Anyone who has worked on cars…especially older ones…has learned that one project often leads to another. This week I was reminded of that.
First, it was a simple project of replacing the seal between the tail light bulb holder and the body. With new seals in hand I expected a quick job and chance to look at the inside of the rear quarter panels. The good news is the area inside the rear fenders was clean and free of rust. However, on the driver’s side for some reason the ground wire was not in its normal location and had been modified to be held in place by one of the bulb holder mounting screws rather than attached to the bulb holder itself. I thought that will be easy, just change out the terminal ring type connector that had been install with a stock connector that attaches directly to the bulb holder. Well of course, the wire was not long enough so I need to splice in a short piece of wire. With all that done the bulbs, reflectors and inside of the tail light lens cleaned and everything is back in place.
 |
 |
Another example of projects multiplying was the decision to replace the glove box. Volkswagen used a fiber board type of material to make the glove box. With time that material begins to disintegrate. The bottom corner of the box had broken away and the trunk release handle which is attached to the inside of the glove box was about to come loose. Of course, you have to remove the windshield wiper motor and frame in order to get to the glove box…so another project to source and install new seals for the windshield wiper posts. With the wiper arms off, those might as well be cleaned up and painted.
 |
 |
There is a good aftermarket replacement for the glove box made out of plastic but…the late model Karmann Ghia has a fresh air system that means the aftermarket glove box will not fit without modification. Looking at the old glove box I realized the side and top need to be modified. Using a heat gun and applying the right pressure I was able to reshape the after market glove box. Then a few holes drilled for the trunk lid release handle and I am back in business.
 |
 |
Once I got the glove box out I noticed that the hinge for the glove box door was not attached properly. I had noticed the glove box door was not operating smoothly and now I know why. Further inspection I found that the hinge mechanism was “frozen.” I took out both hinges and worked them over with penetrating oil.
 |
With the freshly lubricated glove box doors hinges installed it was time to put the glove box door back in place. Oh yea…note to the file: with the glove box installed, NEVER remove the screws holding the glove box door hinges!
When I purchased the car the owner did not have the key for the glove box so I sourced a used latch with a key making this was the perfect time to replace the latch mechanism.
So let’s see…replace the glove box created four additional projects. No wonder it takes so long to do simple projects!
