The Cal-look Lounge

so,
as some of you guys might know I was rebuilding a 1970 KG, but that project kind of died, the body was a little twisted and I couldn't get is straight enough.
So now I bought a new body and will be using that one to make a new KG
The new body is from a 1967 KG, the guy I bought it from wanted to make a dragcar out of it, so  he cut out the front and rear inner walls, I'll be putting them back in probably.
The car will very likely become an '80s looker, not sure if I'm gona close the nose holes, I like the look of the car without them, but they might come in handy to put some oil coolers in there for the engine.
all the trimwork is gone, wheels will be original empi 8 spokes
1967 porsche 912 gauges, kamei console, simcaseats, custom rear seats (new and improved)

the engine will be a turbocharged 2276
these are the parts I have for now:

- AS41 case
- Wiseco 94mm Pistons and Mahle Cylinders
- El bandito 94mm heads (40*37.5)
- BVW 82mm Forged Counter-Weight Crank
- BVW 5.5" Forged H-Beam Connection Rods with ARP 8740 Bolts
- Webcam 218 Cam on 10° Lobe Centers
- CB Performance 28mm Ultralite Lifters
- CB Performance 3/8"/0.058" Chromoly Pushrods
- Schadek 30mm Oil Pump
- 48mm Jenvey throttle bodies
- Water injection

still waiting on the CBperformance hideaway exhaust.
For the turbo I'm going to begin with a turbo from a 1980 2.3 mustang, not sure if that will be enough, might go bigger..
ignition is still open for discussion, I was thinking an electronic ignition from mallory or something like that.
here are some photo's from the car, I'll try to make some more soon.
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nice one!!

Nice!
Is the 67 coming from the ottobross?

Good luck!

gr
Wout

jup, that's it, I hope I can get the car home this weekend..

Glauco, GO GO GO!  we want to see this car at EBI this year! Make it happen.  8)

Dem

karmann is home, tomorrow I'm going to start cutting down the old one to complete the new one, will post some pictures later this week!
Glauco

your brother told me yesterday when he came to help my sorry ass with some notchback problems that you were on the road to collect the KG.  I want to see pictures asap!  ;)

what did you do wrong this time? :P
I started cutting up the old kg today, probably will be finishing her up tomorrow, so I can start putting the new one together :-)

finished up breaking down the old KG today, the only thing that is left of the car is the inside of the trunk and motorarea
I also managed to get the new car in the garage
the plans for this week is to cut out the parts I need and make sure they are rustfree, that will keep me busy for a few days I think
Also I will be fitting the fiberglass hood in front and get rid of the racelocksystem and go back to the original, maybe I'll use the race ones for the back.
I'll upload the pictures tomorrow, have the make them smaller...

Glauco

The pictures
I removed the windows and will be mounting rubbers without the chrome strip
Also I will be putting in the correct doors, the previous owner placed later model doors, need to check the alignment to..
Glauco
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some more :-)
all of the aluminium plates (including the dash) will have to make place for original panels
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I will be adding bars to the rear of the the car, makes it a little nicer I think
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last ones for now

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Some pictures of what is left of the old car.
all in a days work, and 30 cutting disks later
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I like the cleaned nostrils! :) are you keeping the car flat black or are you going to paint it?

thanks! I like them to
I was thinking to keep it flat black for this summer, maybe try to polish it a little bit or even maybe ad in a few coloured stripes, but that's going a bit out of the callook lines..
something simple like this
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will be painting it someday do, I realy like the light porsche blue
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or something more in the orange range, I realy love this colour!
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if you choose for the blue you need to check some pictures of marc sauters' blue 67 with golden empi 5 spokes!!!!  :o  :o  :o
I can't find the link but the pictures (full colour) are on the lounge somewhere, if someone has the link?

It's such a FUCKING GOOD combo, it blew me away for sure!!!!  search the pictures, you won't regret it.  ;)

would like the see it, but I'll think I'll stick with my 8 spokes, but maybe in gold..
what I also like is the blue and then paint everything that was chrome black :-)

painting trim black seems to become popular, indeed :D ;)
and for the record, gold 8 spokes rock!

I say remove the trim, keep it flat black with gold 8-spokes ;D

yeah, that's what I mean man, keep your 8 spokes but in gold!  it sounds like a weird combo with blue, but trust me, it isn't.
god damn, I really need to find those pictures!

here it is!!  killercombo  :o  :o  and check out the interior, owww yeah baby!

http://cal-look.no/lounge/index.php/topic,13715.0.html

wait untill you see the interior I'm preparing, that will be killer :D
I'm thinking of trying to paint the car black in one coat, just to pass the summer..
hope to get some work done soon, if I ever come back from france...:(
glauco

update!
rear end is almost ready to go in the car, as soon as I have the bumpermountplates I can weld them in and then the back is finished.
than I can start with the front.
I had photo's, but I lost my memory card, I hope I can find it soon so I can post some pics !

Glauco

Hello there.
A small update here.
Haven't done much this week because I'm in sweden for 2 Weeks for works
Gold thing is I can visit Turbotown this weekend:-D
I'm almost finished welding up the inner back end so when I return I return I can start with the front
I'll try and post some pictures later
G.

ok, apparantly it has been almost a year since I posted on here.. :-\

the floorpan is converted to IRS, bought rear trailing arms and  disc brakes and all from a porsche 944 (also front brakes)
the pan has been sandblasted and powdercoated and is ready to be assembled, gearbox is stock for now, not yet made my mind up what I'm going to do with the gearbox, for now a stock one will do just fine.
wheels for now will be porsche coockycutters

the body has had some serious welding, the inner parts are installed and welded, ready to finish

the left side has had a complete new donor part between the door and the wheel arch, the car has had some kind of accident in the past I think, the hook for the door was almost 1inch out of place, , they just put a filling plate underneath and filled everything up with filler.

the right side has had new weld in parts as well, the wheel arch was rotten away as well as the part between the wheel arch and the door, the part in front of the door needs to be welded in and that thad side should be done as well.
both sides has new chassis beams installed as well.

pictures will follow, need to downsize them..
Glauco

here are the pictures!

