Monday, September 7, 2009

Rebuild Complete

Dominic and I have spent many hours on the front end rebuild. The dissassembly took about 4 hours. I'd estimate we have about 60 hours in the rebuild.

We began with a complete rust removal with sand paper and a wire wheel on a drill. After much clean up, the parts were labled, identified, and spayed with a rust conversion paint. The rust conversion paint takes any rust and converts it to a paintable surface. After this prep, the surface was painted with several coats of rustoleum.

After the rust removal, it was time to replace the king pins and link pins. These critical suspension items required a trip to Ken Friends shop for use of his expertise and a heavy duty hydraulic press. With the king pins installed, it was time to focus on the brakes and braking components. Dominic cleaned and painted the backing plates and I enlisted the help of good friend and all around expert Jimmie W. who stopped by and helped with the brake install.

Today, Dominic and I spent some time measuring for the net tie rod ends. Like the king pins/link pins these measurments were critical for the suspension install. We used a measuring tape, string, and a make shift plumb bob to be certain that our tie rods and ends were exactly correct. We'll do a final measurment to make sure that everything is still correct before we bolt on the wheels and tires.

While the front end assembly was out, we were also able to replace the master cylinder and front brake lines. This should make the car safe to drive. Hopefully this week, we'll turn the car around and begin a similar refit to the rear end of the car. Then it will be safe for Dominic to drive around town.

Thursday, July 30, 2009

Front End Work


And so it begins... Yesterday Dominic and I placed the Ghia on jack stands and removed the entire front end assembly. This includes the suspension components and brake drums. It was a bit difficult to get out from under the car. Working on our backs with 44 years of rust, dirt and grime raining down upon our heads was not pleasant.
We worked for about 4 hours and our results were successful. Dominic is pictured using the pressure washer to remove the years of accumulated grime. Hopefully, this will make the next part of the job a bit cleaner.
Our plan over the next few weeks is to replace all the moving components on the front end. We'll begin with new king and link pin assemblies. The left king pin is badly worn, the right one seems okay, but we will replace both. Additionally, we'll add new shocks and a steering dampener. The the braking system including new wheel cylinders, brake lines, a new master cylinder, and new shoes. This will make the car much safer to drive. So, stay tuned to our blog and we'll show you photos of the next few steps. Fortunately, we have good documentation in about 3 service manuals, so this project was fairly easy so far.
Mike and Dominic

Wednesday, June 17, 2009

1964 Karmann Ghia Coupe


The Karmann Ghia was marketed from 1955 until 1974 by Volkswagen. It was a collaboration between the Germans and the Italians. With German engineering and reliability, coupled with Italian styling, the Karmann Ghia was a success full design for a number years.

Our Ghia sports a 1.2 liter engine. Volkswagen had many firsts that seeming went unrecognized by the mainstream automakers. Chrysler claims to have invented the mini-van. However, VW aficionados know that the mini-bus was really the first soccer mom transportation.

So why a Ghia? Dominic and I wanted to restore a car. Figuring by working together we could both learn about cars and eachother. I had partially restored a 1965 Mustang about the time Dominic was born. It was time to do another restoration.

We shopped. Watched Craigslist and Ebay. Checked out local papers. Did research. Looked and some junk. Dominic really wanted to have a 60's or 70's muscle car. I wasn't so keen on this idea for many reasons. The Ghia was a compromise. It's actually a perfect compromise between an Italian designed sports car and an American muscle car. The fact that this car has a small 40bhp engine and sips gasoline is a plus for being environmentally responsible. This car is capable of 30 miles per gallon! The car appeals to Dominic because it's unique. Think about it... you just don't see to many Karmann Ghias on the road today. Hopefully, with a great restoration this car will be a legacy to Dominic. He'll have the memories of restoration and the car.

