German Look Ghia - The Basilari 306R
 

Greetings all.. I plan on using this thread to document my German Look low light ghia.

I have a thread on ShopTalk and the Samba but the GL forums seem to be more euro-centric and I've had some requests to document the build here, so here we go. I'll try to post different photos here, etc., (some of which haven't been made public).

The build goals are:

1. A low light Karmann Ghia.
2. New/modern chassis with all the German Look pieces. ;)
   • Mendeola Front and Rear suspension
   • Mendeola Kafer bar system
   • Disc brakes all the way around
3. Subaru power and drive train:
   • 6-cylinder EZ30R
   • 5-speed transaxle with Torsen LSD

Last summer, I picked up a low light in this condition:

The car, loading for California:
http://www.basilari.com/wp-content/u...0440794374.jpg

The boot/trunk area:
http://www.basilari.com/wp-content/u...0441440245.jpg

The rear needs major work but the nose is very good condition. There are the normal Ghia problems but it all appears to be very workable. Given what I paid for the car, it will all work out in the end.

Loaded (you can see the hack job rear end here):
http://www.basilari.com/wp-content/u...0440919198.jpg

I had found an EZ30R motor on eBay and needed to get it shipped to the shop. Here's how the full motor looked on arrival:

http://www.basilari.com/wp-content/u...0442268481.jpg

EZ30R markings:
http://www.basilari.com/wp-content/u...0444402229.jpg
http://www.basilari.com/wp-content/u...0444493109.jpg


We then sent it to Outfront Motorsports to get prepped for the Ghia. The guys at Outfront took off the unnecessary items(AC compressor, power steering, etc), flipped the intake, added a linkage based throttle body (from a Ford 4.0L), rebracketed the alternator and provided headers. They offer more services but this is all we needed at this point.

This is motor after the Outfront work (sorry it's a bit blurry):
http://www.basilari.com/wp-content/u...0442672112.jpg

Closeup of the throttle body:
http://www.basilari.com/wp-content/u...0444198669.jpg

Variable Cam sensor locations:
http://www.basilari.com/wp-content/u...0444707871.jpg

Clutch installed (it originally came as an automatic). You can also just make out the ends of the headers:
http://www.basilari.com/wp-content/u...127-121632.jpg

Better shot of the six cylinder headers:
http://www.basilari.com/wp-content/u...0444859930.jpg

Will post some pics of the chassis work later..

Look Ghia - The Basilari 306R
 

I gotta say I am looking forward to watching this one develop :cool::cool::cool:

Yep, keep it coming.
You won't get all the flack you cop on the samba!

Amen to that!!

Early chassis work..
 

Pics of the chassis work:
http://www.basilari.com/wp-content/u...9738368783.jpg

Welding in frame rails for the Audi TT seats:
http://www.basilari.com/wp-content/u...120-184011.jpg

Test fitting of the Mendeola front end:
http://www.basilari.com/wp-content/u...0535291614.jpg

Does this qualify as GL?
 

Does this mock up qualify as a German Look Ghia?

http://www.basilari.com/wp-content/u...lit-wheels.png
:)

Awesome build man. Got room for 2 turbos off the ends of those manifolds? Also where did you source the manifolds from?

They came from the guys at Outfront Motorsports. John the owner builds Subaru engines for desert racing and has these headers for the EZ30 engine. My builder, Kevin is building the rest of the exhaust system and I sent him some Porsche black chrome dual oval tips to put it over the top.

The car probably has room for turbos but I think this motor may do well with a supercharger. No time soon though, as it's already going to be a beast naturally aspirated with the AVCS!

My opinion (and it is just that) is that it's too low, notch it up 50mm so that the wheels fill the arches and it'd be sweet :)

Looks pretty good going, that motor should make it shift

Hi

In another thread you posted a picture of a rear mounted radiator. Is that what your going to use?

Steve

Alky, yes - I agree it's way too low in the mock up. This is just my artist's rendition. Your suggestion will be very close to reality.

Steve, yes - still plan on going that route.

roll cage work..
 

We decided to cage the car for additional safety. Here are some photos:

http://www.basilari.com/wp-content/u...4333895656.jpg

Bought some Audi TT seats off eBay. Seat in the car with the cage:
http://www.basilari.com/wp-content/u...042012-118.jpg

Just for you Steve:
http://www.basilari.com/wp-content/u...1835375200.jpg

You have fitted the fans on the wrong side of the radiator... if you want to use aero of negative static pressure over the engine lid to pull air through that direction. Fans work more efficiently as a pull design and shrouding like that is supposed to be on the back side to aid fan efficiency. I also can't see yet how you plan to get ducting up to the radiator from underneath.
Love the rest of the build, I just can't see any logic in chasing the rear mounted radiator...

The goal is to take advantage of the natural higher air pressure from the transaxle side of the radiator. Ducting may or may not be necessary because of this differential although we'll be helping the flow with deflectors. We are not *pulling* air in from the engine lid (the vents of which we may relocate), but rather pushing air out.

To your point though, the fans are on the transaxle side because of space constraints on the engine side (lid hinges). We will be testing this setup thoroughly with manometers, yarn, etc.

If it doesn't work, we can always move up front. :)

Maybe I wasn't clear, I understand which direction you want air to go, I meant pull air out at the back through your decklid. Your fans will lose efficiency from being 'pushers' but I'm more concerned with you blocking flow with that shroud..

Do you have target date for getting it on the road? Are you doing a test build before stripping it back down for detailing etc etc?