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Glauco

Keep up the good work!

nice one!

what ECU are you running? i'd run ignition off that if it can (most can) and will give you great control over your ignition... especially for turbo bet it would be great!

thanks!
ECU will be megasquirt, but turbo engine will be something for next year or maybe later..

i'd defiantly let the MS do your ignition, via crank fired ignition ;) loads of control! which version of MS are you planning?

Its my old MS.
Its an MSextra with EDIS so he has all he needs...

Thank you peter ;-)

GO GO GO!

Get on with it.

will do some more welding tomorrow, if I don't forget I'll take some more pictures too
Ordered the 2 last peaces to weld in last week but the shop forgot about it so have to wait untill wednesday..

did some more repairs today, the rear edge for the window rubbber was rotten away a little so had to put in a new peace
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the front had some small holes that I repaired as well
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test fitted the dash today, not sure what I'm going to do with it, can't find desent gauges to put in the original holes, so might use the fiberglass mold I made so I don't need to cut and weld an original dash.
first plan was to put my set of '67 porsche gauges in the car, but that won't fit the look I'm going for so thinking of some other gauges to put in the car, we'll see wat it will be, maybe gauges from a 'newer' porsche ( late 70s early 80s) or some other vdo gauges or so, thoughts are welcome  ;D

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glauco

Nice job Glauco!!

Sell the early gauges and go for vdo jet cockpit or newer (80's) porsche gauges.
I would use the stock dashboard with some additional gauges.  Don't go too wild with custom dashboards, keep it basic, keep it simple.
less is more.  ;)

Dem

A couple of ideas for you on the dash
The Autometer 5" face gauges fit into the stock holes thru the front. A couple of "L" brackets screwed onto the stock mounting tabs holds it in position.

Another thing I did on my wife's Ghia was to use a stock clock bezel as a holder. A hole was cut into both the bezel and the clock face so a 3 3/8" tach could fit into it. I used the glass to cover it, and I left the stock clock markings on the part of the face that was still there. Once assembled, the entire assembly bolted up as if it were stock. It looked pretty cool I thought.
(http://home.comcast.net/~mlawless29/cindy8.jpg)

look at jeff benedict's ghia or something like peaches 'n scream, I want to go in a direction like that, looks badass!
still liking the porsche gauges do.. we'll see what I find first  :)


thank's for the info, will keep both options in mind!


Thanks! get on with your beetle as well! I still need to take the gearbox of the pan for you, will try to do this this weekend  ;)

Will Porsche 924 gauges fit? I know they've got that strange conical glass, but they're pretty cool and fit the look.

not sure if they will fit in the holes, but they would definitely fit the look and the price range, I think I got a new first option  ;D
Thanks!

I always thought that the titty style 924 gauges looked cool.  Most people install them with flat glasses, that's a shame.  Go wild and free the titties!  ;D

gauges ordered today, can't wait to get them!

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will only use the speedometer and the rev counter
might search for the 3 smaller gauges ass wel (clock, fuel pressure and volt meter)
I'm glad I can start on the dash in the near future  :)

Glauco

the smaller 924 gauges are also very easy to find and not expensive.  Check ebay.de

I know, that's where I got the other gauges as well :-)

update!

Ordered a complete set of 944 gauges, so I should get the speedometer, tachometer, clock, voltmeter and the fuel pressure somewhere next week!

Welded in 2 more pannels and installed the dash today, once I get the gauges I can start fitting them in the dash.

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The front part, I kept the Karmann ghia insert

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The back is replaced as well, still need to attach it to the inner pannel.

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The dash, fitted right back where it came from  ;D

that's it for today!

another update

welded the (hopefully) last 2 parts in today! so too pass the rest of the day I started sanding down the car in search of some more rust, did the complete front end and only found 2 small rust parts next to the holes for the bumpers and a little bit next to the nostrils, was repaired once, but wasn't done properly, so will fix that tomorrow!
some pictures:

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The first part, the lower part of the nose

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welded!

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The second part welded in

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Some rust that still needs repairing

some more pictures of the sanded body

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the nose

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glauco

dude, you found a secret speed stash over there?  :o  what's up with the crazy progress?  I like it.  ;)

I wish, then it would go even faster  ;D
I just have some extra time this week, so better spend it right  ;)

Found period correct doors, will have them thursday if all goes to plan!

again an update!  ;D

was going to rough sand the complete car (wich I ended up doing anyway) but had a change of plan because I got my gauges today!
So I had to try them offcourse!
as I tought they were to small for the holes, but I used the old plastic surounding of the meters and made a ring so they fit in the holes, will order some finishing rings so you won't notice the plastics  :)

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the meters

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the cut (first try, but ended up cutting even more of the plastic)

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et voila! it's a pitty that there is a mpg meter inside the tach, not sure what I'll do, maybe search another, or just get it out of there, or find another purpose for the meter, we'll see :)

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looks pretty cool if you ask me!

and some pictures of the car, rough sanded it completely, didn't find any more rust so that is fun :)
did find a lot of filler where there shoudn't be any, and some extra dents, but nothing too bad!
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side 1

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Side2

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The roof

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did some welding today, I closed all the holes in the dash, I'm going to keep the glove box for now.

tomorrow I'll fine sand the car and finish some welds that weren't good enough.
somewhere next week a guy from my work is going to come and help me with the body (he worked at the opel site as a body repair guy for more than 20years, so he knows how to work with led  :)

glauco

Did you ever check the finish grade of an opel?  I wouldn't trust that guy!  ;D  Just kidding, awesome to see this much of progress.

