Chassis Preparation For 1971 Karmann Ghia Cabriolet with Pan-Off Restoration

Because we didn't really take any close-up images of the chassis, we're blowing all these up to "full width" (a theoretical 12 inches), so you can better see the detail.

The chassis is truly in remarkable condition, especially considering that the rockers needed so much work. We did nothing to the floor panels whatsoever. Of the four sections, three were original pieces in grand condition and the fourth was already replaced, and, unusually, it was done correctly.

We fitted it with new shocks all around, we did a complete "brake job" with new hoses, master cylinder, rear slaves and rebuilt calipers. The rear shocks are heavy-duty in anticipation of the heavy batteries we ended up not needing. We attended to the steering damper, bowden-tube ... and, well, just everything that was easier done without the body in the way! ...We didn't mess with the alignment, so just to be sure, it should be checked by someone.

Also note that the tires are clearly visible in all these images; they're in good condition and we just re-mounted them on the stock optional chrome rims we happened to have on hand - here, they're still mounted to the original rims the car came to us with.

BELOW: Here, and in all the images that follow, the chassis has already been prepared for mariage with the body. The perimeter seal is already in place and the white stuff you might see there a little of are glimpses of the caulking. Here you can also see the new front and rear shocks as well as the new steering damper. We have more detailed images of the brake system below but you can easily tell here how the front axle is clean and in good order and that even the paint on the axle beam is nice - this is true of the entire suspension. (The sharp-eyed will notice there's a 36hp based Okrasa engine visible on the left edge of this image.)

BELOW: A second shot from the front - just another angle on it. Here, the caulking spoken above can more easily be seen.

BELOW: Here you can see we painted the new (dual circuit) master cylinder since we don't like the unsighly rust they usually promptly develop.

REMAINING IMAGES BELOW: Of course, the electric motor seen fitted in the below images doesn't come with the car! If seeing it here confuses you, go read up on the history of this car on the car's main page (link above) - it was almost an electric Ghia!

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