VW Karmann Ghia | Complete Restoration Series | Metal Fab 

Hey Guys, Check out my buddy Mike F channel. He made a section from scratch! ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-AyU710kG_lY.html

You've already learned a lesson that took me a long time to learn: Don't fall in love with your work you've done. Sometimes you can get so sucked into making something you built work that you overlook how much time you can save yourself by getting a patch panel and welding that on. I spent days recreating a rear roof panel that never did look right, when I could have just spent the money and bought a new panel. But you're leaning and that's important.

Don't forget to clean the inside metal you are welding . Great 1st try with the fab piece👍, maybe cut it out and buy the replacement repair panel.

You probably don't want to hear this but you should remove an replace the outer rocker skin under the door area. I can see in the video that it is rusted and this area rusts from the inside out. Meaning your inner heat channel is rusted. All that dust you were blowing out was more than likely what used to be your heat channel. If you are going as far to put the car on a rotisserie there is no reason to not go all the way. Patching the outside skin is like putting bandaids on to mask the problem. Plus the heat channel is structural.

One man didn’t build that car, it took several. You are only one man. Keep going. You’ll get there.

Yes, Mike did a video tutorial for you CT. This is a perfect example to learn the basics from that you're going to apply over and over. You got this CT!

New skill to learn for shaped pieces: Sheet Metal shapping using Leather Sand bag and shaped Ball Peen hammers. (Metal Working Sandbag). Company like Eastwood makes them.

You can actually buy that piece as a repair panel from various KG specialists, but good on you for attempting such a complex panel

Learning to do the metal work is the most difficult part of restoring a car. The real experts did not learn it over night either. You came up with a solution, maybe not the best or really correct, but it worked for you. Remember the original was made with dies and a press, molding bending and stretching the piece in one motion, something that fabricating can never reproduce. Keep up the good work and keep learning. ;-)

Hi CT. Nice try. Put the outer piece on first using cut and buff. Once the outer piece is in place weld the lip on but make it bigger so it protrudes inward and outward then after its welded cut to shape, you were close. One important thing. Brace the body on the inside using 1/2 inch box tubing. Hanging like that it will distort and your repairs will lock in the distortion. Watch Fitzee again he does this kind of repair all the time. Also, just in case make sure you are using .024 wire with 19 gage you will get a good weld with it with the shield gas you are using.

A shrinker tool is a must for curves. I think you could have made the part one piece with the curve profile then bend the angle. Before shrinking the inside to get the right curve cut some slots in the angle to tuck in to match the outside profile. When you do your cut in butt just do a little section at a time. And don't worry about the extra on the inside. Just want it flush on the outside. With filler it will look great and save having to buy replacement parts. If it's a big area and the part is available then that will save you time for sure. The learning curve has begun👍

I would have done this: you do it all as a flat piece. bend the fender well lip first. Cut slits int he fender well area so it will bend. Then bend the bottom bend. Pie cut and butt weld the fender well bends so they are stationary. Lap one over the other. Then cut into a butt weld the whole piece.

CT, it great to watch you teach yourself to do the metal work. I just went through all that on my bus. I am still learning and I think you know about Fitzie. He uses 18 gage steel on the Datsun he working on. He also cuts the edge in flush before he welds in the main part. Keep it up!

HI CT If you make a new piece of metal, first my friend uses a piece of paper or some board press into the inside of the wheelhouse and press it out to the end from the outer rocker bend it around then you have the perfect form. remember always work from the inside to the outer side..Good luck with the practice☮👍🏻.Greetings Hubertus.🇳🇴

Blowing out the rocker looked like Nasa rocket boosters for moving the shuttle in to place in orbit. lol

Fitzee boy is smackin his head. I love welding and I hate it at the same time cause I suck so bad at it. Kudos for not giving up.

I love watching the progress in each video! 🖤

Very good for a first time, Go CT! I believe this rotisserie is a good investment, it makes work easier.

"Let's get this rotisserie cooking" and seeing the shot of the rust and media coming out of the holes like smoke, that was very clever and humorous. Nice one CT!

That's a great beginning. That cut and butt isn't as easy as it looks. I still don't have the hang of it. Have you been watching Fitzee's Fabrications? He makes it look smooth every time. I have been backing my welds with copper plates, they work pretty well. Also, you can weld on a strip of sheet metal to the back, especially where it can't be seen. Can't wait to see more.

