 Date: 09/01/2013 Pan bolts and washers.
DSC04620 Date: 09/01/2013
DSC04512 Date: 07/09/2013 Left front wheel well suspension detail.
DSC04509 Date: 07/09/2013 Left rear wheel well suspension detail.
DSC04510 Date: 07/09/2013 Rear suspension detail.
DSC04627 Date: 09/01/2013 Some of the electrical wires had been cut into over the years and needed some repairs.
Also some rearrangement of the wires.
DSC04628 Date: 09/01/2013 The instrument light bulbs were test and some replaced.
DSC04629 Date: 09/01/2013
DSC04626 Date: 09/01/2013 The original engine sound absorber was dirty and left side damaged due to the battery acid.
DSC04576 Date: 08/30/2013 Engine sound absorber was replaced. This is a kit that comes precut. Sounds good but doesn't always fit like it should. Some adjustment was needed.
DSC04579 Date: 08/30/2013 Starting to straighten up the wires in the engine compartment.
DSC04581 Date: 08/30/2013 This was added to the positive wire to the voltage regulator. Not sure what it is or why?
DSC04621 Date: 09/01/2013 New Karmann/Ghia badge.
weldpaintarea4 Date: 10/09/2013 The next 4 pics are the areas that the support bars were welded in. The bars were cut out and the areas were refinished. Look back at pic DSC04507 and you will see the support bars in the door openings. All of these areas are covered by interior panel and won't be seen but needed to be protected from corrosion.
weldpaintarea2 Date: 10/09/2013
weld paint area Date: 10/09/2013
weldpaintarea3 Date: 10/09/2013
DSC04635 Date: 09/27/2013 New Bosch starter.
DSC04638 Date: 09/27/2013 Starter installed and wire terminals repaired.
DSC04640 Date: 09/27/2013 New positive battery cable.
DSC04641 Date: 09/27/2013 The voltage regulator had been recently replaced and still looked good. It needed cleaning a little and some of the wires repaired that attach to it.
DSC04643 Date: 09/27/2013 Brake fluid reservoir and lines cleaned with new hose installed.
DSC04645 Date: 09/27/2013 Bottom half of brake fluid lines going to master cylinder.
Also new boots on the brake light switches.
windshield 2 Date: 10/24/2013 New windshield, mouldings, and gasket installed.
windshield 1 Date: 10/24/2013
windshield 3 Date: 10/24/2013
DSC04661 Date: 10/30/2013 Left & right door glass channel needed cleaning and had some minor rust. They were sanded, sprayed with self-etch primer and painted.
DSC04664 Date: 10/30/2013 Self-etch primer applied.
DSC04666 Date: 10/30/2013 Gray color applied.
Door glass Date: 10/31/2013 The glass was cleaned and polished to remove contaminates.
bumpers Date: 10/19/2013 The bumpers have arrived! They look great, Spacecoast plating in Melbourne Florida did the straightening and chroming. Spacecoast Plating
bumpers2 Date: 10/19/2013 2 original bumpers and 4 original guards were straightened and chromed.
guards Date: 10/19/2013 Karmann Ghia bumper guard.
DSC04983 Date: 01/31/2014 Bumpers were installed and aligned. Then removed to coat the back sides with rust preventative coating.

The center black stripe, and bumper guards were assembled and installed.
DSC04984 Date: 01/31/2014
DSC04981 Date: 01/31/2014
DSC04982 Date: 01/31/2014
DSC05032 Date: 02/04/2014 The inside of the bumpers were not refinished very well by the chrome shop, but that was understood and I was told about this.
I cleaned the backsides to remove any loose material and coated them with the rust coating product listed in the next picture.
DSC05069 Date: 02/18/2014 Rust Bullet is a unique single component high solids industrial coating. Rust Bullet products protect solid surfaces from oxidation and chemical attack. A cured Rust Bullet Coating provides protection from steel rust, iron rust, metal rust and metals corrosion.