I would search chrome bezels for the gauges to accomplish a better match with the wooden steering wheel, or else wrap the steering wheel with fancy leather to fit the looks with black bezels.

not sure I want chrome bezels, maybe some aluminum or in black or something like that..
and I still have the same leather wrap to put on the steering wheel as you have remember  ;)

I removed mine to reduce some weight.  ;D  So you can be one of a kind.  :-*

Awesome work on the Ghia! I love me some 924/944 gauges too! I have a set I put flat glass in for my bug dash. I also have another set for sale if you (or anyone else) are interested in another set... its MPH speedo...

http://www.thesamba.com/vw/classifieds/detail.php?id=1425440 (http://www.thesamba.com/vw/classifieds/detail.php?id=1425440)

some more news!
started assembly on the floorpan the last week or 2, the rear is finished as from today, the porsche brakes are in and made the adaptor for the E-brake myself  :)
works fine, just need to assemble the handbrake to finish it completely
placed new rubbers in the gearshift as wel, so now I can finaly find reverse.

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the new hook for the E-brake, took the part that is pinned on the brake and welded a hook on it so it can grab the original beetle cable

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the rear

did some painting as well, painted some engine tin and the exhaust
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some more pictures!

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the fan shroud, welded the holes for the heating

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bugpack dqp

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the 4in1 exhaust

hopefully tomorrow I'll receive my 87mm cilinders/pistons and the external oilfilter so I can start to put the engine back together..

glauco

Are you gonna detail the parts a bit more?  gearbox, shocks, bolts, ...?
keep up the good work!

Shocks will be replaced in the near future, and this is a temporay gearbox, I have a second one that will be rebuild for the next engine.
Next winter the rear suspension will be professionally rust protected/painted, no funds for that for now :)

good thinking, get her on the road and detail her later when the funds are available!  I've been detailing for some years now but still I'm getting nowhere!  ;D

update!

did some more work on the floorpan and started to put together the engine
the adaptors for the front porsche brakes caliper are made, the hub adaptors are being made so it fits the vw spindle, hope to get them somewhere this week.

the engine is coming along nicely, it will be a 1641 with Italian 40 idf's with electronic fuel pump, complete accuspark electronic ignition, case adapted for full flow with a oil pump from a 92 beetle with screw on oil filter, the oil pumps exit is blocked of and a bypass after the filter was made to go to an extra oil cooler. hope to get the breather box on wednesday
I matched the weight of the new 87mm pistons (there was a differance of 6grams!) and started work on the heads, the inlet at the manifold side was opened a little more towards the valve, the valve side will be worked tomorrow and after that the exhaust will get some changing also. I'm still waiting for the manifolds to arrive so I can match them to the new shape of the inlet.

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the pump exit blocked of at the pump and at the lid.

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test fitted the exhaust on the engine to make sure the pump doesnt touch the filter and made a hole in the pulley plate for a tube to enter the engine (didn't see another solution..)

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the head-work, got the valves out today so I can start on the rest of the work. once the ports are finished my brother will put in new valve seats and give it a higher compression ratio, somewhere in the 8,5-9:1 area..

Finished the rough grinding of the ports, inlet is completely smooth now and the outlet ports are opened up some more as well.
The heads will get new valve seats and one of the spark plug holes needs new treads.
Tomorrow we will see how much led-work it will take to make the car look a little better..
Took the wheels out to wheelshop so in a couple of weeks I will have 4,5 and 5,5inch cookiecutters :-)

Those cookie cutters will make some great water hose reels.  ;D

I'll keep that in mind if the wheels don't turn out what I hoop them to bee, but I'm pretty sure it will turn out great  ;)

didn't get to do as much work on the ghia as I would like to but managed to get some work done yesterday

the engine is ready for assembly, matched the manifolds and smoothened the grindwork.
heads will get new valve seats with 3 angles instead of 1 somewhere this week.
also got stainless steel valves witch will get some radius on the exhaust side. Along withthe 1.4 rockers, heavy duty single springs, hardened hats and chromoly valve retainers this will hopefully be an interesting 1641 engine  ;D

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this is how much I needed to take of the manifolds to match the port

The guy from work came to have a look last week and he put some led on the welds, but it will take some filler to get it just right.
the body got its first coat of filler and started sanding down the first headlight. Took me the best part of yesterday to be honest  :P
the line on top allone took me more than an hour to get it where it should be, a well trained body worker will get it in this stage a lot quicker, but I'm still learning as I go. (that's probably why that most things take me longer that I would like to, but I get more satisfaction of doing (or at least trying) it myself..

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looks like a lot of filler, but it's actually not that much concidering that the complete front was covered with at least 4mm of filler to begin with..

because of pain in my nek and back, thanks to an accident with my van from work I didn't get to do much, but I had to try my new sanding machine so did a little
Rockers arrived as well..

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right side, second go. After getting the line right I blended it in with the headlight cirkle.

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left side, first go

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Panel behind the door, first go, needs a little bit more, but it's getting there

the rest we will try to hammer out a little more before filling it with led or filler.

cheers.

keep up the good work man!  See you next thursday @ the monthly dinner.  Okay that I take the merged header with me?  ;)

Perfect! See you next week

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Front porsche brakes are on!

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some more sanding..

that's it for today, problems with my neck and back are getting better, so hopefully I can get some more work done again this week.

glauco

Good work! ;D

worked on the front brakes some more today, just need to mount the adapter plates for the caliper and then it would be finished.
Handbrake is finished as well, so when I get my wheels it will be a 95% finished floor.
just need to source the type 1 gearbox to Type 2 flanges somewhere in europe, because the customs here charge way too much tax on products coming from the states..