CT, the important thing to remember is, you wanted to learn new skills from this build and you are. Learning takes practice, practice, practice! Another thing is, you never intended this to be a Concours D’elegance restoration. If you can get it to look good and you learn some new skills and you are happy with it, then it’s a win, win, win👍 Keep at it young man😊

General tool makes a contour gauge. You can use that to find the complex shape of that rocker. I would also use a touch thicker gauge of metal to shape the pieces out of it'll cut down on the blow through with the welder. Some solid round stock steel stood on its end or in a vise in different diameters will give you a round shape also to use like an anvil to mold the different radiuses you could probably fold with a ball pin on one of those radiuses instead of having to weld that edge piece. It's just a thought but definitely the contour gauge is a must. I'm loving this series on this car it's awesome. All that clay and sand and dirt you'd most definitely need to get that out of those rockers and then treat that rusted area was something to stop that rust or it's going to come back to greet you down the road it'll rust from the inside out.

For a first attempt, I think you did great. Its easy to sit in front of a computer and watch an expert make this stuff look easy. I think your very brave doing this stuff on video. Regards Mike UK

I've had a 68 and a 69 Ghia and just loved them!!!! To me it's the best looking car ever!!!

CT, I just finished watching Mike F's video on your patch panel dilemma. I commented that my first thought would have been to look at the other side of the car, perhaps make some templates & do a bit of mirror image engineering. Mike's demonstration broke down that compound angle into several simple steps as you know. For the first time doing something like this, you do a great job on it! Keep up the great work and videos! All the best!

That was quite a complex corner to attempt for your first go. I saw a bit more of a radius on the corner? I am sure you will be a pro at body work in no time flat. Enjoying watching your restoration.

It’s making me want to learn I’ve just contacted my local college 👍🇬🇧 now all I need is a ghia 🤣

What little I know, and from what I’ve seen done, making a thin cardboard mockup of the section before you cut the cancer out is a huge benefit. If that’s not possible, making a thin cardboard mockup is still helpful. When satisfied, create the shape in metal. As for fitment, of course, make it a bit bigger then trim to fit properly. Another method for joining is to use magnets and clamps where possible to make a seam. It’s supposedly easier to grind smooth, than overlapping, but you have to weld bead seams on both sides. I sucked at it so bad and had such crappy equipment, I hired someone to fix my “work” and finish the rest. Good luck and kudos for having the balls to do it and on the Internet, no less, with all the trolls. Ignore them and keep learning. I’m glad you’re learning on the Ghia so you’ll be more proficient when you get to the 914.

Man i love that youre not scared and just try things. But its still kinda hard to watch lol. Sometimes you just need the right tools when doing sheetmetal work. A shrinker/ stretcher would be great

Я твой подписчик из России и смотрю все твои! Ты молодец! Лайк. Жду новых выпусков! 👍

CT, really like watching you. You just jump in and start going at. I'm enjoying Giha project, I hope you are too.

you are getting there looking good the guys that do it for a living were not born with that knowledge Hange in there we are rooting for you

hey we actually might need that geometry lesson from school after all lol pieces like that little one seem easy but turn out such a pain in the tookus, stick to it youre learning as you go, as are many of us right along with you!

I think you are doing great. I have done similar patches before, and learned that it was easier to fit the new panel first and then remove the rusted metal, or most of it before welding the new piece. This helped me follow the original shape a little more accurately. Cut & butt is a great way to weld. You did great making the patch panel out of 2 pieces. When you have a few minutes, watch Fitzee's Fabrications; he makes all his pieces from 2 pieces at a time, no matter how complex they are. He has a number for videos on how to fabricate patch panels. Thank you for sharing your work.

Nice work! That nuts with all of that dust.

You’re learning more and more with every task small or large. It’s good to see you moving forward CT. BTW, have a Very Wonderful Christmas 🎄

Ooh don't buy a new bit after all that work! Watch Fitzee fabrications,he's got just what you need for your panel repair requirements. You done good!

