Tony's 63 Cal Look Ghia build..... Lots of pics

[Scoops]

I've been bugged for a while to put up a build thread of my 63 Ghia, so as the saying goes  'A journey of 1000 miles starts with a single step'

This first post is the impetus to get the thread going, i'm just sorting out the pictures and i guess will have to get them uploaded to photobucket to post.......

Watch this space, as the next post will have pics!

[Scoops]

So after selling my split bus, i had some cash burning a hole in my pocket, and the itch for another air cooled VW. Having always loved them, and never owning one before i started looking for a Ghia.  Bingo! after about 5 minutes browsing on The Samba, i found one. Two problems..... it was in California, and it had no engine or tranny.

The car was owned by Jim Smith, who many of you know well and after a few emails, pictures and a chat, a deal was done and Jim agreed to kindly source and fit a tranny so that it could be rolled into a container. With some trepidation, the money was wired and the long wait for the trip over the pond started...

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After several weeks of waiting, I got a call to say the Ghia was in Chatham Docks, clear of customs and ready to be collected.....



So it was loaded up... not an easy task with three flats!



...and finally the ghia, with all the goodies Jim threw in with the deal was sitting on my driveway.....

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Jim threw a 1600 tp longblock on the drivers seat, so after a quick tear down and clean up, it was put togther with a hotch potch of parts i had in my stash...



slung it in the ghia, using the unknown tranny that Jim sourced....



A quick tidy up, a few electrical tweaks and the stuff needed for a UK MOT test, and she was rolling, registered and legal...







Just in time to hit a local cruise night...

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A few fuelling issues (turned out to be too much pressure from the rotary fuel pump) took the car off the road, and it was at this time i decided to start the tear down for restoration....









more to follow....

[RobtheManx]

Is that Tony ?

[Scoops]

Yep, thats me Rob

[Scoops]

Ok, so with the car stripped down to a rolling shell, it was time to start getting the paint off....a labourious but also cathartic process involving my trusty paint scraper and a heat gun....







After a coulple of weeks of spare time stripping (not that sort!) I was left with this..... (the under bonnet and engine bay areas are pigs to do)





So it was time to call in Aaron and his flat bed, to get the shell off to Simon & the Boys at The Paintbox, just up the road...





and into the dirty room.....

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The body was really solid, it had quite a few 'dings' over its life, but nothing too serious. There was also a bit a terrifyingly bad welding on the rear lower quarters, courtesy of Ray & Stevie's Auto Body Shop!















Now the bulk of the paint was off, it was decided to see what the real story was after a little media blasting....

http://youtu.be/mxHjC3GIuK8?list=FLh3-FBw_-a9fHngqQU6uBFA

and to be fair what came back was a pleasant suprise....

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Before I started oi knew the pan halves would need replacing...



so it wasn't long before i was at the point of no return with the floorpan!

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After the boys blasted the Shell in etch primer it was time for Shane to crack on with the repairs and the odd custom touch here and there....

From the start i wanted to go with as little trim as possible, so first to go was the nose badge. As those people who know Ghias will know...the swage line is flat where the badge mounts. So Shane beat a new section of the swage into place....



Then I had the idea to extend the swage line further down the nose as i wanted the horn hole filled too, Shane duly obliged...



Then the aerial mount hole was filled, and the Karmann badge from the lower wing removed also along with a small lower inner wing repair







followed by a few more small repairs at the front...

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The rear lower quarters were replaced..



The crinkly out of shape rear wing was massaged....



The outer sill were replaced as they had 'pinholed' in a couple of places, but the inners were solid as a rock...

The engine bay was tidied up...



and then the dash got some treatment... incl filling the stereo hole which looked like it had been chewed out! the speaker grill and grab handle holes were filled and the switch gear moved across to sit above the ignition key....



The body was then rolled to one side, whilst the boys got on with another job or two

[RobtheManx]

Yep, thats me Rob

Ah thought so , good the see a build thread for your car . I'm gonna be doing the paint stripping job soon !
 
Rob

[Scoops]

Soooo, while the pan halves were being welded in, i got to grips with the components for the pan rebuild. I cracked on with the Drums & starter motor and was quite pleased with the results from a rattle can....





Steve took care of the rest of the bits in 'Chimpy Black'....







Whilst i was at it, i spent some time shaving the lettering off of the rear light lenses, and polishing them back.......the devils in the detail

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Back at The Paintbox, the body was test fitted back to the pan..



Then it was shot in primer and seam sealed...



and Steve broke out the gun again for some more "Chimpy Black"....

[Scoops]

So it was now time to get the pan back home and into the Man Cave for building up.....



and this is where i put my collection of Gold passivated nuts and bolts to good use.....













Even the OG ally Moon pedal got a lick of paint and a detail....

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Then it was time to get the wheels on and roll the pan outside...







and get the Line Loc fitted.....

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Meanwhile, back at The Paintbox, the body was in primer......and nice to see how the body turned out now it was all one colour....

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...and the shocks give the first hint of body colour.....

[Jos]

Tony, you're Ghia is looking amazing! I can't wait to see the updates.

[MYTOY]

Very cool!

[low oval]

Awesome job Tony!  can't wait to see pics of it on the road.
jim

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At this point, i now got a proper look at how the colour choice turned out, as all the inside and underside areas were shot.....







Then a couple of days later, Steve had shot the rest........ wow i was blown away

[Scoops]

Soon after cam the momentus day....... the coming together of pan and body...

[Scoops]

The doors etc were hung, and time to get it back into the Man Cave at home, and start building up...







starting with the rear lights



then the front end. I wanted to do something different with the nose grills, but not too far from stock, did you spot it earlier in the thread?

[Scoops]

First bit of wiring back in......



then i couldnt resist putting a few shiny bits on. Given the cars history, i had to use and appropriate license plate frame!



Those tbars are noo good though, i didnt realise when i bought them that Ghia bars need to be longer.......still on the hunt for those

[leec]

Stunning

[Zach Gomulka]

Very very nice. What's the colour??

[Jos]

Very very nice. What's the colour??

This could be the Ghia build of Asshuls car if it goes te right direction 

[Zach Gomulka]

Very very nice. What's the colour??

This could be the Ghia build of Asshuls car if it goes te right direction 

There's still hope!