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driver side

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Passenger side

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'New' Exhaust, will get painted tomorrow
thank you wolfwest  ;D

 :o :o killer exhaust bro!  ;D  it can handle 190 HP easy!  :P

put on spray filler yesterday and sanded it down today, real glad with the result, the nose will be done by the end of the week I hope; so I can start doing the back next week.
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the spray

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After sanding with a 240grid, need to respray and than sand it for paint.

will get some more picutres tomorrow

 :o  ;D  Don't forget to give your inner wheel arches the same love, it's all about the details!

that's the next step ;)

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my new wheels, a set of dan gurney's from a 914/6, will get a painted heart and polished rim.
not yet sure what colour, will see what colour the car will be..

Test fitted the body today, all the holes match perfect, didn't expect it to go that easy, altough I measured 67 times, you're never sure unless you test fit..
The pan is now finished, just need to order and than hook up the rear disc brake hoses and than it's completely finished..

Tomorrow I will take the body back of so I can finish the bodywork, hopefully this week or the next, I have 2 more weeks of Holiday before I start at my new job, so I'm going to make the best use of it  ;D

didn't take pictures of all the holes, but you get the idea  ;)

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didn't weld the outer bodymetal to the chassis beam yet because I was afraid I needed to take it of again..

long time no post (again)
to get you guys back on pace, the ghia's interior is painted and is mounted on the chassis again.
I'm in the stadium where I'm testfitting everything one last time before I paint them.
I'm painting the doors and hoods tomorrow and hopefully the car itself somewhere this month..
tried the wheels on, but I'm gonna need smaller tires in the back, it was worth the try..  :P
glauco
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Great colour!  Hope to see it in the flesh one of these days.

Welcome any time,  I'll be there all day on monday ;)

did some paintwork today, will polish them friday.
Also cut the rear trailing arms by 1inch to give me a little more space for tires, just need to find a place to shorten my axles..
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homemade fiberglass hood  :)
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didn't do as much as I hoped, but I got around to weld te trailing arms back together for a test fit. Also michiel (migier) took 7mm of my rear drums so that my nut goes on far enough to secure it.
In total I got almost 6cm of with of the rear, so now the Duelers 205/70's fit just fine..

Before
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After
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Apparently I always forget to update this page every now and then. So here is to get you up to speed.
The body is ready for paint, it's sanded to a good finish. Still isn't painted do, the paint shop that was going to lend his paint booth is still drowning in body work from the hail storm we had locally a couple of months ago so it looks like this is going to take a while. We'll probably make a instant paint booth in an extra room in the garage.
The suspension is ready, got koni adjustable shocks in front with the porshe brakes, stock drums on narrowed 944 trailing arms with 5"something axles. Stock shocks for now. Brake lines are mounted and as soon as the Volvo 240 brake fluid reservoir arrives I can start bleeding the brakes..
So again not as much of an update as I hoped, but we're getting there. Someday..
Glauco

never loose the faith!  8)

Made a template for the trunk yesterday (actually my father did) so once I start on the upholstery I can put some fabric on them.
After work I'm picking up the Volvo brake fluid reservoir so hopefully I will have functioning brakes somewhere this weekend!
Test fitted the windows one last time so everything should be ready for paint :o
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Glauco

Cal-look Ghia mathematics...

Great colour + no nostrils   = big thumbs up from Jick!

I d love to see it finished dude!!

So do I! I've said this every winter for the last 7 years, but I hope to have it ready for next season:)

Thanks! I really love the color as well, doubted for a long time, but happy with it..
Doubted about the nostrils as well, but felt that I have to eliminate them to get the car completely like I wanted.

Got the brake lines filled today and after solving leeks on about every joint I got them to work!
Handbrake is mounted and functional ass well..
Not a 100% convinced about the handle but it will work for now. ;)
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Glauco

Gave the karmann a first coat of paint, looks good already, but will need a few more layers before the yellow gets its deepness..

Glauco

(http://images.tapatalk-cdn.com/15/04/25/8406551a2d9ea0a41ec55f0335c9763a.jpg)
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The good thing on having a father that's retired is that you get these messages every once in a while saying he sanded al the mistakes out of the first coat so we're ready to put the next 2-3 coats on this weekend.

Glauco

Cool dude!
cant wait to see it done

apparently I haven't put all the updates here yet.
Wiring loom is installed, really was a pita because..
switches are installed as well, I've put them in a different place than stock, just because I liked the look.
steering column is in as well. Because I didn't have an original one it became one of a 1302, with the ignition switch on the column. Why? because it was a whole lot cheaper ;D
made a new rear seat, one that folds down so I have good access to the inner trunk.
I'll make good pictures after the paintjob.
I do have some pictures of the sanding my dad did today, he uses the same picture angles as me apparently  :D

Glauco

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I hope to see this gem run this summer!

gave the car 2 more coats today, I was hoping it would be enough (also because I'm out of paint now) but I'm going for an extra layer just to be sure, going to get some extra paint tomorrow..
collour is looking good do  ;D
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Started putting stuff on again today, front and rear windows are in (thank you wolfwest!), front seat is in and it flips! Door is mounted, rear deck lid as well.
Feels good seeying the car come alive step by step :D
Glauco
(http://images.tapatalk-cdn.com/15/05/14/2a345345aa320c33b4cf77d93de538ef.jpg)
(http://images.tapatalk-cdn.com/15/05/14/30c04c4c9cc85d6e455ab86e465a9f70.jpg)
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First pop-out installed, took me 2 hours to get it half ok..
Got the skoda felicia starter in as wel..
Glauco
(http://images.tapatalk-cdn.com/15/05/21/c9d48692f92fb7f423a03e12dfad4a78.jpg)
(http://images.tapatalk-cdn.com/15/05/21/b439ae99c27968fbc3e3b658b5385469.jpg)

First pop-out installed, took me 2 hours to get it half ok..
Got the skoda felicia starter in as wel..
Glauco
(http://images.tapatalk-cdn.com/15/05/21/f18d717208d76c36a6efe52afd01ab88.jpg)
(http://images.tapatalk-cdn.com/15/05/21/a4ef6b0a2fa2c5c06ecb871a115bc22e.jpg)