Mike makes it look easy. I’m glad you’re doing this first before I try on my Ghia. Good job 👍

It's not bad! Doing that kind of patchwork is not easy and it's nice to see the way your work is improving! Go on and don't give up! You'll get it right! I always enjoy watching your videos and seeing you working on those cars! By the way, there are a couple Brazilian channels named "Oficina Ribas" and "Paulão Funileiro", which are from body shops in which they restore and repair some old cars and hand craft sheetmetal parts with great quality! The videos are spoken in Portuguese and, besides all talking, in which the professionals give some explanations about the kind of work they're gonna show, they show themselves doing all reproductions, especially of those parts you can't find even as aftermarket items! I believe such scenes could help you a bit! Besides those, there are some nice American channels in which such parts are reproduced! I'm willing to see some more videos about the Dragon and the Beast!

Olá, meu amigo, você está melhorando sua modelagem de metal skills. Congratulations

10/10 for effort and giving it a good go, but I would just get the repair panel, just saying

Shriner and stretcher tool will be invaluable for this job. Also, no need to purchase a copper spoon. Just take a piece of cutoff copper tubing, slit it open and hammer it flat. Boom, custom copper welding spoon. Save some $$ and make it from scrap.

looks good and is also interesting, keep it up! As a tip: it would be even better if you had a little more knowledge of sheet metal working, cutting less, making better sheet metal with simple stretching and shrinking machines.

CT watch Bad Chad good ole Canadian boy like myself ...hevis a master at metal work....he uses coat hanger to fill in tiny holes. ..with welder ...man you did well tho

Good job dude! First I was like "what the fu*k this men is doing" but end of the video it looked pretty cool!

don't overthink , just enjoy fixing the Ghia. at the end of the project you'll have a good solid car

Looks pretty good to me. I'm not a body man though.

Nice work, I wish you numbered this series easy to binge watch

Nice work, man.... greetings from Porto Alegre, Brazil.

Nice job CT for your first time doing metal work it looks good 👍🏻

Not bad for a first time, when doing shapes like this make a paper or cardboard template then u have better size. Do the big piece first get it to shape then put your lip in. Can trace shape exactly to metal and cut it out. All in good time just keep at it. Great job love the videos.

Have you ever watched Fitzee's Fabrications ??

Shape a piece of hardwood or aluminum to that corner. Clamp in vice and bend the .020 around it.

I would say that for a first attempt you did a lot better than most. The next tool you need to add to your arsenal is a shrinker/stretcher, it will take you miles farther! You're on the right track for sure. I like your idea of using this for a practice patch. Fill it, grind it, play with it. If you are happy with the end result, keep it. Otherwise, like you said, start over or buy a patch panel. Good job so far though. Be safe, stay healthy and have a very Merry Christmas!

Should wear a welding hat lol haha. It's coming along nicely.

Great video I don’t know but would do it on cardboard then metal 👍👍

bravo !! jolie travail de bijouterie !!

For the first time it's not too bad I think. Before cutting any metal piece maybe you can use cardboard for the shape and curves.

Personally, I would use a shrinker/stretcher, after bending the flange. Just keep working the flange, 'till the curve is what you want. Eastwood has these tools for certain, and Probably Harbor Freight. I think you may have one already, but a panel flanger/punch is another great tool. It will bend an offset, allowing you to overlap patches to facilitate welding. Oh yes... and eleventeen pairs of the vice grip c clamps!

That part was a nightmare. Probably I would have given up earlier. Instead, I would have try getting a thin cardboard template of the right side of the rear fender to be "unrolled" on the metal sheet to use as reference for cutting and modeling... Anyway, nice job.

CT i love watching you work because you're always trying to learn some new skill. Also not afraid to try some new techniques to get it fixed.. Great work

The easier way is to take the new bit of curved sill you made and weld it at 90 degrees to a new flat piece of steel. Once welded you can then trim the flat piece of steel to form the wheel arch lip

Смотришь работу, и такое впечатление что мастер проводит кузовные работы с металлом первый раз в жизни. 🚙🤔🤠👍👉.

Wow, how far have you come since those early tries with Rusty. Well done and all the best 👍🏻

Hi CT I would just buy the new pice from karman ghia parts & restoration.

Ok, this video has definitely talked me in to buying a clean driver and just doing the bolt on’s.

Coming along nicely. Congratulations 👏

you almost got keep going you will get there

I think you should replace the complete rocker. The inner and outer. The dust shows it. They are dead.

