Mikey's Ghia Thread...
 

Hey Guys, after seeing all the build-up threads, I thought I'd start my own. :cool:

I took a big step today. I worked on it for about 10 hours. I got my radiator and fan in from Summit Racing last week. Today was the day to mount it.

I first started by making a braket to hold the radiator. I had a friend of mine bend me up some C-channel. After I cut it and bent it to fit the radiator, I then I added some angle iron to the corners to make it a little stronger. (pic 002) Then I added angle iron cross braces to hold the fan. (pic 004) Because of space reasons, and I wanted to be able to slide the radiator in and out with the fan in place, I mounted the fan infront of the radiator. I made sure to buy a push/pull fan for that reason. My goal today was to get the radiator braket made, and the radiator mounted in the car. At least tack welded. I didn't get that far because I ran into some rust issues. Strangly in the front of Ghias. The two peices aren't welded, they just stuck a gasket in and pushed the two parts together. I went in and pulled the gasket out and added some welds. You can see where they burned though on the last picture. I'm adding a grill I made in the big hole under the front. I just didn't think to stick it in there for the last picture of the night.
I had soo much energy I wanted to keep going untill I had the radiator in, But my body was telling me it had enough. :rolleyes:

Werd!! Looks like there'll be good airflow to the radiator where you have it.

One humble suggestion based on what I'd experienced in my TR6, you may get better results mounting the fan behind the core instead of in front of it. Even though the fan moves air, the parts themselves actually block natural airflow when running at highway speed. Mount the assembly on the other side of the radiator, and natural airflow won't get impeded.

Keep the updates comming. :agree:

I was hard at it today. I worked about an hour each day monday-thursday, then I worked 4 hours friday, and another 10 today. So far I figure I have about 30hrs into getting this radiator installed. It would have been faster but I made sure to fix any rust I found, and prime the places that'll be hard to get to after the braket was installed.

I snapped a few pictures just before running out. :rolleyes: Not the best or steadiest shots, but they kinda show what's going on. It does look better in person.

Let me know what ya'll think. Be kind, this is the first car I've built by my self. :o

Thanks Yeti, I figured that the fan would some what obstruct the air going through the radiator, but I thought that it would make the same resistance in front of the radiator as it would the rear. Feel me yo? :cool:

I have nothing to add but I am enjoying the updates. :)

(FWIW, Summit is not a typical resource for me for my air- or water-cooled VWs but my experience with them has been good.)

I was at it again today. I had a local club meeting or it would have been another 10 hour day. :laugh: I got my grill welded in today. I love it, I think it looks great! I had a few people look at it, they agree too.
Now I've got to figure out what to do after the grill is finished.

Let me know what Ya'll think. :)

Thanks Oasis, even encouagement helps. :D

PS... Sorry this isn't on the VKG site. I thought it would get comments faster here. :o

Yeeh, dats on mad wax up in tha membrane dog...

:laugh:

My car's radiator is about the size of two encyclopedias! You're right about your's. Fan placement's not a huge concern on that monster. :D

I like how you did the grille below the nose.

:agree: Me, too. Looks very natural. :agree:

Hey Mikey,

Glad to see you made the trek back home safely from the great white North :D

Project is looking good !
Are you going to make a shroud to cover the rad on the inside ?

Rob.

I made it back alright. Only took 11 hours to get back. :rolleyes: Well, 11 hours and a bunch of energy drinks.

Thanks, Yes I will be makeing the radiator area air tight from the rest of the trunk, not sure how I'm gonna do it just yet, But I'd love to be able to see the radiator when I open the hood.

Oasis, Thank you. I figured if I use parts from a volkswagen, they'd look like they were suppose to be there easier. the two big grills are off of a '70 or '71 bug deck lid, and the other smaller grill is off of a late model bug hood. :laugh: Both were free so I can't complain.

I called out to Kennedy and they said that my adaptor is on the way. That might be what I do next. After I find an engine. Not sure...

I just thought I'd throw in a few pictures of what's going to stop this thing. The set up isn't even close to being finished, but it's a work in progress. :cool:

Do you still need '87 and later 944 hub's? I should have asked this in the wanted section, but oh well.

Yeah, Pm me what you're asking for them. Maybe we can work something out. :)

thanks,

My weekend update...
 

