Classic Alfa Forums

I've had the hatch belonging to Lou with me for a little while now needing the usual corners repairing, so it's ready to be used I thought it about time to get it done.
It had been previously repaired which wasn't really good enough as there was no recess for the window seal to sit in so a fresh start was needed.
The end result is this...
Sounds and looks simple?
The reality was with the complex creases and angles that repair took me about 4 or 5 hours, mainly time spent making a jig to create the folds....
This is how it was done..

Started off with a 4" square piece of mild steel, section needed for the top face marked off and folded, that's the easy step..
You'll notice in the next picture the folded section which is sat on the base of the jig I made, just some 2mm steel welded together.
Next step is to use another flat section of the steel to trap the angle up against the welded top edge, like this..
Then fold the piece forward making sure of a flat crisp edge, keep the piece tight in the jig. Could have drilled the halves and pinned it but I'm confident enough now to not have to, especially on bodywork thickness steel like this .9mm stuff.
You'll end up with this..

Next step is the tricky bit, you need to create the fold which will be the width of the channel where the seal will fit before it angles down to the flange.
This part of the jig was 2 pieces of 2mm steel welded together at the correct distance to match the width needed. Confession, first attempt was about 1mm too small so it didn't quite look right so the jig needed cutting apart and remaking, thankfully carefully measuring meant 2nd time success!
This is the top of the jig with the step visible, it sits the other way up to be used.
When clamped down the jig looks like this, ready for the return to be folded allowing for the seal channel width..

Start to bring the piece up to an almost right angle, doesn't need to be a full 90 deg bend but more than this demo pic shows..
You then have to make the final fold for the flange joint, this I did by clamping between two flats rather than making anything fancy..
Which gives you this.
So a fairly complex piece with regards to the tight folds can be made with a little effort and imagination.
Other side won't take half as long as most of the time spent was making the jig, might hang onto the pieces rather than chop them up and reuse incase I get anymore to do!

Superb Job Kev your efforts are appreciated

Nice looking repair kev

Hi Kev

as its such a common problem Kev I suspect there would be a market for that as a repair panel.
I'd make a few up and flog them on fleabay.

Now you have done all the hardwork fabricating the jigs you deserve to get some benefits from it.

How much is a solid S3 hatch worth these days?

Cracking job Kev. Hope the bellies getting better?

rsfruitbat

Super job Kev - literally just found these pics from 10yrs ago.

Other side done today, inner section needed a bigger repair which meant recreating the square etc. All the same ideas.

Superb quality work as always Kev

Belly healing nicely thanks Ade, scabbed over nicely and predictably itchy, I won't offend by showing a picture!

I could make more repair sections if anyone wants them, for a donation to the forum upkeep to keep us online..

viewtopic.php?f=56&t=2243

Say £20 for a pair of repairs + £5 for UK postage.

I’d say that’s an absolute Flippin bargain Kev. £20 for quality Hand made repair sections that You know Will actually Fit. I Know id defo order a pair but my hatch Is now in brill condition. Knock a pair up and take a picture And post in parts for sale.

I'll do that Lou, see if anyone wants any..

This pic shows the superb quality of the fit

Seriously, you have some skills there Kev

That's brilliant . As Darth Vader would say . Impressive, most impressive