This was a really fun car to restore. I’ve known three of the previous owners of this Ghia. It was first discovered on the side of a house out here in Tucson, Az.
Tear down
After initial intake, the tear down begins. We strip the car, bagging and tagging all the parts. We make a list of everything that needs to be replaced and what needs to be reconditioned or sourced. We document what metalwork needs to be done and how to approach it. Karman Ghias have very few sheet metal components available on the market so most of the metal repair will need to be fabricated by hand.
Once the car has been fully stripped and documented, we strip down all paint and body filler to reveal the true state of the metal underneath.
At this point the real work begins. Everett and his son, Little Everett, begin the process of removing dings and dents. Replacing sheet metal, and fabricating the patch panels. Many of the curves can only be replicated with an English wheel. Complex curves are difficult, but it is important get a complete match, any imperfections will show later in the reflections of the paint.
Once the bodywork has been completed. The metal is sealed with an epoxy primer.
After primer we go through a couple more sessions of sanding to prep for the color.
In this stage you can really see how important good metalwork is. The paint is so smooth it looks like glass and it will reveal any imperfections.
The pan has been fully prepped to install the body. We have built a special cart that allows us to mate the two parts without and risk of scratches or damage to the new paint. Once the two parts are joined, the real assembly work begins.
The correct chrome wheels wrapped in 1” white walls really improves the look of the car.
Engine rebuilt and reinstalled. It’s almost time for a test drive.
There are a lot of trim pieces on a Ghia. Piece by piece they are installed carefully. Bumpers are assembled and installed, and testing of the electrical and hydraulic systems are done.
