Classic Alfa Forums

Would he like it ? If yes pm me your address again.

I hope it doesn't pea in , now you've fixed the leeks.

Haven't posted much lately but have been busy, both sills are now on but that's an easy way of summarising progress.
Of course once the old sills are cut away the repairs start to make a sill lip to actually weld to..
Inner sill and floor needed sections making up
Outriggers needed some work too.

Wing bottom needed remaking where it had dissolved along with the sill end

Passenger wing needed the same bottom repair but also up around the arch there was some scabs that meant new metal making up and letting in.

With the sills in place and lined up the hateful task of cleaning off the underfloor old sealant, rubberised underneath the bitumen that had been sprayed over it began.
This task is probably the single worst thing to do. Not helped by the mini heatwave we're having.
Hot air gun and wallpaper scraper worked well with little chance of damage but was slow and tended to make you a little warm.
Knotted wheel was effective but they're a nasty thing to use and make a huge mess with flinging stuff all over the place.
I used an air chisel for most of it, peeling the lot off in long strips. Still not a perfect solution as care is needed not to snag and make a hole in things!
Took me almost 3 days to get it all off

Finally got it all cleaned up this Wednesday so got some etch on it all, apart from the very rear of the back inner arches as that will need repairs which can't be done whilst on the tilter.
Seam sealed all the welds then so it should be dry enough to stonechip it all tomorrow.
I've had some 2k straight colour matched up to go over the stonechip rather than just paint it black. Topside will be basecoat & lacquer but easier to do the floor in a single phase.

I've also been busy cleaning all the suspension bits that didn't go to the powder coaters, electrolysis rust removal technique then red oxide.
Had some jet black 2k paint to hand so sprayed them all, 25 items in all.

Finally a word of warning, to myself as I seem to keep forgetting.
Knotted wheels in angle grinders are a nasty tool that like eating flesh, hands and knees are a favourite.
Had it snag on my spray suit that was trying to keep me clean, dug through and wrapped in my shirt.. not pretty..

Not that pretty before the damage either

Every time I get one of those on the grinder I think do I really want to do this!

So much done there Kev.
Stirling effort, as usual.
Well done.

Close call that Kev . Let that be a lesson to us all. Get well soon

Yes I have some light scars from using an angle grinder with a wire brush after it snagged on something. could have been much worse as I was under the Sprint in a confined space, not having a welder powerful enough to make a rotating frame. Scared me so much that I haven't been under the car with anything bigger than a dremel since.
As for the work on the Lancia, you are an inspiration to us all, Kev.

Yes, one of those stupid things that could have gone so wrong, could have been so much worse it isn't funny. I blame myself, I've down it to both hands and at least one knee so chastise myself every time I use it one handed....
Until I thought I'd use a hoover to suck up the mud dust whilst cleaning it out, leaving one hand for each implement, snag the wheel arch lip which rips the grinder out of your hand and before you can react its wrapped around your shirt and you're trying to switch the thing off before it burns out, which would have been worse if it'd caught fire!

Been up this afternoon mainly to apply the stoneguard, which is so much easier to apply with being able to rotate the car to both sides at 90degs and laying flat, no excuses for any missed bits now. Front half was some grey I had left over, I promise it all got coated!

Looks great . Bloomin good job esp doing 3 days of scraping off the underside. Enjoying following the thread,

so keep posting please..

Good job the knotted wheel didn't get you any lower!
Could have been a quick vasectomy.

Wear a cricket box in future!

alfadave wrote: ↑

Mon Aug 17, 2020 9:46 pm

Good job the knotted wheel didn't get you any lower!
Could have been a quick vasectomy.

Wear a cricket box in future!

that could indeed have been nasty

Vasectomy ?

More like Eunoch

A week off work so had hoped to get more done to the Y10 but I've gt other stuff done so all works out.
Was gonna g tomorrow morning to paint the underside but went this afternoon instead.
The colour was matched by the paint suppliers in a solid straight colour for ease of application rather than the correct colour which is only available in basecoat & lacquer, pretty pleased with the match they came up with though. As it's just for the underfloor it'll be fine, rest of the car and wheel arches will be done in the correct stuff.
After that I hung up the back axle and painted it in the jet black 2k paint like the rest.
Actually starting to get a few things done ready for the refit, but a fair bit of bodywork to go first.

