House of Karmann

[greg356a]

Yes, Group 4 rims would be great, not sure of the offset working. The 18x7.5 on the front were ET50, largest I can see is 36 but on a 7" rim might be ok. Very confident something will fit and look better

Will Group 4 work out the offset for you? I assume you would normally replace rims like for like.

[911hillclimber]

I know Image Wheels up here in the West Midlands will do a lot of the 'design' work on many of their wheels.
The diagrams they provide are nice and clear; they may also have a style for your car?

[greg356a]

Image wheels can provide the "look" size and offset but the cost for a Karmann Ghia is a bit high. Will just have to suck it up and pay

[911hillclimber]

But you get what you want for this great car.
Wheels can make a car, so important to follow your heart!

[greg356a]

I wanted to achieve a bit of a wow factor under the bonnet, absolutely love a fuel cell, but hate the cost. So bought a cheap ebay tank, actually the largest that would fit, almost too large. So its 80l tank.

It was worth exactly that I paid. The filler cap really did not work the fuel sender was glued into place really poor quality. But the welding does look good with good pen through the joints.
Fuel tank
The engine needs two filler 10mm pipes and a 10mm return.

Also purchased a new aluminium top plate, VW sender, breather valve, and filler neck with cap. With massive thanks to Pete the tank looks pretty good for fraction of the cost of a fuel cell.

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The rear of the tank at the bottom needed cutting to allow a better fit so basically cut a step off

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Also Pete cut off the fixing brackets and re positioned using the original 4 KG holes.

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The last task was to add filler sections to the body to create a good fit around the tank.

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These are welded from underneath so as to leave the shape visible thought it looked more OEM. I will source some dome head hex key bolts and cup washers to use everywhere. At present the plan is to brush finish and lacquer the tank and maybe paint the top cap etc in gloss black.

The very observant will notice the tank is very slight offset this is too allow space for the brake fluid reservoir and billet ali windscreen washer bottle.

Trying to source some baffle foam inserts to stop sloshing, but wow how expensive can a piece of foam be? obviously too expensive!

Very pleased with the result.

More updates to follow

[rhd racer]

Looks great, nice job


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[911hillclimber]

I think people use balls now to go inside the tank?
Merlin motorsport or Demon Tweeks, but may be others?

[greg356a]

Yes, seen you can buy 50x50x50mm or 100x100x100mm cubes, do they work? I also read the less foam sections the better.
The foam is more expensive than the tank

[rhd racer]

I had foam in my last one and never caused any issues / not tried the balls / cubes


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[greg356a]

Afternoon,

We have been working on welding over numerous small holes, removing unwanted metal brackets, clips etc. I want to fit a set of belts to the bonnet same as my 356's;

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One of the big issues will be the need for a new wiring loom which is compliant to the IVA test. Will need several switches and warning lights, far more than was originally fitted. Found a series of smooth to touch switches which has every combination needed.
Switches

Not an easy fit into the space, seemed best to add a switch pod underneath the dash. Mock up stage;

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Amazing how many switches and warning lights need to be fitted. The original driving gauges really don't include anything, I have allowed a couple extra to future proof.

[rhd racer]

Remind me why you are going to SVA - is it the points thing due to the suspension changes etc?


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[greg356a]

Primarily yes, IVA is required because of the suspension changes, although the original stub axles and drive shafts are used. Some of the elements are for safety so make really good sense. Including hazard lights, low brake fluid level warning light, seat height/ head rests, and a few others. The custom wiring loom will certainly prove a challenge.

[greg356a]

The switch pod has been fabricated as a bolt under the dash option. Hoping this will aid the fitment of the multiple switches.

Started with a laser cut front panel and paper templates
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Side panels were hand fabricated by Pete using a tube for the radius and then a 90 degree return for strength.
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The final pod will be body colour same as dash. The plan is to bolt to the under dash with a gasket to prevent any creaking or squeaking. For IVA is will need a gasket to form a protective radius, although you are allowed 127mm outside the steering wheel diameter. All the cables will feed through a single hole under the dash (including a grommet for protection) which will be hidden behind a cover in the fronk.

Next job is to fabricate a roll bar. Single hoop with a bar going back to the body on each side and than one across the width. This will allow for fitting a three point safety belt at the correct height and also a harness should it be needed in the future.

[PMNorris]

Getting there, looks great.

[greg356a]

Lots of work done over the last few weeks. Now coated in black epoxy paint, wow every panels has dents. The chassis is in black satin and black rapture underneath for long term protection.

These dents are being worked out slowly. Also manufactured a roll bar that bolts into original rear seat fitting to avoid cutting any holes in the body chassis. I don't want to upset the DVLA. The hiem rose couple joints allow a certain amount of tensioning/ adjustment. I think we have managed to restore the chassis and body to original 1963 spec. Obviously the front and rear bolt on double wish bone suspension cradles are different but are fixed via original bolt locations. Also the rear engine valance is removable, but really VW should have done this originally to aid engine removal. IVA test compliance is still the goal. Sourcing a bespoke wiring loom to accommodate all the additional electrical requirements is currently on the list of many things to do.

Also purchased a second bonnet via ebay to use as a paint swatch for the final colour/s choice. Will reveal soonish.

Very difficult to get sharp photos of black body in lower light condition, but hopefully get the idea;

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