1972 Volkswagen Karmann Ghia
Restoration Of My Daily Driver Since 2014
03.20.2023
Say Hello to Daisy
17 Mile Drive
In this leisurely blog I will share personal insights, lessons learned over the years, the ups and downs of the restoration process, and anecdotes about my beloved car, Daisy.
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Why I Settled On A Karmann Ghia
I love the flow of curvature, and I find curved auto designs aesthetically pleasing because it showcase elegance with smooth rendered lines and shapes. Not only does it have sex appeal, but its low drag coefficient is more aerodynamically efficient and result in better overall performance. As far as I can see, this style of design is mainly found in vintage, classic, and luxury sport cars. Some of my favorites are Porsche 550 Spyder, Jaguar C-Type, Shelby Cobra, Mercedes-Benz 300SL, Aston Martin DBR1, Tesla Roadster, Ford GT, Ferrari, and Lamborghini.
Lucky for me, I learned about the air-cooled Volkswagen Karmann Ghia through my brother-in-law, Ross, and I found one in Lodi, California, and within budget. Although I initially wanted a 1969 with smaller taillights and turn signals, I ended up with a 1972.
Taking On A New Challenge
Other than routine oil changes, one oil pan replacement, and playing with Plasti Dip paint, I had no real auto restoration experience, but I was ready and willing to take on a this project.
With the help of tremendous research, technical studies, and resources such as the Volkswagen Service Manual, VW Beetle & Karmann Ghia Haynes Repair Manual, and an amazing community of air-cooled content creators like vwdarrin, theEZGZ, Greg’s Garage, and TheSamba, I was able to learn, understand, and successfully completed the majority of restoration work and upgrades myself.
Restoring a vehicle as a daily driver is not easy, and I would not recommend it, especially if it’s your first restoration. Due to my tight budget and living circumstances, I could not afford a second vehicle. Therefore, I had to be very methodical and strategic with each working session to ensure that I could reasonably accomplish what needed to be done.
U.S. Route 199
Out Of Gas
My unexpected restoration work started a few days after I got her. While driving back from work she ran out of gas on a major freeway, after sunset, and during commute hours. I was in the middle lane when she started to lose power, and right away I signaled and pulled over just in time before I she went dead. My brother-in-law, Jason, came to the rescue with a couple gallon of gas.
The next morning I found there was a small gas leak coming from the electronic fuel pump, and with further inspection the old braided gas lines needed to be replaced due to cracks. Of course, I had to fix this issue right away.
No wonder why she was so gassy on our way back to the city!
I found an exact replacement fuel pump at a nearby auto shop, Daisy came with some usable fuel hoses, and couple of hours later I was back on the road.
I eventually upgraded to an EMPI 41-2604 Inline Fuel Pump that came with a metal-fuel filter. It outputs between 2-4PSI and has been performing well with the Solex German 34 PICT-3 carburetor. I used a new German fuel-tank filter (111209147A) and added a shut off valve to the fuel tank for when I need to work on the fuel system. The streamlined layout allows for more efficient fuel maintenance and engine repairs.
My ideal setup involves using high-quality AN fittings, metal braided hose, and a fuel pressure regulator, but it’s not necessary until I have funds for a full engine upgrade.
You must have tenacity and stamina to push through all the frustrations that will come with the territory in order to get the job done.
Self Reliance
I strive be self-sufficient wherever possible, and when I make a decision to work on a project, I go all in. My goal is to comprehend every aspect of the project to improve efficiency and effectiveness. I’m not afraid to get down and dirty. I want to become fully immersed in my project, visualize my approach, create a strategic plan of action using available tools, and executing the process to the best of my ability. Nothing will ever be perfect for someone like myself, but I can always be proud of my hard work.
Assuming there’s no major issue, I have full confidence I can solve any problem if Daisy breaks down on the road. I have replaced almost every component in the car, and I have an in-depth understanding of her functions, as it’s been years in the work. I know her inside out, except for the inner workings of the transmission and the main engine block, which I have not yet taken apart.
Cars, like other man-made objects, are simply made up of components that work together to perform a specific function. The same applies to learning and selecting components to build my PowerPC, repairing my Apple iPhone and laptops, conducting household maintenance and repairs, creating a professional photo studio, and understanding software features and components required to create specific effects in digital photography, digital art painting and drawing, or 3D modeling and animation. It’s also similar to cooking in the kitchen, where various spices and sauces are used for specific cuisine.
I enjoy knowing I can rely on my brain power and use my technical skills to learn and problem solve. I have thoroughly enjoyed working on Daisy, even though she can drive me crazy at times. Above all, I love taking her on the road.
I took my 1972 Karmann Ghia exterior down to bare metal because she had paint bubbles, and I was curious on the condition of the metal. I did the body work, and then PPG primed and sealed it. I initial hand painted the car but that took too long. Daisy is coated with Golden Heavy Body Artist Acrylics - Iridescent Silver (Fine) mixed with GAC 200. More details in future blog posts.
I dedicate significant time to learning, researching, and comprehending how things work in order to accomplish my goals, rather than dismissing them as being overly complex based on other’s opinions.
Safety, Technical Abilities, and Confidence
When working with tools and heavy machinery, safety is your number one priority. Never be afraid or ashamed to ask for help if you’re unsure of what you’re doing. Team effort in any work environment is essential. ‘WE’ is always better than ‘I’. If anyone tells you otherwise, you’re working with the wrong people. Don’t ever be lazy about safety.
Confidence in your technical abilities goes a long way, and if you don’t have it you’re better off getting help when you need it. But never give up on yourself. “Practice makes perfect” is my motto. All it takes to be skillful in anything is the will, time, patience in your own learning process, and being appreciative your own personal growth as you become more experience in the work you choose to do.