I'll be posting updates as do a complete restoration on our 1964 Karmann Ghia. The car was delivered last weekend by flat bed wrecker. It has a strong engine and runs and drives. Dominic and I took a ride "around the block" last weekend. I'll use our blog to chronicle the restoration.

The car needs a few things to get it road ready. This 1964 has not been in a serious accident, however, it does show some wear and tear. The paint is in bad shape and there are several dings, dents, and some rust on the rear quarter panels. With that said, it runs and drives and the tires are good.

On Monday of this week, we pulled the car into the garage and put it on axle stands. Then we took all the wheels off and started to examine the pieces and parts. Upon examination, it was decided that the undercarriage was way too filthy to begin to work on. So we pulled the Ghia back out of the garage, jacked it up took the wheels off and pressure washed it! It's much cleaner now, and will make the next steps a bit easier. We'll begin with a total restoration of the braking system. One of the front wheels needs some attention, Dominic and I are unsure if the brake is hanging up or the wheel bearing is cooked. It's really hard to turn the wheels! We'll address this problem this week. Our plan is to remove the wheels and brake drums and do a total restoration on that portion of the car. Our goal, get the car the ready to drive!

I'll keep you updated with photos and stories as we restore this classic car!

Monday, June 8, 2009

Metal Art


Robin, Dominic and I have made several trips to the British Virgin Islands. One of our favorite places to hang out is Trellis Bay. This well protected anchorage is nestled next to the airport on Beef Island. Trellis is one of the more populated places in the islands, it sports a few beach bars, a couple of art galleries, grocery store, and an internet cafe with great coffee. We have stopped there on each visit to the islands.

During the full moon, Trellis bay transforms into a family friendly outdoor party. Complete with mocko jumbies (stilt walkers), artists, food, live music, and fire!


The photo above is an old anchor or marker buoy that has been cut with a plasma cutter. The tessellations form an artists impression of the island people standing strong and holding up the sun or sky. There are several of these in Trellis Bay and during the full moon. The artists of Trellis push or roll these tessellated shapes into knee-deep water. They are filled with dry kindling and set ablaze in a most remarkable display to celebrate the full moon.


Many of the members of Beaver Lake Sailing Club have traveled to Trellis Bay and sampled some of the local flavor. Everyone it seems, has found these burning orbs captivating. When my friend Tom approached me about an old 1000 gallon propane tank that was collecting dirt at Mike's house in Elkins, an great idea was set in motion.


First, how to get the propane tank somewhere where could work on it. Well with some Egyptian engineering (using round pipes to roll this behemoth) we managed to load this tank on a flat bed trailer. It took several hours and 4 guys, chains, come-alongs, a tractor, and a stout Toyota 4Runner to coax this tank aboard the trailer. We did this in early May when the ground was wet and slippery.


Next, we hauled the tank to my good friend Jimmie's shop in Fayetteville. Jimmie, now retired, has much experience working with things metal, he used to build racing car frames and suspension components for the dirt track folks around the area. Jimmie also has a large selection of grown up toys. A wire feed welder, a plasma cutter, and many other cool devices all dedicated to cutting, slicing, or joining metal.


So, we spent an entire day sectioning this tank into smaller more manageable pieces. It was no easy task as this tank had held flammable gas at one point in its life. Putting a plasma torch to this enclosed tank was a bit unnerving. We cut it open and began to create art.

As it turns out Jimmie's plasma cutter was working at its maxium capacity and cutting was fairly slow going. Enter Jesse, of White River Hardwoods, who had a much more macho plasma torch that sliced though the 1/2 inch thick steel like a hot knife though butter. Add another entire day and part of a morning and the tank was beginning to look a lot like the fire art we have all enjoyed the in the BVI.


Today, was the last and final push for finishing the tank. There was much grinding to do to even the rough edges left by the plasma torch. Using a grinder and Jimmie's advice, I worked for several hours and leveled things up a bit. Then off to the scrap metal place for chimney and by the days end, we have an awesome looking outdoor fire pit.
The years enscribed (1979-2009) represent Beaver Lake Sailing Club's 30 year presence in Molder Hollow. We'll start a fire this weekend during the Founder's Regatta to commemorate this auspicious event.