I slowed down a little this weekend, this is the third weekend in a row I've been all out, and it's starting to wear me out. This car, school, and working everyday.

I managed to make a new mount for the front beam. Since I cut out the old one. Sorry no picture, I forgot. :shrug:

I got my engine adaptor in the mail, along with a new set of front disk. I don't have a pic of the adaptor either. I'm really slackin'. But I do have a pic of the disk behind the wheel. :cool:

I also fitted my guages today. I know it's probably over kill just a little. But I had the gauges, so I figured, why not? :laugh: Seeing the gauges finaly mounted in the car was a great feeling. I couldn't stop staring at them. I love my new racing wheel too. ;)

(Left to right)
CHT, Tach, Fuel Level, Speedo, (top) Boost, water temp, (bottom) oil press, and oil temp.

Comments??

Thats' good stuff!!

After installing the gauges, did you do what I did and sit in the car on a milk crate and make VROOM...VROOM sounds?

:laugh:

Thanks :)

What? Sounds, not me. :p Well, maybe a few... :laugh:

You got to wire up the back lights and wait untill dark to do that :laugh:

lookin' good mikey :D

Looks fantastic! Keep all of the good pics coming. I just wish i had as much time as you to work on my project.

Go Mikey, Go Mikey. Woo, Woo, Woo :agree:

Thanks a lot guys. Getting encouragement like this makes me want to work twice as hard. Especialy since you are the ones that built and are building the cars that inspired me.

I'm sure after my engine gets in I'll have a very long weekend. :laugh:

I have a few ideas I'd like to toss around for getting my coolant from the front to the back. Ahem...

1. Run round tubing inside the main tunnel. Send and return. Pro- Neat/cleaner look, practical since everything else is in the tunnel Con- Tight space, and I havn't figure out a good way around the rear torsion.
2. Run one pipe inside the tunnel and one on the passenger side. (right next the tunnel) Pro- Not as clean, but clean. Con- A big hump on the passenger side of the tunnel, and the rear torsion.
3. Square OR round tubing under the car. Pro- More room than the tunnel. Con- Might limit ground clearance, and I'm a little uneasy about the pipes under the car.
4. Heater channels. Pro- Clean! I can check for rust while I've got them open. Con- A lot more work.

I'm thinking either 1-1/2 or 1-3/4 diameter. The radiator inlet and outlet are 1-3/4. The engine I don't have yet. I can always get an adaptor to a smaller diameter for the rad or weld a smaller diameter pipe on it. (I love TIG :D ) As for material, Aluminum, Stainless, and Carbon Steel are all options. But the cost might be a limiting factor. I have the capibility of welding all. I kinda want to say away from copper. Question... Would a smaller diameter pipe put a strain on the water pump by restricting the volume of water it can move? I'm an aircooled guy. :o

I'm sure I missed a few pros and a cons, But I've just gone blank on some of them. :rolleyes: And please excuse all spelling errors.

Let me know guys. I'd sure love to have another perspective on this.

Any Ideas? :cool:

What I just got last week for mine...

http://pic9.picturetrail.com/VOL267/.../129743980.jpg

1.5" al-you-min-e-um, schedule 40 pipe.

...and some nice braided hose from ebay to make my connections...

http://pic9.picturetrail.com/VOL267/.../129743976.jpg

I didn't have to go that thick on the pipe, they have tube that is cheaper and thinner but mine does run under the bus and I wanted some protection. I picked aluminum because it can only help with the cooling (even as thick as it is) and is easy to work with.
Your project is looking AWESOME by the way!

Weekend Update...
 

Thanks Panel. :o

I think I might go with that kind of a set up too, I finaly looked under the car while holding up a peice of pipe, and I realized from the seat tracks back, it's pretty much protected by the pans. The only place it isn't is under the driver's and passenger's feet. It would also disipate heat like you said, and it would be easier to route around the rear torsion.

When I originaly made a front mount for my 914/01 tranny. I had no where near the experiance I have now. So I made it to function first, and look good second. Actually, it looks horible. So I made a new one. Also it was directly over the rear torsion housing. So putting a rear sway bar on would be impossible.
The first picture shows the old mount with the plates for the new. Honestly, at this point I had no idea what I was going to do. :rolleyes: Next two pictures are the finished product compared to the old. A big improvement in function and looks. I thought about making my own rear tranny brace, but I decided against it for now.