Second pop-out installed, fits a whole lot better.
Passenger side door + seat installed with window and rubbers.
Installed the gauges a last time as well.
And finally tried the gurney's with the original size tire (thank you jelle (aka lowfastbus)
Glauco(http://images.tapatalk-cdn.com/15/05/25/2b9cc8be286d4b8a2bcc8ba8115a3a33.jpg)
(http://images.tapatalk-cdn.com/15/05/25/b8646921e76cb146859c0a99bf0af811.jpg)
(http://images.tapatalk-cdn.com/15/05/25/42d467a2d651f3508dbcf0aebe2f2f70.jpg)

Second pop-out installed, fits a whole lot better.
Passenger side door + seat installed with window and rubbers.
Installed the gauges a last time as well.
And finally tried the gurney's with the original size tire (thank you jelle (aka lowfastbus)
Glauco(http://images.tapatalk-cdn.com/15/05/25/2b9cc8be286d4b8a2bcc8ba8115a3a33.jpg)
(http://images.tapatalk-cdn.com/15/05/25/b8646921e76cb146859c0a99bf0af811.jpg)
(http://images.tapatalk-cdn.com/15/05/25/42d467a2d651f3508dbcf0aebe2f2f70.jpg)

Fitted the headlights and wheels today. The repro sealed beams needed some grinding so it took me longer than I wanted it to take..
Got the stance rather ok. I may put the back up a little, the front will lower itself once i got the smaller tires on.
Glauco
(http://images.tapatalk-cdn.com/15/06/05/05dea196817a573b2bbede3319e01ff2.jpg)
(http://images.tapatalk-cdn.com/15/06/05/2273fbbbd65302dfcf585635a540dacb.jpg)

nice work! love it  ;D
which tyres will you go in front and rear?

Thank you!
Tyres now are 165/80. Maybe I'll keep them in the back, maybe 175 (185?) if they fit (don't have that much room left, will know for sure once it's alligned properly). Front will be 145 or 155/65. Don't want to go to narrow, I wan't to feel more or less safe on the road :D
Glauco

145/80 R15 at the front sounds good, 155/65 will be too small i think.
I have 185 R15 at the back on my bug, they are pretty tall but I love the look  8)
165R15 will be a good choice  ;)

I would love to fit 185, maybe they'll fit with the narrowed cookies, but with the gurney i don't think I can go much bigger than 165 or 175, we'll see. First getting it on the road again :D

(http://images.tapatalk-cdn.com/15/06/07/c6dc7a321463e6a68ce0f5bcc3b77a61.jpg)

nice window"cranks"  ;D

Thanks! I like them as well  ;D
was just to test window function, and it works, passenger side works flawless, driverside hasn't been completet yet, need the window mounting frame to complete that side..

Glauco

Installed the engine today, happy day!
Started putting in the carpet as wel, I know the tmi set isn't the best, but it came cheap, and it fits better than I hoped.
Glauco
(http://images.tapatalk-cdn.com/15/06/13/f8d7c7caa71a2c15f1b122116643d6da.jpg)
(http://images.tapatalk-cdn.com/15/06/13/bd3a4107ce600f86921d4fb21747eee3.jpg)

2 years further and if I reread my thread it seems like not much has changed.. buying a hose and still not having the car in my own garage doesn't help much apparently

engine was toast because of faulty machinework (the shop that line bored my case gave me the wrong main bearings with all of the problems you can imagine, also part my fault because I didn't measure them..)
exit broken engine, enter 'new' one, nothing special, but it was all the budget let me build.
specs are:
1641
stock case with full flow
scat counterweight crank
scat connection rods
FK-65 with 1.4 lifters
stock semiported heads (nothing fancy)
stainless valves with HD springs
1 5/8 exhaust
lightend flywheel
damper pulley
stock carb, but will get twin 40IDF's if it ever gets an MOT..

simca seats are lowered with a new frame to give me more access under the steering wheel and tilt-mechanism from a peugeot 205 to gain access to the new custom rear seats.
for the time being I repared the old upholstery, but I was hoping to get a new one stitched up this winter, or next, I'm getting afraid of setting deadlines for the car :p

After changing my mind on the looks for the 67th time the baby turbo mirrors were changed for one talbot 333 I still had.
I also was able to find some bumpers for the car and will get them rechromed somewhere in the near future.

the window gap for the drivers door is set properly, also fitted all new rubbers and felt in the door. along with the empi doorpullers the doors are now ready for their panels.

electrics are almost ok as well, just found out the turn signals died again, probably a faulty ground somewhere, need to look into that.
the fiat 850 steering wheel is fitted with a working horn button.
Also made a panel for the glovebox out of aluminum, was going to paint it at first, but I kind of like the look, so maybe I will keep it like this..
set of vdo gauges installed, just need to make 2 more holes for extra meters, but that can wait until after MOT.

So without making any big promices I hope to get the car on the road somewhere this year, but it seems that this year isn't the first year I was hoping to do so..

glauco

rear lights
[attachment=1]
mirror and door rubbers
[attachment=2]
glovebox
[attachment=3]
doorpuller
[attachment=4]

Nice work Glauco, I hope you get it ready before DDD ;)

nice colour!

can you tell us more about how you fit the Fiat steering wheel?

I made it easy for myself and just bought a custom steering wheel hub from empi.

After I removed ther rivets of the original hub and made the central hole in the steering wheel conical I just centered it on the main steering shaft with a conical washer. Than it's just a matter of drilling the holes in the steering wheel and installing the horn.
Only extra thing I had to do was to bend the turn signal switch a little to clear the steering wheel.

If you want I can take some more pictures, but there isn't that much to it :)

glauco

after 6 (7?) years of being stored in a place where I couldn't get her out, this weekend I was sick of it.