This is a really great product. For more info on their products, click Rust Bullet
DSC05035 Date: 02/06/2014 The bumpers were masked and 2 coats of Rust Bullet was applied to the backsides.
DSC05036 Date: 02/06/2014
DSC05037 Date: 02/06/2014 The bumper guards were coated with Rust Bullet also.
DSC05093 Date: 02/19/2014 The old front bumper supports were in bad shape and were replaced.
DSC05089 Date: 02/19/2014 The old rear bumper supports were in bad shape and were also replaced.
DSC05039 Date: 02/09/2014 Front & rear bumper supports were replaced with new ones.
The front fit good, but the rear needed some reworking to properly fit.
DSC05040 Date: 02/09/2014
DSC05042 Date: 02/11/2014 After everything was reassembled the bumpers were reinstalled.
DSC05045 Date: 02/11/2014 The bumper guard impact strips and mounting seals are new.

All of this really makes this look fantastic.
DSC05046 Date: 02/11/2014
DSC05047 Date: 02/11/2014
DSC05054 Date: 02/16/2014 Right inner fender splash shield. These were repaired and new gaskets installed.
The pics of the repairs are on page 16-17.
DSC05055 Date: 02/16/2014 Left inner fender splash shield. These were repaired and new gaskets installed.
The pics of the repairs are on page 16-17.
right fender mldg clips Date: 01/23/2014 New clips for the body side mldgs.
DSC05058 Date: 02/16/2014 New stainless steel body side mouldings.

These should continue to look great for sometime.
DSC05057 Date: 02/16/2014
DSC05012 Date: 02/02/2014 The convertible top had some rusted frozen bolts that hold the brackets for the front header bow. These brackets will be replaced.

Heating the bolts helps to break them loose.
DSC05014 Date: 02/02/2014
DSC05015 Date: 02/02/2014
DSC05018 Date: 02/02/2014 The convertible top frame was blasted to remove paint and rust.

Daisy approved!
DSC05021 Date: 02/02/2014 Blasted the passenger side foot rest. It's getting primed and painted with the top frame.
DSC05025 Date: 02/03/2014 The convertible top frame was sprayed with self-etch primer then refinished black.
DSC05026 Date: 02/03/2014 Top frame sprayed black.
wipers Date: 11/15/2013 The replacement wiper blades only come in black. The originals were silver so I disassembled them and sprayed them silver. The wiper arms were blasted prior to painting also.
DSC05095 Date: 02/19/2014 Nice and just like original.
DSC04668 Date: 11/01/2013 Left & right door latches needed cleaning from old grease and paint from prior paint jobs.
DSC04669 Date: 11/01/2013 Left & right door latches were cleaned and greased before being installed.

More on these later....
DSC05085 Date: 02/19/2014 Right door latch cleaned and lubed.
DSC05086 Date: 02/19/2014
DSC05087 Date: 02/19/2014 Left door latch cleaned and lubed.
DSC05088 Date: 02/19/2014
DSC05060 Date: 02/16/2014 The rear engine lid rain tray had a hole worn into it from a breather hose clamp rubbing it.

The panel is made of fiberglass and was repaired with the same material.
DSC05061 Date: 02/16/2014 The tape is just a backer to keep the filler from falling through.
DSC05062 Date: 02/16/2014 The back side had to be repaired also.

Note the red tint on the panel. It was covered in red paint from prior paint jobs.
It should have been removed before the car was refinished and wasn't.
DSC05064 Date: 02/16/2014 Fiberglass material.
DSC05065 Date: 02/18/2014 The fiberglass was sanded, shaped, and primed.