I also installed my Kafer cup brace. Long story short, it was a PITA! Especialy with the body on! If you don't put those tabs in the right place, you can't take it out and put it back to weld it and paint it. It does look good up in there. I will take better pictures once the body is off.

I've have tomarrow off from school for Pres. Day. I'll probably get over to the shop for a few hours and do a little more here and there.

What Ya'll think up in hur?

You got da kuh-nowlege poppin' off all up in 'dis joint, yo. :laugh:

With that new crossmember you made, you could prolly use a regular aftermarket rear swaybar, and not have to fab up something like I had to. :o

Mikey,
Your car is going to be great, thanks for the updates.

Long over due update...
 

Thanks Nigel.

Oh man, I've been out of it for a while. Too long, I took a weekend off, and last weekend I didn't do much to make an update, and I had no pictures.

I figured out my water lines. I've got a bunch of pictures. Tim got me two 10 foot sticks of 1-1/4 ID aluminum conduit. I started with the pan on it's side just to get an idea of what I was going to have to do. It didn't take me very long to realize it needed bends. I didn't have a bender and I couldn't find one to rent. So played on my streights, Welding and my creativity. After a trip to Home Depot. I had a few peices, a steel pipe coupler and 1-90* bent peice of galvanized pipe conduit. (sp?) I only bought 1 at the time incase the idea doesn't work, I don't have to return the second curved peice. I started out laying the 90* pipe where I needed the first turn, then I found a place to cut it. I then added a peice of straight pipe. After I got it towards the torsion housing more, I added the other half of the 90*. It worked out perfect, and the peice of 90* was only $7. I had to go buy another 90* for the other side, but at least I had an idea. It seems like the two pipes will miss the tailing arms. The only problem is welding the galvanized (sp? again). FYI, the fumes are Toxic. If anyone welds it, Weld in a Very WELL ventilated area, don't rush only weld a little at a time.

My next head ach was the front. How to get it to the radiator. After some thinking, scratching my head. I decided that I'd start on the passenger side, then go from there. It wasn't bad really. I still need to work on my aluminum welding. But at least they're tacked now. I didn't want it to go past the frame head. The frame head on my Daily driver hits sometimes, so these lines would die. (stock beam w/ drop spindles on the DD) It had to come up before the beam. I figured out a good spot, cut an angle into the aluminum tubing, and a hole into the frame head. Doesn't look bad. Although I was kinda uncomfortable with the way it looked. I made an Arnald of a protector for it. 1/4" sides and 1/8" top. (My girlfriend has a tall curb at the end of her drive way. That's what gave me the idea. :rolleyes: ) The driver's side wasn't as easy, after a lot more thought and a little... :banghead: I just tried to avoid the master cylinder and get the water above the frame head. I'll figure out the rest after I turn the pan over. Confidence? I made another cover for the driver side. As for the way to hold the two covers over the pipe. I thought about welding, but if I ever had to remove them, it would be a nightmare. So I just made a few tabs, and drilled a few holes so I can bolt them on. The tabs aren't the most beautiful I've ever made but they'll work perfect. And "Form Follows Function". My best guess is that the water lines are maybe about 75% finished. I need to finish my aluminum welds, then finish attaching the lines to the pan. But the really difficult stuff is out of the way. :D

Let me know what you guys think.

Mo' pictures of the water lines...

Annnd... I ran my 3/8" fuel line last weekend. I thought about running just a send, but having a 25' roll. I decided to run a send and return. I still have about 8' or 9' left. That wasn't terible. It took a little to get it in position, but it's a lot better than the original. It was stopped up with either dirt or rust. Picture 2.1 in the last post shows the Kafer cup brace, the coolant lines, and the fuel lines. You won't find the original because I removed it completely.

Sorry for the EXtreemly long post. If you read it all, thanks. If not, I understand. I didn't re-read it to check for spelling. So don't hate. :cool:

Let me know guys, I love the feedback. Good, bad, or anything.

Hmm... did I scare people off with the long post? :laugh: I'm surprised that there's no comments.

