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VW Karmann Ghia VW Beetle VW New Beetle
 
My VW Karmann Ghia Convertible

The restoration

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Fall 1997: A view over the dashboard covered by a new (rebuild, not NOS) wooden cover. Even in 1997 it costed 150,- Euro, but it fits well and imho the colour and quality is very good.
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The selfmade doorpanels to fit three Magnat speakers per door. A lot of work and an ugly design, so later I decided to remount doorpanels in original design.
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The engine compartment. Note the activecoal-can and the second fuel line (US specification) and the special parts for the Stickshift.
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By viewing these oildrips I decided to restore the car. A view at the bottom of the engine.
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A view at the tranny.
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A view through the hole where usually the fueltank is mounted. The fueltank is already dismounted and one can see the parts of the steering and the master brake cylinder.
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Another view. Please note the earlier mounted new shock absorbers.
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I raised the whole car at 1.50 m and after that I began to build a wooden construction to hold the body at this level.
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A photo taken from the underneath of the car showing the temporary installed support and the first few parts of the wooden construction.
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Spring 1998: The wooden construction grows.
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Note the cutting for the jack-whole and the hookes to prevent the rocker from slipping through after lowering down the chassis.
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I used appr. 500 Screws and appr. 50 dowels to support and fix the construction. I would like to warn everyone explicitely not to seperate his VW using this method. Sometimes it was dangerous working under this construction.
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The exciting moment of the seperation. This photo shows the right front corner of the car.
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A few centimeters between the body and the chassis after nearly 30 years of this marriage ;o)
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An interesting view between chassis and body from the front to the rear of the car. Note the pedals in the foreground and the engine in the background.
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The same view.
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The front of the car photographed through the inner of the car. Naturally I changed the carped, now there's a carpet in origianl quality installed.
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After removing the body, the dismounting of the engine is a lot easier ;o)
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Note the rusty floorpanels.
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At this position the engine parked for another year.
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I widened this rusthole by force. It was the onliest until now. I decided to let replace the whole floorpanels (only the panels, not the whole chassis).
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The front end of the chassis in detail. Please note the pedals and the front axle.
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The rolling chassis .
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The place where you normally can find the transmission. A thick layer of original american undercoating covers the underneath of the car. It costed weeks to remove it.
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The right corner of the back end of the car. Note the visible point the rear bumper was screwed on.
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A view in direction front of the car, showing the right rear wheel housing. Please note the opening for the heated air (left).
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The engine compartment just after dismounting all parts.
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Don't imitate this, ask an expert ;o)
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The left side of the engine compartment. Only a litte rust at the surface of the battery holder and lots of dirt of 30 years ;o)
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After the use of tons of sandpaper I applied grounding and two layers of red paint and another layer of clear paint.
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The left side.
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After installing several things.
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Note the stickshift specific ATF-can and the vacuum-can that contains the vacuum to support the automatic clutch.
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Autumn 1998: The chassis came back from Karmann-expert Neuffer. The front axle was also restored and painted.
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The chassis itself became new floorpans, was sandblasted and painted.
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The left rear wheel housing.
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The front axle was equipped with ventilated Kerscher discs and several new parts, f.e. new master cylinder for the brake and new brake fluid lines.
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Also the rear brakes were changed. Kerscher delivered solid discs. To attach the parking brake cables were very difficult. Kerscher should check this point of the rear disc brakes.
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After repainting: The tranny would be here in future.
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The stickshift transmission prioir to the cleaning.
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Lots of days later.
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The ATF-lines were no longer available at Volkswagen so I let them rebuild at a company in Frankfurt/Germany.
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The clutch of the stickshift transmission. In nearly new condition :o)
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And there the tranny should be mounted in a few minutes.
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And there it is :o) In reality it took longer than just one mouseclick ;o)
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The first New Beetle equipped with an aircooled engine in the rear of the car ;o) I picked the rebuild engine up by myself at Toni Seemaiers Boxershop near Nuernberg/Germany.
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I checked out whole germany for months to get the special tool VW792 to press in the ATF sealing ring. I found it finally near Stuttgart/Germany.
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Tonis work is great. I drove a lot of kilometers in the meantime without any problems :o)
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I cleaned, painted and mounted the parts of the engine by myself. It was a lot of work to do this.
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Mounting the engine was different from dismounting it: Placing the engine under the still raised car and letting of the car carefully.
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Finished. The engine is back again.
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The engine is mounted but f.e. the exhaust is missing so far.
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A solemn moment: For the first time since nearly two years the car stands with it's own wheels on the ground.
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A lot of work has been done but a lot of work still was to do: Note the broken windshield, the missing fueltank and (not visible) the not so far electrically attached engine.
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It was october 1999 when the engine starts for the first time and due to the oil in the cylinders the neighbourhood disappears in blue fog ;o)
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What a difference: The car after it's first polish.
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This photo was taken at the day in november 1999, when the car passes the national test. This day was the start of the second life of my convertible.



I would like to say Thank you to the following companies:


Rebuilt of the original engine



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