Engine and mechanical work
Engine:
Since I first got the car I have replaced most of the exterior parts of the engine: the carburettors and most
of the linkages, the generator, the fuel pump, the coil, the distributor, the oil cooler and the kickdown switch. All of the wiring has been replaced. I have also replaced the engine mounts as they previously had lost all of their
rubber and the engine was lower at the rear than at the front. More recently, I have replaced the exhaust, the fan, acquired all of the missing engine tin, and cleaned and repainted the old tin.
Transmission:
I replaced the gear selector lever and connected it up and adjusted it. When I first started the engine
the gear selector was disconnected so the car wouldn't go backwards. I also reconnected the ATF filler tube which was wobbling about. I also replaced the kickdown switch and adjusted it.
I drained and filled the final drive, replaced the CV boots and greased the CV joints. More recently, I replaced the ATF pan seal, the governor seal, the filler tube seal, the torque converter oil seal and the torque
converter itself.
Brakes
The braking system was overhauled at a garage. The disks and drums were machined, the shoes relined, the front rubber hoses replaced, etc. I also replaced the hand-brake handle.
Steering
I filled the steering box with grease and replaced the steering damper, and a garage replaced one tie-rod end. The wheels were realigned.
Suspension
I replaced all of the shock absorbers and one missing rear bump stop.
Electrical work
When I first got the car no electrical items were working. There was no wiring. I have wired the car myself using my own wires which I have cut to fit and installed. Most of
the wiring is by the book, with a few tiny improvisations here and there. AS OF 2ND JUNE 2003, ALL OF THE WIRING IS FINISHED AND THE ENTIRE ELECTRICAL SYSTEM WORKS.
Outside
I now have all of the missing lights. Removed loads of rust from bumpers and hubcaps Installed rear decklid latch Replaced "B"-pillars
Added beauty rings to hubcaps Installed Mini headlight rings Installed authentic repro exterior rear view mirror Mounted "Karmann Ghia" and "automatic" scripts to rear
Installed home made rubber seals to doors and windows. Installed new windscreen washer nozzle. Installed simulated chrome trim over windows and on "A"-pillar Treated various small patches of rust
Installed front hood latch and rigged it to work somehow. Installed passenger side outer window scraper Installed passenger and driver-side a-pillar trim Installed new rear lights Installed foglights
Installed rear pop-out windows Rebuilt one windscreen wiper shaft using epoxy putty. Installed genuine windscreen wiper arms. Installed rubber seal behind front windows Replaced both door locks.
Replaced driver-side window winder mechanism. Replaced driver-side window felt channel Installed rear boot lock
Inside passenger compartment and trunks
When I first got the car it was basically missing its interior so I had to find practically everything. Rather than list everything I did I will just say that the only parts I did have were the speedometer and the fuel gauge; everything else had to be found. I brought seats from Germany. Among the more interesting parts that I obtained are a 1969-only rear view mirror with an anti-vibration stalk and a clock with the same manufacture date as the speedo and fuel gauge. I had the speedo overhauled at a garage.
(c) Daniel Baum 2002 Last updated 9/9/2006