" THERE IS...A LEVEL 0 NOW "

Excellent video CT :) also Cut & Butt usually done factory assembly plants by welders people or factory Robots arms also take lots practice makes perfect too ! Also I used had doing Cut & Butt welding but overcome also lots hard practice plus doing it too and takes lots fun efforts to do! But nobody see after fix up also weld grinding with little bondo filler and primer then paint up be done ! You do excellent work and looking nice !

Your doing the exterior body work and you should be concentrating on the interior. The floor should be your first priority. You definitely have to brace the body so you can get the proper gap. Once you have that done by measuring your door gaps, then you should install the doors to check the fit. Also be aware you have the body on the rotisorie and that is definitely bowing your car in the middle. I think you should consider this advice. I wish if it was possible I would like to be there. Good luck.

you should have bent it at 90 degree and then cut the flange as you did at first, and then bent it to shape and then welded it. Bruce from Australia.

Nice job CT ghia coming alone nice , keep up the good work sir !!

Sehr gute Präsentation. Ich habe auch einen Karmann Ghia Typ 14. Sehr schönes Auto. Good work!😉

I'd recommend watching a few of Halfass Kustoms videos. He does cut and butt in most of them. The secret is that, after tacking your patch in place, you only cut small sections at a time - and butt weld that small section (making sure to get the two edges meeting exactly level), before moving on to another section of the repair. Maybe start with this one -> ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-XeqjKQ-2xes.html

Glad to see another video - keep them coming! To help do it with cardboard first if needed copy the other side and invert it :)

Nice CT more and more you doing great stuff,. Always read to the combi

I simpely love your work.

Overlap the metals and cut through both metals in between the metal edges to make a perfect match fit, like it's done when laying vinyl or carpet flooring. And anvil for shaping metals with a hammer might be handy.

Draw the shape of the curve, then cut from edge of l metal to line and make cuts about one inch apart and bend each tab to form panel .

what you need to do is watch fzees fabrications it easy his way

Great deal; those nooks and crannies can be treated with rust converter a la Mike Fn. That prevents the thing for rusting again; at least in our lifetimes.

take Copper pipe ( water line )...smesh it Flat or curved as needed....cheap copper backing fir welding...i have copper blocks too i found ( salvage stuff i collect )...anything copper is useable for welding help.... think out of the Box for tools ...you can buy yeah...but you can get it cheaper too...all the Fancy Tools and gloves don't make you a Craftsman ..years of work get you there....and study others ( easy with internet now )...

Evil Rust, always very time consuming to deal with

Keep up the great work CT

I do not know if you tried this. But use cardboard box from Amazon to make your shapes before shaping metal or welding complex shapes on the car? Saves you time and stress with metal working. Cardboard is more flexible and you can a better visualize on how to shape the metal You need to fabric on the car.

All that stuff will come out during Painting too..

When I was a kid I worked in a mustang restoration shop and all their cars were dipped to remove ALL the rust and to prevent any internal rust from coming back. We would go as far as undoing factory welded panels. It's not hard, just labour intensive but well worth it in the end. If you don't do the dip trip your car will continue to rust. ☹️

Make a paper pattern of the hole to fill then cut the new metal to begin the patching process.

cut patch wider and roll corner and shrink to fit then cut off excess at side and weld in place

I know you want to learn on your own BUT it doesn't hert to watch some pro's doing it you can pick up a lot of tips, try some one like Fitzie he is a master, good luck...

Next time you do a patch, make a curved cardboard pattern on the car. Then transfer it to the flat steel. Should prevent a lot of the cut and butt pain. Also, I agree with other commenters. Better metal working tools would make the process less painful and more accurate.

Take the original piece you cut out, cover it with tape and make a template .. then you can lay the template down flat….should give you all the information you need to fabricate a new piece… you’ll have to Cut darts in the metal in order for it to bend around the edges.

Hi CT great job buddy, love Mike FN video to show you how it’s done. What a great bloke. Also have a look at Fitzees Fabrications channel for setting your weld settings mate

Nice Job, but think I would get a patch panel.

Fitzzee's Fabrications is a good reference if you want to do such repairs.

Hay C T you should watch Fitzee’s fabrications and see how it’s done He’ amazing

Draw the curve on a flat piece of steel that looks like this. ))

👍👍👍