After 3h of making room I was able to pull the car out and place it in front of the rest.

In al the excitement I forgot to take a full before picture, in front of the golf stood my VW T3, witch I already pulled out before.

It's amazing how much garbage 2 men can gather in a few years...

 

I was very happy to see the karmann outside for the first time since it was painted..

Now I just need to make the turn signals to work after a shortcutted wire, will try to get this sorted tomorrow..

 

glauco

 (https://uploads.tapatalk-cdn.com/20170925/77fab992492e5be0630318a0765eb43c.jpg)
(https://uploads.tapatalk-cdn.com/20170925/d992c92d5e60241bb15d0771f9f2b25a.jpg)
(https://uploads.tapatalk-cdn.com/20170925/ee89d4804c8b3974b557677ec3e9aab1.jpg)
(https://uploads.tapatalk-cdn.com/20170925/f0c7d159e6de53017805156c186d3a66.jpg)

As you can see in the picture, there is something strange going on in the bumper area  ;D
This is a golf 1 bumper so I can put the turn signals in the bumper. The MOT in belgium doesn't like blinkers in the headlights...
(https://uploads.tapatalk-cdn.com/20170925/ff38b05c701cd54c776dbbb965225bb8.jpg)

the end/beginning is near!  8)

so, little update!

after months (I know, I'm no electrical guru) of searching for the flaw in my turn signals, yesterday they suddenly worked!
turns out there was a short to ground in the left turn signal wiring, everything works now!
Tomorrow will be installing everything to get her ready for MOT somewhere in the near future and after that, detailing can begin!
10 years is a long time to 'work' on 1 car, to say the least..

OK, this must be one of the slowest progressing builds on here. but we're getting there!
This week the car passed the technical inspection so she is officially roadworthy!
couldn't be happier to finally take the Golf bumpers of and replace them with T-bars (just until I find some decent bumpers or get my bumpers chromed)
took the Dan gurneys of as well because I wasn't completely satisfied with the look after all.
The cookiecutters are going to be replaced with fuchs wheels because the offset of the wheels only allow for 165's in the rear without rubbing the fenders..
nonetheless I'm happy to finally being able to drive her!

Glauco

The money shot! ;D still needs a lot of detailing, but going to drive her for a while first! :)

Glauco (https://uploads.tapatalk-cdn.com/20180520/207f7d66f45d34d1dee2e0c7fc46186c.jpg)

Verstuurd vanaf mijn SM-A320FL met Tapatalk

Great job.

As they say better late than never!!  :D  ;D

thanks :D

Installed the headliner today :D

Glauco (https://uploads.tapatalk-cdn.com/20180523/0294204e5d05a777983f1fd81834e8d3.jpg)(https://uploads.tapatalk-cdn.com/20180523/9039eaa898a9886e2680f5c60d0c3cbf.jpg)(https://uploads.tapatalk-cdn.com/20180523/2e2201985db3cf1b3bf02a9ed151d3d1.jpg)

Verstuurd vanaf mijn SM-A320FL met Tapatalk

Dashpad installed.
Test fitted the 40 idf's, but ons side is off again because I broke a flange. ::)
Still happy with how the dual carbs change the looks of the engine..

Glauco

[attachment=1]
[attachment=2]

couldn't wait any longer so I made the jump and bought some ssp fuchses.
they were oddly detailed so I stripped the paint completely and started polishing them.
[attachment=1] [attachment=2]
Just need to clean up the polished area's again and they're good to go.
[attachment=3]

don't mind the chips in the black paint, they come from the tape..

glauco

looking forward to it!  :)

Did some interior detailing and finally got to install the fuchses. Slowly getting ready for summer!

Painted the seatrails and steering wheel and put some sound insulation under the floormats.

(https://uploads.tapatalk-cdn.com/20180704/3bc36f58709de63f7a1c587b37def3af.jpg)(https://uploads.tapatalk-cdn.com/20180704/b68a63b86aa7b579e80a9608244a1fe8.jpg)(https://uploads.tapatalk-cdn.com/20180704/0d4d6d2d2404b826a209c807d103c1a1.jpg)

Verstuurd vanaf mijn SM-A320FL met Tapatalk

not sure if it's worth mentioning, but wanted to share my misery.
built me a shelve 3 years ago that actualy needed some strengthening witch I never got around to.
found out the hard way..

[attachment=1]

all in all not that much damage, but too much to make me happy...

[attachment=2]

glauco

ouch! that sucks! it could have been worse though

Yeah, I know, but it still hurts... :)
I will try to get it fixed before the cars and coffee in my hometown tomorrow evening

You always have the bikini chick option, although it's cloudy and not that warm.  But that's maybe a good thing for the extra visual effects...  :D

unless you'll be wearing a bikini tonight I doubt there will be any bikinigirls there ;D
but hey, in stekene you never know ;)

Cars and coffee was a blast!
[attachment=1]

And who is the new owner of the *Jelle KG*?

Dem (Wolfwest) is the new owner. Very happy that the car stayed in the club. It got a lot of detailing in the last few months, it truly is a sight to see now!

Pulled the engine out last week to fix an oil leak in one of the oil plugs. And to install the new engine tin I had laying around for a while. More pictures on that later.

With the engine out I took the opportunity to fix the clearance issues I had with the narrowed Porsche trailing arms.
I wanted to make it easy on myself so I bought 2 left drive shafts of a type 3 auto box, which are 25mm shorter. So the arms needed to be narrowed 25mm as well..
Because I didn't know five years ago that it is way better to cut out the axle support and place it further in the arm then the way I did it.
I thought it would be easier to cut the pivot point in half and reweld it on the other side. It looked good at first, but the spring plate support kept hitting the shock tower, which resulted in a suspension that couldn't operate completely.
To fix this I used my high school brain (or what was left of it), calculated the numbers, cut the support of, lengthening it 16mm and rewelding it 30mm further on the arm so the support was back on it's old position.
I then had to address some more clearance issues at the pivot point, but now everything works like it should so I painted it black as well.
With the suspension out I also cut out the lid on the torsion bar support and cut some tread in the torsion bars to make it easiee to adjust the settings without having to loosen the whole support. Kind of what elephant racing is selling, but then 600euro cheaper..
I'll take some pictures when everything is mounted later this week..
Lastly I painted the wheel arches black, something I should have done long ago..
No I just need to go to jelle to blast my 944 calipers so they can be painted and the rear discs can be installed..

