Karmann Ghia parts & restoration projects from Californian Classics - VW Karmann Ghia Specialists

1957 lowlight Karmann Ghia 70 day build

I have had this car for several years, The ghia was worked on by another local contractor prior to us starting on it!  The work was unfortunately done to a very poor standard and has had to be re done!  3/4 inch of filler on the rear deck between the engine lid and the decklid is not acceptable in any standards we removed the filler and witching 20 mins Duncan had beat the panel back into shape, there is no filler there now!   There was a lot of other work that would need to be replaced and re done too!  The brief was to go from project to Showcar in 70 days.  We spoke to the team and all of them decided we could achieve it alongside working on customer builds (????????thanks Guys).

the body needed a new nose as the previous repair work was shocking, the nose template shows just how far out it was. The door fit was appalling and we had to remove loads of material from the a panels, the door skin on the rhs and the b pillar, along with re fitting the sills too!  The gutters where rebuilt, the rear valence was needed to be removable and had been poorly done previously so Mike  re worked the whole area.  Mike reskinned the LHS door. The bonnet decklid and doors where all properly gapped before final fabrication work was completed and the body was handed over to Duncan.

Duncan and Aaron put in the hours to get the body perfect  the shell was painted with the original colour of Antelope brown and a special blend of our own on the roof with a little bit of metal flake thrown in for good measure

 

We can build you a car to this standard either stock or wild. Please call us or email for further information

Dan stripped the chassis down and got rid of all the sound deadening material that had been applied over a rusty floor pan to make it seem solid.

 

Matt removed all the rusty steel from the floors and replaced with new sections after some re working of the pressings had been carried out.

new gearbox mounts were fitted and roll cage installed then the front beam gearbox and brakes were fitted. Before the body was fitted up.  We had many modifications to carry out to the braking system from Airkewld as it simply didn’t fit  “out of the box” Bad Brakes is what the brand is called  the name flipping terrible would be better!  Still we modified, adjusted and overcame all the issues thrown up to get the chassis and brakes to function correctly.

 

 

We can build you a car to this standard either stock or wild. Please call us or email for further information

 

The engine and transmission are seriously special!  The engine is  a 2332 198 bhp normally aspirated monster the carbs are modified 48 IDA Weber’s, genuine Italian ones!  The heads are comp eliminators the cam is a FK89 and we are running straight cut gears.  The exhaust is a Turbo Thomas Sebring style system.

 

its a animal!

 

We can build you a car to this standard either stock or wild. Please call us or email for further information

Dave Champoin our trimmer fitted a new beige cloth headliner, the seats where re trimmed in brown corduroy and vinyl with brown piping as a nod to the original factory interior along with matching door cards.  The carpet set was from Dave at Spirit interiors.

the look has been finished off with a complement of our gauges from ISP,  Gene berg shifter, formula steering wheel, seat belts by Crow and a set of our Race trim seats retrimmed by Dave along with our ghia roll cage

 

 

We can build you a car to this standard either stock or wild. Please call us or email for further information

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1957 lowlight Karmann Ghia 70 day build

1957-lowlight-karmann-ghia-70-day-build
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