Well, another weekend is coming to a close. I worked a few hours friday, a few Saturday and a few more today.

I spent most of the time working out brackets to attach the water lines to the car. I bought two small bags with 4 brakets each in them from Home Depot. After I laid them on the water lines I noticed the hole on the tunnel side was too close to the pipe, and had to either be moved by adding another peice of metal, or look for another method of holding my water lines up. I chose to add a peice of metal. I also added a small gusset. I thought, the further I move the bolt away from the pipe, the less it will resist bending. Over kill or not, they're done.

After I had them all mounted I flipped the pan over to check how much ground clearance I sacrificed. I don't have a picture. I only lost about a 1/4 of an inch. The two covers hang about 1/4" below the lowest points of the pan and frame head. I also wanted to see where the pipes came out on the top. The driver's side will need more cutting and more :banghead:, but the passenger side will only need cut with a small angle. It points right at the long tie rod right now. :rolleyes: Before I pulled the water lines off the pan. I put all the bolts going though the pan pointing down so I could weld the head to the pan. That way if it comes loose, if I need to pull the water lines off because my aluminum welds leak, I don't have to pull up the carpet. And wouldn't you know it. I took the driver's side off first, and I was almost done with the passenger's side, I went to take the nut off the bolt I welded to the pan, and it broke!!! I cut the bolt out and welded another one back in. I ran a tap and a die on all the nuts and bolts I used just for that reason, so I wouldn't get a lemmon. Oh well, all I can do is fix it and keep going.

After I fixed the bolt problem, I started cleaning up the heads, just hitting them with a grinder then some paint so they don't rust. Since I don't have a garage I had to leave my pan outside for about a year. My new pans were starting to get some surface rust. So, I knocked it all down with a wire brush on a angle grinder. Seem sealed the top of the pans (again, but with a better more liberal bead of seam seal) and coated them with some rust inhibitor/ paint I had for a while. (I don't know what it was really, but it was just sitting there, so I used it.) and before I could get pictures, I flipped the pan back over to do the other side. I first wire brushed it, seam sealed it, then painted it with the same stuff. Half way though the PS I ran out. So raided Tim's paint cabinet. In the back of the cabinet, found something of a brown rust inhibitor and some black. I used the black on my two pipe covers and the brown on the rest of the pan. I was going to lay some welds on my pipe, but I forgot my Pure Tungsten at school.

The first picture is what it looked like when I stopped saturday afternoon. We worked on Tim's '47 for a few hours. The second and third pictures are of when I stopped saturday night, about 9pm. I got there in the morning about 9am. But I took a lunch break. The last two are pictures I took before I left tonight. The creaper on my wishbone has my brakets on them. Sandblasted and painted in gray primer for now. You can see the bolts sticking up from the pan. The holes in the tunnel are tapped 8mm x 1.25 (I think) The lone bolt sticking up in the tunnel, it stripped so I just put a bolt though and welded it on the back. After looking back I could have welded a nut and you'd never know, but then again. How many people will climb under my car and notice that small detail?

Any thoughts or opinions are welcome. I can't spell very good.

On a side note: On my way back to Tim's after my lunch break saturday. I said hi to my friend standing out side my house with a neighbor of mine. He asked me where I was going, I said back to work. And my neighbor said, and I quote. "Sucks to be you" I said "No it doesn't, I love my work. :D "

I read every update. Sometimes multiple times. I'm enjoying it.

Don't be put off by no responses. I'm sure I'm not the only one reading this with interest. To me, it is like a tutorial. I promise not to be bashful with comments or questions when I have something to add. ;)

Please continue. :)

Very nice work Mike. :agree:
I have been bowed up on Joel's Bus and then my grandma passed last Sun. Joel and I took the bus to Ohio for the funeral. While Nancy and Jordan took the TDI Jetta.
Good to see that you are thinking things thru so well. The details look very nice. That will be one bad @$$ Ghia,,,,,,, even if it will be laden wiff one of those water bags. :laugh: :agree: :agree:

Post as long as you want, we love it! Hope to post some progress pics of my own soon.


Jeff-

Mikey,

I'm not sure if this will be a problem or not, but it's just my $0.02...

Typically it is not advisable to put 90 degree bends into any type of plumbing lines. A radius should always be used to keep the coolant flow as smooth a possible. (Same thing goes for exhaust systems, etc...)

