iichels 1967 VW Karmann Ghia 1500 Coupé

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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

So, update time... what's been happening to my KG... a lot!

I changed all the wiring in the front half of the car since it was in pretty bad shape.

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Finished:

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This is what came out:

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It's all in poor shape. Corrosion, wear and tear on the insulation, stiffness, etc.
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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

Some other mods I did, these I'm listing but will perhaps elaborate later

- Ignition changed to 123 digital ignition
- Added a new fuse box + relays
- New spark plugs, coil and leads
- Changed the alarm light switch and indicator relay since old stuff was not OEM and broken
- Changed the radio for a 1966 Blaupunkt Frankfurt + noise filter EF-20 + new antenna
- Changed the front indicator fittings for bay15d so I can have US lights. after all, it is an original US car.
- Added fog light switch
- Changed the windscreen wiper to a 2-speed wiper (OEM of course, motor + switch)
- Changed the windscreen washer pump from air pressure (from the spare wheel powered) to electric one from a Mexico Bug + modded switch to take a microswitch + relay
- Changed the light switch to a 1968 model with logo
- Added a low tone bass horn to accompany treble horn
- Fixed the front windshield heating (repaired the cables operating them)
- Fixed some rubbers
- Cleaned the tectylation from the boot (front compartment)
- T5 blue LED in the high beam indicator
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Some mods upcoming:
- Other instrument cluster with warning light for low beam, heated rear window and ATF temperature
- Brake circuit warning light (will use ATF temp light for this)

Next job is to change the brake light switches from 2-pin to 3-pin versions and I'll be doing that on friday.
Will also add a nice rubber 'hat' to cover the connectors.
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ciclo
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by ciclo »

Nice job with the wiring in the front, hoping to see that nice hat. I guess it wasn't easy to remove the rust/dirt.
I think I remember that in 'Wheelers dealers' they also renewed those covers on a Karmann.

Super interesting thread iichel, I like the improvements you are making.👍
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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

The rubber hat is nothing too special:

Image

It will be an extra protection over the brake light switches as shown here:
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Now they are in the wheel well and very exposed to water, dirt, sand and other stuff you drive through. Not very nice
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by ciclo »

You will also have to find a solution for the oil leak seen in the upper part of the image ... :?:
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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

No haha that's WD40 that I'm using to get rid of the brownish substance that's covering the inner paintwork.
Look on the first picture here on the right --> viewtopic.php?p=577943#p577943
It's now all gone, using WD40 and a toothbrush (no joke).

I took the time to install the rubber boot for the brake light switches already
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OEM number 311 945 521 A

The cause of death of the previous switches was water ingress and when the membrane tears, it can leak too. Better keep it nice and tidy in there!
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by ciclo »

Well done!👍 It is a significant improvement, it looks better with the rubber hats.

However I was referring to this oil leak, which is generating a layer of crust and dirt all around.
Image
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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

Yes, we're talking about the same leak haha.
I already dipped it dry, it smells like WD40. It will leak from the luggage compartment to below the fuel tank, driven by gravity.

The hose you're (almost) circling is the fuel line from the fuel tank to the rear of the car (it goes through the central tunnel of the car).
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ciclo
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by ciclo »

ah ... ok, haha, sorry. :lol:
With the enlarged image I understand it better ... :wink:
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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

Hmmmm... a 1500cc type H single port engine. Would fit a 1966 KG 1500 nicely, no?
In fact, it is the engine that originally belongs in this car.

There is a service where you can get the 'birth certificate' of the car. Here is mine:

Image

The car currently has a 1600cc type AD dual port engine (every cylinder has its own inlet port). It comes from the T2 transporter.
Fits to the Ghia plug and play since they are both type 1 engine with identical sumps.
This give a bit more top end power, 3hp to be precise.
But it's a 1972 engine and my car is from 1966. But that's not the biggest problem.
The biggest problem is.... the current engine is very very bad. It has axial play on the crankshaft and it has very bad compression on cylinders 1 and 2.
The most likely cause is a cracked cylinder head, this is a common issue on the dual port 1600cc engines.
The metal between the spark plug holes and the inlet/outlet valves cracks and this causes the engine to lose compression and performance.

Like this: https://www.thesamba.com/vw/forum/viewt ... p?t=580904

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Today I've been to a VW specialist for these engines and he was very clear about my Ghia: this engine is f*****g crap.
So my plans to uprate it with other carburettors are now irrelevant.

But look what I has here:

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A good engine! H type 1500cc from... October 1966. So more or less matching numbers :mrgreen: :mrgreen:
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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

The rear window is out, the old window is an imitation window with no heating.
The new window is a window with heating stripes on them, OEM :) :) :)

In the process of removing the window, we found some rust below the window rubber. Remember, the window is held by the rubber and not glued into place.
So it's easy for water to get caught below the rubbers in the bottom corners and eat my car very slowly.

The solution is to grind out all the rust, weld it nicely, prime and paint. So that's what's being done now :)

The holes:

Image

The welds:

Image

The primer:

Image
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by ciclo »

Super interesting, good engine inspections and good corrosion/rust repair.

Thanks for the detailed explanations/pics, and congratulations on that fantastic certificate. 8)

---
Well, as far as the engine is concerned, it must be taken into account that in those 60's everything was a little slower, even in San Francisco.
I have seen some videos of the San Francisco of the 60s where people pushed and even turned the Tramways to change direction.
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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

As with everything, OEM is good, OEM+ is better. So I decided to improve some stuff!

- Installed an OEM windshield (there was an aftermarket window with bad scratching on the inside)
- Installed the rear heated window and wired it all up
- Installed some VDO instruments for rpm, oil presse and temperature, outside temperature, system voltage and rpm
- Installed a rear fog light + switch

I also decided to completely overhaul the cars ass.
- Overhauled the engine
- Move the battery to the rear seat aera.
- Re-do all wiring

Before:
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The engine bay was completely stripped and re-painted too.

After:
Image

It's a 1500cc 'H' engine. Single inlet port, 44hp. Everything either new or as good as new. Never been better!

The battery now lives below the rear seat, this is the standard place for the Bug.
Remember, the Karmann Ghia has the same lower chassis as the Bug, although it's widened by about 25cm (10 inches)

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On the other side, there is now the voltage regulator, the starter relay, the terminal 15 relay and an extra OEM fusebox.

Image

Nice and clean and works like a charm. All new, copper wiring with good diameters and nice insulation.

Slowly and surely, the Karmann Ghia is becoming a very very nice and technically sound car.
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by ciclo »

Yeah! very well done Michel, the improvements are clearly noticeable, I like the evolution (the good way) that this beautiful project has.
Thank you very much for the information, reminders, etc ... very, very interesting.

Nice! 8)
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iichel
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Re: iichels 1967 VW Karmann Ghia 1500 Coupé

Post by iichel »

We've been to the beach on one of the Dutch isles called Ameland.
It's wonderful here.

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