made some progress today - Karmann Ghia

js292 said:
really like the work your doing on this, looks like a fun little project.
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thanks :thumbs:

it is fun, it actually becomes more and more fun the closer I get to see the end of this ..... been woking on this Ghia on and off since 2007 and changed direction in the middle of it (change color and return it to coupe)
 
little progress: installed the fancy steering wheel to add a touch of luxury :)

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then started on the oil filter adapter plumbing..... these engines don't have a oil filter, only a strainer from the factory......

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Started working on the engine, removed heads, cylinders and pistons. The bores were in good shape but too bad these are stock 1500cc, 83mm bore. I bought a set of 87mm cyl/pistons so soon it'll be a 1641cc engine.
Rods and crank look and feel good, no reason to take this thing apart any further.....

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it was leaking oil. there's about a pound of oil crud and dirt mix on each cylinder. That crap was blocking airflow over the cooling fins...... not good......

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the clutch disc shows a weird wear pattern, probably time to replace clutch, pressure plate and flywheel...... the disc is worn toward the outer diameter, much more wear than at the inner. On a new disc the grooves go all the way to the OD.

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I'll take some measurements with a dial indicator to see if the flywheel is still useable or needs to be resurfaced.... well, the flywheel is only $90 online so I doubt resurfacing is an option....

Today I cleaned the ngine case and saw that one of the studs that hold the case halves together had its' nut missing. :shocking:
Put a new washer and nut on there and tightened it, thought it was a good idea to check the other studs/nuts ... well, all of them were only hand tight, one was backed off two turns....

Because of this I took a wrench to the rod bolts , fortunately these were tight.

now I'm thinking about throwing a cam in there, damn I just cannot leave stuff original ...... :lol:
 
little progress, got a new ALC sandblaster and it does a great job.... blasted the tank, sprayed 3 coats epoxy and then base/clear.....

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and back under the hood.....

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Damn good thread boss!
Always wanted a ghia. If i ever get one i might drop in a busa turbo motor just to wind up rpms lol.

G/l and keep up the good work. :thumbup::thumbup:

Sent from my dumb 4g motorolly
 
engine is kinda simple to work on :)

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fancy pushrod tubes that supposedky don't leak....... well, we'll see..... feedback online was good so I hope for the best......
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head is back in plac.... one done, one to go.....
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looking thru older photos ..... Looking at this stuff makes me realize what a POS it was and how much work it took to get it where it is today LOL

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gotta love that Home Depot angle iron that was pop riveted to the car .... rivets, silicone, duct tape and sheet metal screws held this crap together.....

new floorboards are like $200 so I was wondering...... WTF ???

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going to finish up the engine this weekend hopefully.....
 
ok, engine is back in one piece.... clutch is next..... have to get a 36mm socket tomorrow to get the flywheel off.... that's almost 1 1/2" - I hope they make these in 1/2" drive... :smash::smash::smash:

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rear glass is back in place.....

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That sandblaster is one of the best purchases I've made this year (it's only January)

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made some progress on the engine as well... new crank pulley and new engine tin behind pulley....

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new clutch disc and new pressure plate.... flywheel was still ok..... got a new flywheel nut with a new bearing just in case....

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and here's the brandnew windshield installed.... new gasket too....

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Thanks guys :)

I use playsand - CAUTION - do not use sand without proper respirator..... silica will mess up your lungs..... google "silicosis"

http://www.osha.gov/Publications/silicosis.html


$3.69 plus tax for a bag..... does not harm my lawn either, just get the hose and water it in.....

I use a 5/32" nozzle, the 1/8" will plug up with this stuff. Every now and then there's a pebble in the sand that plugs up even the 5/32" nozzle.....
 
It's really getting there isn't it... NICE!! What's that heat exchanger for? Oil? I know less than nothing about VW stuff ;)
 
Twin_Turbo said:
It's really getting there isn't it... NICE!! What's that heat exchanger for? Oil? I know less than nothing about VW stuff ;)
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It really is very high tech: the crank pulley drives the alternator via a belt, on the back side of the alternator is a huge fan ... That fan is in a shroud , inside this shroud is the oil cooler ... I am amazed how simple this thing is, you could assemble thos engine with just a spoon and a pocket knife
 
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