Do you think you will have any problems with the double 90 degree cuts you have on the one line? The other one looks like you have a nice angled cut.

I would think that the 90 degree cuts would reduce coolant flow and increase pressure in the system, which might lead to some overheating issues. :confused: Two 45 degree cuts may be better.

Again, just my $0.02. Other than that, the work looks great. :agree:

Cheers,


Doug

Thank you guys for the comments. :o Sorry to hear about your grandpa Dave. I saw the thread about the bus and your grandpa. I hope everything works out for you. I like getting a little encouagement now and then.

Doogie, Thanks for the advice. I'm not sure if I'll have a problem, with the restrictions I have at that one spot. Master cylinder and steering box being the main two. I just tried to dodge them while still getting the water lines to reach the radiator.
I think I have an idea of what you're talking about. I thought about that too, and from what I could tell I could do that and still not cut the lines short. I'll make a rough cut 90* with two 45's today before I start work. Instead of the point in the corner it would make a more gentle turn.

I love the comments. :)

Hmmm... is this what you had in mind? I made it in about 10 minutes. Very Rough also known as Ghetto. :rolleyes: The actual water lines will be a lot neater than this thing.

I think I can add this to my water lines with out an act of congress.

Let me know. :)

I don't know what to look at more the coolant line mods, or the big stack of type I cylinder head cores.

:laugh: Tim's been building vws for 25+ years. We're in the process of rebuilding all those heads. I should take pictures of his shop sometime. There are parts and tools everywhere. For the most part, I'd say about 90-95% of all the parts have their place. That's why I've been hard after this Ghia. I have the space and the tools to do it.

If you havn't, you should meet Tim. He's a real good guy. Some of the VKG'ers have met him at various shows. How many guys do you know that would allow someone full use of their shop and a place to keep their car while they build it?

Mikey,

Yeah, that is exactly what I was talking about. :agree: I know that in the plumbing industry (commercial and residential construction) we had very few problems with the system when the 90 degree bends were made with 2 - 45 degree fittings.

Nice work on that Ghia. You're an inspiration for me to get moving on mine this fall. (Right after I insulate and heat the garage). :rolleyes:

Cheers,


Doug

Mikey,
Great job I am enjoying your updates. :agree:
Any problems welding the aluminum pipe to the galvanized other than the toxic fumes?

Thanks for the feedback.

As far as I know, I asked a friend in my welding class today. I can't weld the two because they're disimilar metals. I can brase them, but he said you can brase about any metal. Brasing isn't an option because it isn't a very clean weld. Not something I'd like to do for my water lines. In my pictures. Towards the rear torsion, there are couplers on either side. I'll probably just use good thread tape and call it done. If that doesn't work, maybe a peice of hose the length of the coupler, then 2 good hose clamps. Thanks for the question. I enjoy answering.

But galvanized is very toxic, I think you end up with the equivilent of a chemical phemonia (sp?). A guy in my class had that happen to him a while back, he was VERY sick.

Thanks, inslulation and heat in your garage is a must. When you get moving on yours. Start a thread. I'd love to follow allong to your build too. Maybe I can help on yours too.

You sorce out another engine yet?

Update!
 

No Nick, no engine yet. I'll probably call out to Nippon-motors monday. :cool:

Wow, what a week. I had intentions of working my @ss off over my spring break, it didn't happen. But I did make some great progress even though I only worked 3 days. :rolleyes:

I finshed the corner in my coolant lines. I had a few failed ideas before I finaly hit gold. I first just cut two 45* angles and tried them up against two 90*s. That didn't work, it left big gaps. So I tried to fill in the gaps. Let me add, I was using a simple tri-square and a hack saw. After a little figureing, I realized I needed to just make two 45* angles with four 22.5*. There was just no way around it. So I thought long and hard.... Chop saw! :idea: I checked the blade, sure enough it's for 'metal'. Tried it, and it worked perfect. Then after I found the right angle. I cut the tubing up how I wanted it, then welded it. Perfecto! I put a small cut and angle in the passenger side to help point the water towards the radiator.

Next is the moment of truth. How will the tubing look with the body and radiator in place? I'll use another post, I'm out of picture room...