It will be refinished soon.
DSC05067 Date: 02/18/2014 Repaired spot on the inside of the rain tray.
DSC05101 Date: 02/21/2014 The color of the panel was originally a grey color and not black.
I color matched the original color so it would look correct when finished.
DSC05102 Date: 02/21/2014
DSC05096 Date: 02/19/2014 Repaired speedometer and clock.
DSC05076 Date: 02/19/2014 The rear top bow was not rotten but it did have a bunch of holes from the previous tops installed.
DSC05077 Date: 02/19/2014 Staple holes needed filling.
DSC05078 Date: 02/19/2014 More staple holes.
DSC05209 Date: 04/01/2014 I didn't take any pics of the repair, but I sanded the wood smooth to remove any rough edges and used an epoxy to fill in the staple holes. Once it dried I sanded it and applied another coat. After sanding the final coat I applied a wood primer and painted it black.
DSC05361 Date: 07/06/2014 Rear bow painted and installed.
DSC04922 Date: 01/26/2014 This is the original header bow. You can see in this and the next pic that is was split.
Also the metal end plates are rusty and rotten.
DSC04920 Date: 01/26/2014
DSC05082 Date: 02/19/2014 Header bow removed.
DSC05083 Date: 02/19/2014
DSC04919 Date: 01/26/2014 Metal end plates were really rusty and rotting away.
DSC04920 Date: 01/26/2014
DSC05365 Date: 07/06/2014 The new resin header bow.
When we are finished fitting it we will add the other screws.
DSC05371 Date: 07/06/2014 The end plates needed some tweaking to fit the bow. The bow was sanded some to allow the end plates to sit flush.
DSC05373 Date: 07/06/2014
DSC05124 Date: 03/03/2014 The rear glass was a mess. The rubber around the edges of the glass was dry and torn. It also looks like someone applied some type of sealant to try and stop previous leaks.
DSC05114 Date: 03/03/2014 The hinge bolts were also loose. I'm sure this added to the leaks.
DSC05120 Date: 03/03/2014
DSC05123 Date: 03/03/2014 More nasty sealant.
DSC05128 Date: 03/03/2014 The rear glass latch was loose and had been rubbing the glass mldg. It had worn place that had to be repaired.
DSC05211 Date: 04/01/2014 Repairing the mldg.
DSC05210 Date: 04/01/2014 The rear glass mldg. is two separate pieces.
DSC05243 Date: 04/10/2014 The rear glass had some bad water spots and dirty marks. I polished both sides and it looks alot better.
DSC05376 Date: 07/06/2014 The mldgs were stripped, blasted, refinished, the hinges blasted and refinished. The glass polished, and new rubber seals installed.
photo 44 Date: 07/03/2014 The engine will be replaced but there are a few parts that will be used for the new longblock.
All of the tin work will be cleaned, blasted and refinished.
photo 22 Date: 07/03/2014 There is some factory markings that I'm going to try and duplicate.
photo 17 Date: 07/03/2014 I checked the engine number and it looks like this could possibly be the original engine for the car. Its dated July 1972. I feel sure someone has done some repairs to it in the past.
photo 23 Date: 07/03/2014 The carburetor was replaced with an earlier model and used an adapter to fit. I'm going to have an original model type rebuilt so the adapter won't be needed.
DSC05350 Date: 07/06/2014 Here is most of the pieces that will be used with the new engine.
photo 48 Date: 07/09/2014 Blasted all of the tins now for some straightening then paint.
shroud repair 2 Date: 07/09/2014 There is some dents that have to be repaired before painting.
shroud repair 3 Date: 07/09/2014 Dented area across the top of the shroud.
shroud repair Date: 07/09/2014 Body working the fan shroud.
tin repair 2 Date: 07/09/2014 The cylinder tin had some dents that needed repairing also.
tin repair Date: 07/09/2014 Body working the cylinder tin.
DSC05383 Date: 07/17/2014 After all the parts were blasted and body worked self etching primer was applied.