The car should be rolling by the end of next month. Yes, the aerodynamics will be worked out/tested and solidified before the body work begins.

For the German Look community only:

Starter system:
http://www.basilari.com/wp-content/u...2173055935.jpg

http://www.basilari.com/wp-content/u...2172991386.jpg

Pedals (not such a big deal):
http://www.basilari.com/wp-content/u...2171089478.jpg

Awesome project! very nicely done! Are you using the subarugears conversion for the transmission?

Yes - Subaru Gears all the way. Todd installed a Torsen LSD as well. Here's a cleaner, earlier view of the transaxle and custom mount:

http://www.basilari.com/wp-content/u...9738199267.jpg

Chassis on the ground (at Hot VW's Drag Days):
----
http://www.basilari.com/wp-content/u...172013-058.jpg
----
http://www.basilari.com/wp-content/u...172013-057.jpg
----
http://www.basilari.com/wp-content/u...172013-048.jpg

How are we coming along?

Jason

The project is still underway. I think I made a tactical error by letting Kevin take the chassis to the show. He got too many orders and got too busy to finish my car!! ;)

It's funny how often that knife edge shows up in life. Hope he can get back on it soon.

Jason

I've been through this a few times and seen this way too many times. They obviously do good work, but honestly no one has the right to jump in front of your project for any reason (unless you want to delay the project?). They're not doing you any favors and all that time spent waiting doesn't change the bill you get in the end.

You pay them money==>they do a service for you

Period. No hard feelings, nothing more, nothing less.

My bus sat in a paint shop for way, way too long. The only way things got done the last nine months was showing up each week at different times unannounced.

Nor does it account for all the free marketing/advertising value by having a totally bad ass chassis setting on the shop floor.

These are good points. I'll ping Kevin to see what the plan is.. I'm getting too much email and questions from people following this build. I know Kevin has been sick recently, but it seems like he's back in the saddle so maybe we'll see some positive progress again..

I did a 1918 Gendron tricycle for my little one this past spring. I took all the rusty bits to a powder coating shop to have them redone. A week went by and nothing happened. Couldn't find the paint color I wanted, blah, blah. Oh really, couldn't even prep the parts then?

I didn't argue, didn't complain, I just picked up my stuff in a box and walked out.

Found another shop, had the color in stock, took a little over a week to get done. Taking on more work than you can handle helps no one.

Keith,

I am sorry you feel this way. In everything in life there are two sides to every story. I thought we had been comunicating pretty good on this project. As far as cost at the end of the job, it does get effected when one of our customers helps us out in one way or another. As far as we are conserned, we end up giving more into the job then the customer ends up paying for. I can tell you already that we have given freebee's on this job. Also what Keith has not added to this is that we have had set backs on both his and our part, waiting for parts that either he or we are supplying. So before people get involved only knowning half the story, please find out all the facts.

My .02 cents

You also run a business, and it's tricky to only have one client so to speak. Most businesses like yours have to make sure that there's another vine to swing to or you find yourself hanging on one vine that will wither with time. Tough spot to be in, communication is usually the key to making things clear for everyone.

That being said, it seems like you really need to give a project of this magnitude and exposure the time it needs to keep momentum if it's possible. If it didn't have so much exposure people wouldn't be talking about it so much and wondering what happened to it, hopefully all the talking will net you some great client leads though.

Looking good still, can't wait to see how this thing turns out.

Jason

I don't quite follow. So you're saying the project SHOULD be delayed? It really doesn't sound like you are doing him any favors at all.

It's your reputation Chief, not his. Please enlighten us on all of the facts or Man-up and just finish the car already.

I'm clipping all the stuff below out because it's not constructive for the project moving forward and not related to things I've said. Other folk have their opinions and I don't want to muddy the waters.

As we all know, there are quite a few people following this build and as we discussed over the phone yesterday, I didn't have any status information to feed the wolves. My only "perceived" negative comment (a reply) was that there is some benefit to having my car sit in your shop to be drooled over by potential customers who turn into real customers that go to the front of the line. Period, full stop. Everything else *I* have said has been in complete understanding and support of you first as a fellow entrepreneur and second as a mechanically talented car artist.

At the end of the day I'm just trying to keep the project moving. I've backed a dump truck load of cash into this and I have the second half of the work (not related to your work) yet to start. So the pressure has been building on this side as people find out about the project, offer services, etc.

Yesterday on the phone, we discussed a plan for better communication going forward and a completed project timeline that we both find acceptable. I'm happy that we've come to concrete dates. We had great positive progress from the time the project started until about 2 months ago. We'll be good if we can get back to the previous level of progress. And, from what you told me yesterday that should be very doable as we don't have too much more work to go.

cut out the bull crap and get this thing done. we all wanna see this thing done and driving. cars dont build themselves. much support/respect from this end and hoping the very best with moving fwd on this amazing project.

Soooo, anything to update??

Yes - body on chassis progress! Will post a few pics later today (traveling now).

http://images.thesamba.com/vw/gallery/pix/1074118.jpg
http://images.thesamba.com/vw/gallery/pix/1074116.jpg
http://images.thesamba.com/vw/gallery/pix/1074117.jpg

here you go

Looking pretty sweet!

Jason

Awesome! What wheels are on that?

Body...check
Brakes/tires...check
Drivers' seat...check
Engine/trans...check

Just need an air filter then time for a little spin around the block??? :)

Looking good.