Tuesday, April 14, 2009

FOJW: Friends of Jimmie White


The title of today's BLOG is "Friends of Jimmie White" or FOJW. It seems that our dear friend Jimmie found his 1970's vintage Trojan cabin Cruiser resting easily on the bottom of Beaver Lake. This boat, which is berthed on the Rambo Riviera region of Beaver Lake, has been Jimmie and Sue's secret get-a-away for a number of years. This Spring season has been a bit different than usual with plenty of rain and even snow to fill the Cabin Cruiser. Our dear friends Jimmie and Sue found their beloved 31' cabin cruiser on the bottom of Beaver Lake last weekend.

No fear, it seems that Jimmie has lots of willing friends who demonstrated loyalty by driving to the Rambo to raise the boat. Think, 19th century barn raising! Johnny arrived ready to get in the chilly Spring water. Elmo had stayed out at Rambo to be there early and lend a hand. Steven and his friend Adam showed up to lend assistance in whatever needed doing. Don with the Rubicon were there with professional experience in raising the sunk. I arrived with provisions for lunch and a willingness to throw my shoulder into it, whatever the task. With the help of many volunteers, we applied straps, cables, winches, and chains and raised Jimmie and Sue's boat.


Lets face it, having a boat is every water lovers dream. Having a boat that sinks is really depressing. However, it seems that Jimmie and Sue's boat is no worse the wear for spending several days below the surface. While the interior was wet, the boat seemed to be fairly clean after the ordeal.

Working for most of the day, we managed to raise her off the bottom and tow her to the Rocky Branch Marina on Beaver Lake. She's now in a covered slip where she can dry out a bit. Jimmie hopes to get her running again by using diesel fuel to lubricate the soaked engines. Yes, this boat was equipped with two 350cu Chevy engines as well as a generator.


Sunday, March 8, 2009

Around LaRue


LaRue is a tiny community in Benton County. Presumably named for L. LaRue Harrison , a Union officer who lived in Northwest Arkansas and surveyed the town of Harrison. La Rue, cut off from any possible commerce by the flooding of Beaver Lake in the 60's serves only as a distant reminder to days gone past and a long distance race at the sailing club.


Friday was the perfect spring day. With temps approaching 80 degrees and a south west wind around 20 miles per hour. I was invited to crew aboard Valkyrie an O'day 32 for the "Around LaRue Race". Valkyrie is stout sailboat the seems to love the wind, certainly much more than our beloved Bella Luna who is tender and prefers days under 20 mph. Valkyrie seemed to enjoy the day.


We departed the sailing club around 11:00 am and motored to the highway 12 bridge near Rogers, Arkansas. Hoisted the sails and headed back "around LaRue and towards Beaver Dam. Then, we headed into the wind and headed for home! The entire trip took about 8 hours total on the lake. Valkyrie and her crew finished in 5 hours and 30 minutes. Posting the new time to beat for the 2009 and sailing season.

Snow and the Sea


The experts predicted only a 30% chance of snow for the last day in February. The snow started around 2 in the morning and was like fairy snow, small flakes that seemed to dance in the air. There was a short respite as the sun came up but the snow persisted as the day wore on.


At our last event at the Walton Arts Center, Michael picked up tickets to see the Naval Sea Chanters. The Chanters are the chorus of the US Navy's Band. Composed of 8 men and 8 women, they gave a stirring performance. The afternoon's offerings ranged from Shenandoah to a tribute to all the branched of the Armed Forces to a medley of 1960's top forty hits. Everyone stood and cheered and sang along under their breath. What an afternoon.


The show finished and we walked outside to snow. Larger flakes now that seemed determined to cover the roads and ground. We slid a little on the way home with our 30% chance of snow.