DSC05384 Date: 07/17/2014
DSC05385 Date: 07/17/2014 More engine tin parts.
DSC05386 Date: 07/17/2014 Even more engine tin parts.
DSC05387 Date: 07/17/2014 Backing plate for the generator and fan.
DSC05388 Date: 07/17/2014 Front breast plate needed some bodywork also but no pics of it, just primer here.
DSC05389 Date: 07/17/2014 Semi gloss black was applied to all of the engine tin.
DSC05397 Date: 07/17/2014 Fan shroud and cylinder head tin.
DSC05390 Date: 07/17/2014
DSC05391 Date: 07/17/2014 More painted parts.
DSC05392 Date: 07/17/2014
DSC05393 Date: 07/17/2014
DSC05395 Date: 07/17/2014
DSC05396 Date: 07/17/2014
DSC05399 Date: 07/22/2014 Muffler and heater boxes.
DSC05400 Date: 07/22/2014
DSC05402 Date: 07/22/2014 Heater boxes.
DSC05403 Date: 07/22/2014
DSC05404 Date: 07/22/2014
DSC05405 Date: 07/22/2014
DSC05406 Date: 07/22/2014 Grey color was applied to the muffler and heater boxes.
DSC05407 Date: 07/22/2014
DSC05408 Date: 07/22/2014
DSC05409 Date: 07/22/2014 Repaired and refinished heater boxes.
DSC05415 Date: 07/23/2014 The intake manifold for the carburetor needed some repairs. The exhaust heat risers (left and right legs that is bolted to the wood) have exhaust heat running through them and over time they get clogged with carbon build up. They have to be cleaned out by running a wire/cable through it. They also burn out in the curve bends because of blockage and need to be welded up.
Sometimes the only way to clean it out is to cut the tube to allow to get to the center section and then weld it back together, and that is the reason for bolting it to the block using it as a jig.
DSC05411 Date: 07/23/2014
DSC05412 Date: 07/23/2014
DSC05414 Date: 07/23/2014 Edges of the tube are beveled for a better weld joint.
DSC05413 Date: 07/23/2014
DSC05417 Date: 07/23/2014 Once welded its ground smooth.
DSC05418 Date: 07/23/2014 Right side heat riser had some rust holes that needed welding.
DSC05419 Date: 07/24/2014 Blasted it clean.
DSC05420 Date: 07/25/2014 Nice and new again.
DSC05422 Date: 07/25/2014 Various straps and clamps.
photo 52 Date: 07/10/2014 Pre heat duct for the air cleaner.
photo 53 Date: 07/10/2014
DSC05425 Date: 07/25/2014
DSC05426 Date: 07/25/2014
photo 57 Date: 07/15/2014 This is the end of the heater box that the muffler attaches to. Over time they get rusty and deteriorated from leaking exhaust.
To fix this you have to cut off the bad section and weld on a repair piece.
photo 59 Date: 07/15/2014 The replacement piece has a smaller section that will slide inside of the heater box.
photo 58 Date: 07/15/2014 Heater box repair part.
photo 60 Date: 07/15/2014 Right heater box.
To install the piece, heat has to be applied so the heater box end will expand allowing the repair piece to slip in.
photo 56 Date: 07/15/2014 Both L&R pieces were replaced and welded in to get a tight seal to eliminate leaks. No pic of the welded part.
photo 55 Date: 07/15/2014 Test fitting the muffler to the heater box.
Left side.
photo 54 Date: 07/15/2014 Right side.
photo 104 Date: 10/24/2014 The new engine came from Scat Enterprises in California.
photo 105 Date: 10/24/2014 The box was strapped to a small wooden pallet and shipped by truck.
DSC05431 Date: 10/17/2014 I didn't get a pic of it out of the box before I started assembly. The engine is a long block. That consist of the engine case and heads assembled.
The oil cooler, distributor, generator stand and engine tin have to be assembled.
DSC05438 Date: 10/17/2014 A new Pertronix electronic distributor was installed.
DSC05437 Date: 10/17/2014 The oil spout was cleaned and refinished and a new oil cap installed.
DSC05432 Date: 10/17/2014 A new oil cooler was installed.
photo 111 Date: 10/17/2014 This bracket was missing from the old engine. It bolts to the back of the oil cooler and the fan shroud attaches to it.