(https://uploads.tapatalk-cdn.com/20181017/c0e37e40842cc9174e5d57f3aecae29c.jpg)(https://uploads.tapatalk-cdn.com/20181017/cbfe37e3e7a49049035fa721bebb2ed5.jpg)(https://uploads.tapatalk-cdn.com/20181017/01ab9af045f8e2fe68843195ea9022c3.jpg)(https://uploads.tapatalk-cdn.com/20181017/f2252830199cda94bcab3581acbce923.jpg)

Verstuurd vanaf mijn SM-A320FL met Tapatalk

Ok, time for a little update.
After winter hibernation I pulled the car out of the garage to make the best of the first sun here in Belgium. Started the car, drove it for half an hour without any weird noises or what so ever and put it back in the garage after the drive. When I tried to do the same the next day the engine was seized. Absolutely nothing.
Started looking for answers.andbefore I knew it I had the engine fully dismantled en in pieces. A main bearing was waisted. Because  i didn't want to waste another summer with fear of getting somewhere I decided to take the engine to Nicolas and let him do his magic to the engine. He will delete my errors and hopefully give me an engine I can rely on..

With the engine out I made the best of the situation and started working on some details.

First thing was to polish the Porsche centercaps I had for quite a while now. Photo is taken before the final buff, but they came along pretty well..
[attachment=1]

After that I made a new mount for my licence plate and installed the new turn signals.
[attachment=2]
Before the summer of last year I've had a problem with my fuel line so I replaced it with an embraded teflon line with an fittings. Now it was time to make it somewhat better.
Starting with fuel pump, it made to much noise so I used a better mount and placed the pump in a bigger tube with insulation.  Mounted the strap on rubber to hopefully reduce the noise.
[attachment=3][attachment=4]

After I've gotten all the fittings in to make sure there was no chance anywhere to cut the line I made the best of the engine bay.
Fuel lines are mounted on the fire wall and installed a malpassi filter king witch doubles as pressure regulator.

Also converted my Clyde's buggies breather box to AN fittings and polished it a little.

Last but not least was the plan to install an external oil cooler.
I got a mocal sandwich plate that I read here somewhere that you needed to open up the oil feed to get all the restrictions out, so I did that before installing it.


After cleaning and with the fittings.
[attachment=1]

And finally installed everything above the gearbox.

Only thing left here is to mount the fan and figure out witch way it should turn...

That's it for now.  :)

Glauco

Continued to install sound insulation today.
Got the doors and sides done and installed the door panels.
Haven't had time to upholster them yet, so painted them black for now. Maybe next winter...
[attachment=1][attachment=2]
[attachment=3][attachment=4]

Test fitted the Porsche 944 sway bar with the mounts I made for them.
Fits perfect, once I get better clamps I'll replace this ones. I used heim joints to accommodate the difference in width with the Porsche rear end.
[attachment=1][attachment=2]

hard to take pictures laying on your stomach under the car. will get some better pictures when she's on a lift someday..

Why a Porsche 944 sway bar you might ask? Because that's what I got. It came with the parts I used for the disc brake conversion, so it was cheap...

glauco

had a problem with my pictures coming up sideways on here, think I fixed it...

glauco

 Had a whole list I wanted to get done this winter, but with a baby on it's way my girlfriend decided to give me a whole other list with things to do ::).
Nevertheless, I got some things done this winter.
I converted a set of dropped spindles to accept the Porsche brakes with a set of custom spacers I made on the lathe.
I had a problem with my brakes after upgrading to the porsche rear discs that the pedal would get spongy after a while. Therefore I ordered the ate mc from Kerscher tuning especially for ac vw's with porsche 944 discs.
Because the connection for the rear are in the front of the mc and Visa versa I had to replace the brake lines as well. I decided to go all the way so I replaced the flexible lines with steel braided ones. But because we live in Belgium where you need to go to mot and that steel braided lines are prohibited I put some shrink wrap on them so you can't tell they're steel.
Only thing I need to do next is to shorten the connecting rod between the pedal and the mc and bleed the brakes.
Also replaced the red bump stop rubbers with stock ones.
[attachment=1]
[attachment=2]
[attachment=3]

That sounds crazy!!
Surely braided steel lines are safer??

 Not in Belgium.  ???
And I have a small feeling I'll he having troubles with the rear disc brakes. Belgium rules are crazy when it comes to modifying cars... I'm hoping they won't make a deal out of it because it's a pre 68 car...

Don’t let you scared of by al the stories you hear.
Few months ago i went with my ‘65 splitbus.
Engine with twin carbs,lowered all around,IRS on the back,porsche 944 on front..
Passed straight away.if the work you have done is OK and it is not to much in there face you will be ok.

Henk!!!

Thank you for the confidence Henk.
Mine is also lowered, with IRS and Porsche discs in front. That doesn't get me worried, it's the porsche discs in the back that got me worried.. but we'll see. Everything on the suspension is done without to much fuss, so I hope they don't make a big deal out of it  ...

Glauco

You happy guys 😂 here in Luxembourg you can t even drive a wheel which does not have German TÜV on it , not talking about brakes , beams etc .....
when you put double carbs on you have to dyno it to get it street legal and so on

ok, YOU WIN!  :D that must suck... how do you get your cars on the road then..?

