House of Karmann

[greg356a]

Yes, will search Kev tonight.

Thanks for the feedback

Was thinking that a classic car retro fitted with an electric motor, batteries, power differential (what ever they call a gearbox) would be considered as a radically altered vehicle and would need IVA? Hence all electric converted cars should be on a q-plate?

[KS]

It gets complicated because you get into the territory of replacement engines requiring the vehicle to meet the emissions requirements relevant to the age of the engine and being registered accordingly. Kev will reveal all...

[greg356a]

Hi Bruce,

The part number 477501065 (82-85 944 NA for steel arms) looks correct to fit the 1303 IRS stub axles, as you surmised I have the later ones. Trying to find a used pair via ebay, market place, internet search is proving quite difficult. I have emailed a few breakers maybe something will turn up.

Thanks for the part number

[Bruce M]

They pop up fairly regularly, although sometimes with “scene-tax”

[greg356a]

Depressingly the Ghia is still stuck down south waiting for the DVLA to visit and issue UK paperwork.

Managed to fit the front and rear suspension parts together. Must say the attention to detail is excellent, even the nylon nuts are colour coded red! More importantly the weld quality/ penetration and precise fit is excellent. I would also say each suspension unit is much lighter than the previous units.

Rear
Original VW wheel bearings, VW CV Joints inside and outside, original VW type 1 stub axles, and type 1 axles. 78mm CV, type 1 axle VW type 1 CV joints inner and outer VW beetle axle
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Front
VW spindles, VW anti-roll bar, VW steering rack
VW original type 1 1968 onwards front wheel bearing kit, (seal, inner/outer bearing, cap
VW original type 1 1968 onwards thrust washer
VW original type 1 1968 onwards Clamping nut Left & Right

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[911hillclimber]

I find that lot really impressive and looks absolutely bomb-proof.
Going to be great this one!

[greg356a]

May seem mad, but I bought the car in lock down 3, fed up with constantly missing project opportunities, I bought the Ghia unseen. It was from a reputable KG dealer and I did my due diligence virtually!

So off on Thursday to see the car for the first time in the flesh. So bring on the coffee and doughnuts should be a really enjoyable day.

[911hillclimber]

1,000,000 pictures are expected and a single paragraph 'bottom line'

[greg356a]

Really enjoyable day with Pete and the team over at Californian Classic. Quality really is paramount. Some really interesting projects going through the shop including Porsche power plants. Also some of the specialist parts available really look excellent.

Very little history known about the Ghia, seems to be a 1963 original Texan car which may have moved across three state lines including California. The dry states have been very kind to the body over the 56 years. Whilst there is rust it seems manageable. The car is remarkably complete. Excited to get started.

The body was split from the chassis ready to go to media blasting next week.

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How low can you go!

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[911hillclimber]

10/10 report!
Looks a nice starting point and will be interesting to get it together.
Worst rot is in the rear lower 1/4 of the rear wing(s)?

Look forward to the pics after the body blast.

What about the floor pan/chassis?

[Mike Smith]

Nothing wrong with that - Fantastic Body

Certainly better than the average 356 that we see arrive from the U.S.

[greg356a]

I agree the body at 56 years old is in remarkable condition. There is some USA mud down one wing, underneath the metal looks good, will change both heater channels and of course the battery tray, bottom of both rear 1/4 panels. The doors look very good, little rust where the seals were at the bottom - hopefully media blast will leave clean metal. The front nose has a parking dent which may take a bit of work. The bonnet might be replaced, by comparison to big brother, there is availability and prices are cheap. The engine lid will be worked on by the team at Californian Classic to fit the twin grills.

The chassis is good, frame head looks undamaged, but the pan half's need replacing, bit like a Fred Flintstone car! The seat runners can be saved.

I have boxes of bagged and tagged parts to go through. One thing I have noticed is the similarity between some of the early Ghia parts and 356 parts. Must have been a common parts bin.

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[greg356a]

Working on assembly of various VW original parts and Porsche parts for suspension and brakes.

The good news is the VW IRS axles fit the early Porsche 944 NA hubs. 944 early n/a rear wheel hub Part number 477501065
Really struggled to find a pair of used hubs. One is NOS whilst the other is a used example both tracked down in the Netherlands. These were cheaper then one new one.

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Rear Brakes
I have 28mm piston (20mm inside) and 30mm piston (22mm inside) calipers. These are the early version pistons with scrapper rings (86 inside caliper)
944 Turbo 1985-1988 rear calipers Left 951 352 421 00 Right 951 352 422 00.

Bad news there is a clash with the larger VW/ Imohr hub carrier. I can move the position of the caliper around 90 degrees ie 12 o'clock to avoid the clash but the handbrake exit would point down rather than towards the front of the car. This may not be a problem, the plan was always to use special made handbrake cable, so I could introduce a slow 90 degree return as the cable exits. Not sure if this would cause any problems with the handbrake operation. Also no idea what impact the new position of the caliper on top would have on braking efficiency, if any. I was think that as long as the bleed nipples are up then braking force is the same anywhere around the circle? Force X moment arm, doesn't matter where on the circle the force is applied, it's still the same torque.

Any thoughts / comments?

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Front Brakes
Found a pair of 1992 968 front calipers, These being 968 & 944 S2/ Turbo 1989-91 front calipers LEFT 95135142103, RIGHT 95135142203 Piston 36mm/ 40mm

The 12.5mm thick mounting plate does not have sufficient additional metal to mount the calipers. The obvious solution would be to cut the plate square and then TIG weld metal to allow new mounting holes to be drilled and tapped for M14 bolts.

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I have been trying unsuccessfully to find a dimensioned drawing on the internet. I guess the other alternative is to find a cheap 944 spindle to measure. I have one on the front of the speedster but don't want to take that all apart.

I think the next step on the fronts is to press in the VW bearings to the hubs fit disks etc and see where the calipers sit. Again struggling to find a drawing of the caliper in relation to the spindle.

To get the right tolerance maybe beyond my machine resources/ skills. Once a have all the parts gathered I think I will have a chat with my local steel fabrication shop, see what they suggest.

Any comments or thoughts gratefully received.

[911hillclimber]

I had some issues sorting the rear brakes on my Lola, AP callipers to hyper rare March F2 magnesium uprights and more.
Worked out a solution, but had no facility to machine parts, so went to B G Developments in Bromsgrove, West Midlands with sketches, parts, and they got it all straight, been good for the last 10 years.
Might be a way round for you?

[greg356a]

Afternoon,

Progress on the Ghia this week. DVLA have produced the V5C so now have UK paperwork! Pleased this has finally happened. Registered as a black 1964 car. Actually built in 1963 but I guess it took weeks/ months from Germany to USA and then through Dealership to final owner.

I have taken the front hubs, calipers to a local engineering firm. They plan to plasma/ laser cut a AutoCAD designed adapter plate for the caliper mounting holes which will be tig welded to the current spindle plate. Offset to correctly position the disk in the centre of the caliper. Should be able to pick something up in the next couple of weeks

Also the body has been media blasted, given how much these cars were prone to rust, the signs look very encouraging

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Is it me are all parts orders taking much longer. So waited 6 weeks for drive shafts and now 2 weeks and counting for 1303 rear bearings. I got sent 9 out of 10 wheel studs ordered. Really have to watch everything, almost completing full good in checks to make sure you have got full order. Packaging seems to be another issue, actually received an empty box! Parts supplier took some convincing to get a refund.