DSC05433 Date: 10/17/2014 The bracket in place.
DSC05436 Date: 10/17/2014 A new flywheel did come with the new engine. The pressure plate and clutch disc attaches to it.
DSC05434 Date: 10/17/2014 The fan shroud installs inside of each cylinder head tin.
DSC05435 Date: 10/17/2014
DSC05444 Date: 10/21/2014
DSC05445 Date: 10/21/2014 This is the rear of the fan shroud. There are air control flaps inside the housing that control the air flow for cooling the engine. The flat bar running from L to R with the spring attached and air flaps inside the housing were missing and were replaced.
DSC05446 Date: 10/21/2014
DSC05441 Date: 10/21/2014 The copper coil seen here is the thermostat for the air flaps inside the fan shroud.
This is part of the air cooling system.
photo 90 Date: 11/01/2014 The carburetor that was on the engine was the wrong one for the year of the car and required an adapter to mount it to the existing intake manifold which caused it to sit higher. This caused problems with the breather tube to hit the bottom of the rain tray on the bottom side of the engine lid. Also it was not jetted correctly for the later model engine it was mated.
I found Volkzbitz.com , Tim the owner of the company restores carburetors to like new condition. This is more than replace a few gaskets. He installs new bushings in the throttle shaft and replates all the hardware. The body of the carburetor is cleaned inside and out. He adjusts the carb before sending them out and warranties his work for 3 years.
It is very nice workmanship and all of his feedback has been positive.
DSC05473 Date: 11/02/2014 This is not your old carburetor. It is just an example of before and after.
DSC05476 Date: 11/02/2014
DSC05474 Date: 11/02/2014
DSC05477 Date: 11/02/2014
DSC05475 Date: 11/02/2014
DSC05478 Date: 11/02/2014
DSC05480 Date: 11/02/2014 The restored carb on the engine.
DSC05496 Date: 11/04/2014
DSC05495 Date: 11/04/2014 New Brosol fuel pump.
DSC05494 Date: 11/04/2014 The coil was the Bosch blue coil that was on the engine previously. It was refinished and a original style decal added.
DSC05479 Date: 11/02/2014
DSC05481 Date: 11/02/2014 A new fuel tank was installed from Wolfsburg West. Nice quality tank and is galvanized inside to protect from rusting.
DSC05464 Date: 10/29/2014 A new tank to body seal was installed.
DSC05465 Date: 10/29/2014
DSC05463 Date: 10/29/2014 A new fuel tank outlet kit was installed.
DSC05466 Date: 10/29/2014 New fuel hoses installed.
DSC05467 Date: 10/29/2014 New fuel overflow hoses installed.
DSC05469 Date: 10/29/2014 New fuel hose to the main fuel line.
DSC05485 Date: 11/02/2014 The fuel gauge cleaned up nice. But it looked warped around the outer rim of the mating flange. It looks like someone had over tighten the mounting bolts causing the warp in the flange.
Its not going to seal so it will be replaced.
DSC05483 Date: 11/02/2014
DSC05484 Date: 11/02/2014
DSC05498 Date: 11/11/2014 New VDO fuel sending unit.
DSC05501 Date: 11/11/2014 New fuel sending unit installed.
photo 84 Date: 10/06/2014 The NOS German muffler that I found at the parts swap.
photo 82 Date: 10/06/2014
DSC05448 Date: 10/24/2014 The engine breather had been abused over the years. It was dirty inside, the carb to breather hose was broken into and someone had taped it back together. The various hoses were cracked or broken and there were some dents in it that needed to be repaired before refinishing it.
DSC05450 Date: 10/24/2014
DSC05451 Date: 10/24/2014
photo 103 Date: 10/28/2014 I'm going to see if I can find a replacement decal.
photo 106 Date: 10/27/2014
photo 107 Date: 10/27/2014
DSC05458 Date: 10/28/2014 The inside of the breather holds oil to help filter the air coming into the carburetor.
DSC05459 Date: 10/28/2014 Top half has a non replaceable filter in it that needed to be cleaned.