Car back on axle stands now so work on the rear bumper mount area started today.
I couldn't do it whilst on the tilter as the car was hanging off the brackets restricting access!
Just a small hole on the outer quarter panel with a scab behind the light fitting... How bad could it be? Knotted wheel had a dig at the scab with predictable results..
Outer panel will need a new bit making so why not cut off plenty to allow a good view inside..
Light in the wheel arch makes new paint look blue with the mobile phone camera, its not that much of a miss match, honest!

Bumper bracket needed removing to have a better look behind it as there appeared to be a bit of rust..

Bumper bracket off and still a layer or two of rust.. Like a game of pass the parcel another layer with rust still behind..
So down to the last layer and yes that too had rust, which meant I finally found solid steel but ended up with some fresh air too!
Brought the bumper bracket home to be electrolysis rust removed so it can be rescued as it is pretty much solid and once treated and painted it will last another 20 years, I hope..

Superb work as always Kev

It will be another rare car saved once you’ve finished it . I like that colour.

Amazing work as always kev

Cheers guys

Carried on with the repairs today, first task to repair layer 1, the inner reinforcer that ties in the corner.
Then to box in the inner arch to floor.
Then the bumper bracket back on.
Soaked it well and truly in red oxide so it ran in all the crevises.
I'll make a new outer quarter repair panel next time along with a piece to box in the inner arch.

Took the engine and gearbox apart to have a look at the clutch whilst it's all out, was gonna fit a new clutch if it looks anywhere near worn but as they are cheap as chips I'll just fit one anyway, only 170mm diameter so a tiny little thing!

Painted a few bits black, seam sealed the repairs then had an early finish. Must keep at it though, darker evenings are only going to be getting colder too

Always planned on taking the front windscreen out as there was a few places of heavy rust, there was a bit of a bullet hole damage which would probably scrape through an mot so I bought a removal tool in the hope that it would be able to be removed without further damage, but if it did break then at least that got the doubts over test worthiness out of the way..
Of course it cracked in many, many more places

At least it wasn't a perfect 'screen I guess..

The rust revealed was predictably no better than I thought, is it ever?

I'll start those repairs another time.

This afternoons task was to crack on with the rear quarter panel repairs.

First job, although not a quick job was to make the repair section for the outer panel so that it would determine where the inner repair piece would go.
It appears to be fairly flat in profile but it does actually curve along its length, more so nearer the light fitting. Cardboard templates were made before cutting it all apart...
I'd already got some folded steel that was intended for the sill repairs, 6" deep so perfect for this task.
The folds that go behind the back panel are mostly covered by the rear light but not simple folds, both at differing angles with the section between them curved.
Keeping the bottom edge the right distance down so it fits as it should where the bumper goes was again preempted by masking tape and measurements on the car, you're dealing with something in 3D when it's in fresh air, up/down and in/out all need to be correct. It helped a bit with the rear light also giving me a guide to keep the shape right.
After a good few hours of work, jogging the edges and using clico fasteners for repeated accurate offering up I was happy with fitment.

With the outer panel in the right place the task was to make the inner section, now I knew where the outer panel would be a much easier task!
A joining section then needed to be fixed to the outer panel, it being curved it was easier to fix a straight folded section and cut it curved to suit the outer. Spot welded for neatness and speed, love my spot welder
I'll attach it all together next time, I wanted to paint the inner repairs first making sure all areas got plenty of coverage.

Believe it or not that was an 8 hour day, fiddly work making repairs that need to line up rather than just throwing stuff together and hoping, minimal filling will be needed too.

Didn't realise the Y10 need so much work Kev.
Great progress on the little beasty.

Kegsti66 wrote: ↑

Wed Sep 09, 2020 10:50 pm

Didn't realise the Y10 need so much work Kev.
Great progress on the little beasty.

Neither did I mate