After you modify it , you have to make a full TüV checkup , meaning they check everything you modified , the papers for the parts you ve used and so on , if you put double carbs on for example , you have to put the car on a dyno , they check the numbers , see if the brakes are good enough for the power you do .
For example , discs in the front, drums in the back , max 100 hp .
When all this is done you get a copy of the report , this one you always have to carry with you for you technical control every year or two , and if you get pulled over by the police so you can prove everything is ok .
Alloy wheels without papers , beams without papers no chance to get it running like that

OK, so corona gave me a little extra time to get some work done. Most of it in the house, but nevertheless, still some work on the karmann as well.

I never really liked the way the rear seat turned out so I decided to start with a new one. I really like the porshe style rear seats so I'm going to try to get something like that in a Karmann. I already made a new frame for the bottom where I can make separate seats in.
just need to score a battery with less height...
next will be the back. I also got some stock front seats that will get some extra cupping as well..

[attachment=1]

I also made some changes to the dash:

[attachment=2]

fitted new warning lights that go better with the rest of the gauges and molded in a Porsche badge in the fiat horn button


last I had some spare time on the lathe so I made a wooden gear knob for the Hurst shifter, only to find out you can order them from flat4,  there goes 4 hours of doing nothing...   ::)

[attachment=3]

last I also fitted the karmann ghia logo to the dash and a correct push knob for the glove box, but because the glove box door originally was for a 70 kg with an other style knob I had to use a washer, so I made a washer that is also a empi style pull lever. Just needs some paint..

[attachment=4]

glauco

Ok, that gives you more work, but in the end you can modify you car and still have it street legal... But nothing like in england I suppose  ;D

Yes they are all street legal and safe to drive , i guess i would get a MOT from here easier without ever showing up in the UK than doing all the paperwork here ;)


Sent from my iPhone using Tapatalk

Made stone progress over the weekend.  Finished the frame for the backseat. First I was planning on making the backseat cup more, but seeing there is almost no place to sit I decided to make it a little more simple. If I have some time this week I might start with the upholstery..

[attachment=1]
[attachment=2]

Also took some time to clean up the wiring of the motor a little.  Used an old broomstick to make a wiring tube. Also wanted to have air filters, so I took some cheap chrome ones and painted them grey. Then I drilled 5 holes like the schenk filters. Also wanted to use the same gaze like the filters but I ended up not using them because it wasn't like I pictured it. Really like how they turned out. Wanted all the same bolts so I turned down some hexagonal bolts to Match the rest...
Also fitted a new cable guide with a wheel. Also with the same bolt.
Fitted a generator stand rather than a (baddly) altered dynamo stand and threw away the made in China alternator pulley and used a original one..
Last I learn a lot from this forum so to eliminate the problems with hot starting I made some erthalon spacers to put between the carb and the intakes...

[attachment=3]

Glauco,

Do you have more picture on how you mounted the simca bucketseats and the frames you used?

Thanks in regards
Eddie

Hey Eddy,

I cut away the bottom of the simca seats and made my own mounts. I had to because my bottom flat flanges were bad enough.
I made a frame to mount them on peugeot 205 3-door frames wherefore I welded nuts in the floor pan for this frame. The Peugeot frames tilt, something that you have to have in Belgium if you have a rear seat but no rear doors...

I have some pictures of the seats out of the car. If you need other pictures, just ask ;)

[attachment=1]
[attachment=2]
[attachment=3]

Glauco

Good point about that tilting and rear seat, have to look into that for The Netherlands.
Thanks for the picture. Got some idea s now

Regards Eddie

and if you don't want to cut up your bucket seats you can always buy mine ;) I'm thinking of switching back to stock seats...

So last Thursday I drove the car for the first time this year - having a newly born and renovating a house takes up all the spare time - and I almost forgot how fun this car is to drive.
Ok, the time in the garage left some markets on the car. Both figuratively as literally.. the hurst shifter's reverse pull cable snapped so I had to drive the 50km back home only using 3rd and 4th. But that didn't spoil the fun I had now the car sits on dropped spindles so finally has some spring in the front.
I wasn't to happy with my first take on 944 calipers on dropped spindles so I gathered parts to do it again. While looking for some cheap spindles I also got the opportunity to buy some 944 turbo calipers witch should make it easier to adapt to dropped disc brake spindles than the NA calipers.
Girlfriend and daughter were away this evening so I took the opportunity to mill the spindles for the new calipers...

The drive
[attachment=1]

The milling
[attachment=2]

Next up is mocking everything up so I can make the correct size spacers..

Glauco

Used the winter to finally start on my interior.
Doubted if I would go for stock seats or keep the simca rallye seats.
I decided to use the simca rallye seats, but make new cushions.
Very pleased with the outcome  ;D
[attachment=1]

Made the same cushion for the rear
[attachment=2]

Doorpanels:

[attachment=3][attachment=4]

Some details:

Glovebox
[attachment=1]

Sunvisors:
[attachment=2]

Now I just need to replace the black carpet with the new brown and install everything..

Glauco

good work, a kind of a hark back to the 70's and a bit modern at the same time. I really like the pocket on the sun visor  ;D

Whoa very cool! Well done  8)

Yannick

Thanks, I like that little detail as well. I was looking for a bit of 70s without copying anything. Pretty happy with the outcome  ;D

Thank you!

Finally got around doing some interior work
Rear seat in its final form
[attachment=1]
Front seats installed
[attachment=2]
Panels and glovebox door with empi pull.
[attachment=3]
Inside the glovebox. Note the book for papers. Wasn't happy about the colour of the wood for the window crank, so I tried to get it as close as possible to the rosewood shift knob.
[attachment=4]

 Closer look at the glovebox interior
[attachment=1]

Good progress! 

2022 is gonna be our...  ;D ;D

let's hope  ;D

Great work Glauco.  Your KG is so nice.  I wish I had your body work skills.