DSC05455 Date: 10/28/2014 Small dents that needed to be repaired.
DSC05461 Date: 10/28/2014
DSC05457 Date: 10/28/2014
DSC05462 Date: 10/28/2014
DSC05456 Date: 10/28/2014 Lower half had some small dents also in the spout.
DSC05460 Date: 10/28/2014
DSC05487 Date: 11/02/2014 All nice and new again.
DSC05488 Date: 11/02/2014
DSC05490 Date: 11/04/2014 These are the original valve covers for the engine. They didn't look bad until they were cleaned and blasted.
They had been abused and were dented pretty bad.
DSC05489 Date: 11/04/2014
DSC05491 Date: 11/04/2014 They were pretty nasty inside. I don't think they were cleaned the last time the engine was rebuilt.
valve cover9 Date: 11/04/2014 Cleaned and blasted.
valve cover6 Date: 11/04/2014 Damage that needed repair. Both valve covers had some bad dents in them.
valve cover11 Date: 11/04/2014 Inside corners.
valve cover7 Date: 11/04/2014
valve cover8 Date: 11/04/2014
valve cover1 Date: 11/04/2014 Inside the covers and the straightening marks.
valve cover2 Date: 11/04/2014
valve cover3 Date: 11/04/2014 Once I straightened them out I metal finished them. I didn't think the body filler would hold up to the heat.
valve cover4 Date: 11/04/2014 I don't have any pics of the filing process but will add some of them after they were refinished.
DSC05679 Date: 06/05/2015 Retro Sound radio.
DSC05681 Date: 06/05/2015 Speedo and clock installed.
DSC05678 Date: 06/05/2015 New dash pad installed, radio, speedo and clock, and glove box door was refinished.
DSC05675 Date: 02/05/2015 The rear view mirror base, and white mount needed refinishing.
DSC05745 Date: 06/17/2015 The dome light cover was cleaned and reused.
DSC05677 Date: 02/05/2015
DSC05744 Date: 06/17/2015
seat4 Date: 09/15/2014 Front seat with old padding.
seat 1 Date: 09/15/2014 Front seat before recovering.
DSC05326 Date: 05/22/2014 Rear seat before recovering.
DSC05342 Date: 05/22/2014 old rear seat padding.
DSC05379 Date: 07/06/2014 The rear seat backrest had some rotten wood that needed replacing.
A new piece was cut and shaped like the OG and installed.
DSC05643 Date: 01/09/2015 Freshly recovered seat.
DSC05642 Date: 01/09/2015 Hardware replated.
DSC05644 Date: 01/09/2015 Side covers refinished with new hardware.
DSC05647 Date: 01/09/2015 Head rest post covers were replaced.
DSC05648 Date: 01/09/2015 New padding in the seats.
DSC05683 Date: 06/05/2015 Fatmat sound deadener was added to the floor in strips to fill the low indentations in the floor.
This was done to the front and rear sections of the floor.
DSC05687 Date: 06/08/2015 A full layer of Fatmat sound deadener was added over the strips.
This was done to the front and rear sections of the floor.
DSC05707 Date: 06/12/2015 Fatmat under the carpet padding.
DSC05708 Date: 06/12/2015 Carpet padding was added on top of the Fatmat to give it a soft feel.
This was done to the front and rear sections of the floor.
DSC05709 Date: 06/12/2015 Driver side.
DSC05714 Date: 06/12/2015 A new 19 pc carpet kit was installed. This required a good bit of time to install. It fit nicely but still needed adjustments all around.
DSC05746 Date: 06/17/2015 A new E-brake boot was installed.
Both of the seat belt latches were disassembled, repaired, and refinished.
DSC05747 Date: 06/17/2015 Opted to refinish and reuse the shifter knob. The aftermarket one was not very good quality.
DSC05701 Date: 06/12/2015 Seats and carpet installed.
Sorry for the bad pic.
DSC05697 Date: 06/12/2015
DSC05702 Date: 06/12/2015
DSC05698 Date: 06/12/2015
DSC05700 Date: 06/12/2015
DSC05699 Date: 06/12/2015
DSC05703 Date: 06/12/2015
DSC05706 Date: 06/12/2015 Rear seat area also shows the new plastic interior panels that covers the vert top hinges.
The panels were bright white and had to be refinished off white to match the headliner.
DSC05688 Date: 06/08/2015 Rear of steering wheel.
DSC05689 Date: 06/08/2015 Horn contact ring was worn and will be replaced.
DSC05695 Date: 06/08/2015 Cracks in the steering wheel on 3 of the 4 corners.
DSC05694 Date: 06/08/2015 Cracks in the steering wheel.
DSC05693 Date: 06/08/2015 More cracks.
DSC05692 Date: 06/08/2015
photo Date: 06/09/2015 The cracks had to ground out to a V shape and then filled with a plastic repair material.
DSC05715 Date: 06/14/2015 Once the material is cured then its sanded smooth and contoured to the original shape.
DSC05716 Date: 06/14/2015
DSC05718 Date: 06/14/2015 Rear of wheel.
DSC05723 Date: 06/16/2015 Prior to painting the wheel it was primed with 3 coats of 2k filler, sanded smooth and then the color and clearcoat was applied.
DSC05724 Date: 06/16/2015
DSC05729 Date: 06/16/2015
DSC05741 Date: 06/17/2015
DSC05740 Date: 06/17/2015 New contact ring installed.
DSC05743 Date: 06/17/2015 The center front and rear horn base was also repaired and refinished.
DSC05725 Date: 06/16/2015 Refinished the steering housing.
DSC05728 Date: 06/16/2015 Refinished the wiper switch.
DSC05726 Date: 06/16/2015 Refinished the TS switch.
DSC05735 Date: 06/17/2015 This is the turn signal switch, someone had replaced it before and didn't install it correctly as it was broken and not functioning properly.
A new one was installed.
DSC05736 Date: 06/17/2015 Turn signal and wiper switch assembly.
DSC05734 Date: 06/17/2015 Steering column housing holds the ignition switch and the turn and wiper switch.
There is a bearing that the shaft rotates on and it was removed, cleaned, greased and reinstalled.
DSC05732 Date: 06/17/2015 Shaft bearing removed.
DSC05731 Date: 06/17/2015 Packing the bearing with grease.
DSC05738 Date: 06/17/2015 Assembly ready for install.
DSC05363 Date: 07/06/2014 The top frame was blasted and refinished. Some bushings replaced, the header bow replaced and the header bow corner plates. The missing screws were added once the final fit.
DSC05364 Date: 07/06/2014
DSC05365 Date: 07/06/2014
DSC05361 Date: 07/06/2014 The rear wood bow was repaired and reused.
DSC05373 Date: 07/06/2014 Making adjustments and fitting the corner plates.
DSC05371 Date: 07/06/2014
DSC05372 Date: 07/06/2014 Anti rattle grommets on the intermediate bow.
DSC05658 Date: 01/28/2015 Once the corner plates were fitted they were covered so nothing would rub the padding or top from underneath.
DSC05661 Date: 01/28/2015
DSC05657 Date: 01/28/2015 Webbing straps connecting the intermediate bow, and rear bow to the car body. This makes everything nice and tight.
DSC05667 Date: 01/28/2015 Front header bow cover with headliner material prior to install of the top.
DSC05666 Date: 01/28/2015 Top side of header showing stapled headliner material.
DSC05756 Date: 06/17/2015 Headliner goes in first from the bottom side. Then padding on top of the vert frame.
DSC05757 Date: 06/17/2015
DSC05750 Date: 06/17/2015 I don't have any pictures of the padding install prior to installing the actual top.
There are still adjustments that need to be made and then it will need to be in the sun for a few days to get the material to relax and take better shape.
DSC05749 Date: 06/17/2015
DSC05751 Date: 06/17/2015
DSC05752 Date: 06/17/2015
DSC05755 Date: 06/17/2015
DSC05753 Date: 06/17/2015
DSC05754 Date: 06/17/2015
[-]
Stop   Pause   Back One Image   Show More Info   delay:   direction:   max size:  
  • Homestart here
  • About Uswho i am
  • Contactget in touch
  • Gallerymy work
  • Forumcommunity
  • Linksresources

© 2008 Zundfolge. Site by Michael Scribellito.
Website hosted by CompuStation.

The names VW and Volkswagen are trademarks of Volkswagen Germany, Any use is for the sole purpose of application and descriptions. Zundfolge has no affiliation with Volkswagen Corporation.

Get ADOBE FLASH PLAYER