Classic Alfa Forums

Hatchback has some rust, mostly on the inside face but curiously at the top edge, bottom lip looks in great shape. Must have been an issue with the window seal or something.
I didn't fancy breaking the glass as it's a bonded in one on this car so the local windscreen guys took it out for me without drama, a bargain for £20 really considering the hassle of finding another.

Rot, as usual, didn't look any better once all stripped down!

Had a few days mulling over the best way to deal with it all, outside face wasn't much more than the flange and a little of the outer face.
Worse though was the rust on the inner face which is all visible once done as they have no plastic cover so needs to look half decent.
Problem is that although the surface looked bad the underside of that surface was equally rusted. So it came down to either having it dipped and hoping something came back, but that would strip all the sealant that's in good order plus any paint from the inside.
I could have it blasted but that wouldn't clean the underside face.
I considered cutting most if not all of the outer skin off so it could be blasted from the inside but that brings it's own challenges and could make more work.

The plan I came up with was to repair the outer skin then cut off the whole section of the rusted inner face so I can put the pieces in the electrolysis tank which is much less harsh than blasting so I've more chance of something being useable..

Outer skin cut out and now you can see the rust inside...
Repair piece welded in.


Once the outer skin was stable then it was just a case of cutting all the rusty piece in one lump with care taken to be able to align it easy to refit but also to be able to weld and grind it back..

Other side was the same process but didn't have to go so far around the corner. But just a little bit which made getting the start of the corner tricky. No less rust on the inside though..
Two pieces brought home, welded a few small holes from behind so fingers crossed it doesn't end up like Swiss cheese as there's a lot of detail that's needed..

Hi Kev
Do you cut stuff out with a Dremel as I can't see overcuts and you seem to be able to get right into the corners????
Rsfruitbat

Mostly an electric angle grinder with a 1mm slitting disc in bit for corners I trim it out with an air powered hacksaw.
Also have a smaller air powered grinder with thin discs in so have some options.

Parts have cleaned up nicely today, only created a few more pin holes so at least it didn't fall apart!


Cleaned and painted a few more bits too, despite protestations that it wouldn't be a fussy build... Well, the rear brake drums did look scabby

Pieces cut from the inner face of the rear hatch cleaned up nicely at the weekend so today I got chance to weld them back in, taking care with alignment as the long oblong slot each end holds the fittings for the electrical connections with pins, not unlike the S3 sud hatch.
I've been meaning to strip the wiring loom out from the engine bay for a while but wanted to label it up better, pencil on masking tape always fades so a better solution was needed.
A half held label printer is the answer. Can't think why I haven't used one before, prints out little labels on self adhesive vinyl strips which loop around perfect, and won't fade!

Engine bay now ready to be prepped for paint, thankfully taking the last few items out didn't reveal anymore work..

Amazing how a simple thing like emptying the bay makes it seem like it's further along all of a sudden, seemed like I wasn't making much progress but now seems very close to the primer stage..

One more step done today that I've been putting off as a real PITA job, the front inners wings needed the rubberised underseal taking off back to bare steel.
Thankfully nothing of note under it all, nothing to get the welder out for anyway.
Etch primed it all including the previous repairs to the rear quarters and bumper mounts then a good dose of the stoneguard which I'll leave for a few days to go off now.
Really close now to finish off the repairs and get ready for primer

What will you do with it when its done?

After all the work done Dave I think I will be keeping it, it's not really worth half what I have put into it money wise but it'll be a nice little car for shows etc.
The other Y10 will get more regular use.
This one though is about £100 a year to insure and less than that for 6 months tax so hardly a big expense, and it doesn't take a lot of room up!

Now I've gone to town and replaced everything, clutch, brakes, shocks etc and all parts refurbed it should be right for a few years yet.

Bit of an update.
A few guys wondered if I'd been busy, I have made good progress and have reached the point where I wanted to be at now.

Hatch repairs went well enough, filler shaped to match the window.


Car all straightened out and primed..

Great work as always Kev

Choice then was what to do with the rear panel and hatch which should have been in satin black originally.
Conversations with my paint rep and great advice as always from Keith sort of gave me an inkling of which way to go. Using different clearcoat to make the rear bits satin but still lacquered sounded interesting but overly complicated for my first time at properly using basecoat and clear, apart from rattle can jobs.

Used an old section of sill to have a look at what it would turn out like With that settled in my mind and a plan laid for the 3 stage painting it went OK, apart from running out of gas at the mid stage putting the blue basecoat on... That's another story... Runs sorted once back from Louth for more gas..

Once the dust was flatted out and polished up I'm happy enough with it, marks in the clear are just what I have to accept with the poor spraying conditions.

Repairs around the grilles blended in OK, wheel arches blown in too.

Long process of putting back together can take it's time now, given myself until end of Feb so shouldn't be a problem.

Great stuff Kev, you have been busy, as usual.
Will look great when it is all back together.

It almost looks like you have done this before. Good effort esp while a lot of people are feeling rather down.

Now the paint is on I can relax a bit more, getting stuff ready to be refitted now although a lot of stuff is ready now.
One thing that needs to go back on first is the fuel tank and that needed some new straps making.
Some strips cut from 1.6mm steel, folded to size with washers welded to the fixings for reinforcement and it should do the job.
I'll give it a final clean up tomorrow and paint with hammerite, should be good for another 20+ years then.
Also got a few bits to clean and prep, steering rack for one which will get a clean up plus new gators and track rod ends. As it's a manual rack a good internal greasing will be beneficial too!

Autoglass came and fitted the new 'screen as promised, rear hatch glass fitted too.
Time to start building stuff up.
Fuel tank straps got a strip of neoprene glued to the painted side that sits against the tank s it doesn't chafe the paint and start rusting.
Axle was pretty much ready for fitting having been built up a while ago. Still took ages to clean and sort all the bits and pieces such as bumpstops and spring plates that needed painting.
New shocks etc and looking complete under there.

Onto the front end and the engine bay started to come together with all the refurbished bits going on.
A few engine mounts deserved to be cleaned and painted before going in to keep it looking tidy.
Engine and gearbox went in without much drama.
New front struts got built up with all the refurbished parts, ready for fitting.
Front suspension and brakes all bolted up, new bushes etc in all parts.

The suspension rods look stronger and more durable than the Sud fabricated types.
I presume they just needed painting/ re bushing.
From a different era I suppose?

More progress this week as a rare few days off work between Christmas and New Year allowed me to get cracking, be nice to see it all done by the end of the week.
Dash needed some repairs around some known vulnerable areas.
All suspension finished off, break lines run and bled, engine all plumbed up and running a treat.
All glass now in, doors aligned, hatch back on, bonnet and wings etc.
I fitted an aerial as the car has never had a radio fitted but had the hole in the roof, a dab/din one will allow a choice of head units.
Just the interior to finish off now, carpets, seats, roof lining etc.
Another one nearly saved

Stunning work as always Kev

Fantastic work. Impressed with the rate you do it at as well. Keep safe.

Is this Y10 now completed?

Pretty much finished, still got to get the number plates made up then off for an MoT.

Realised I've not updated the Y10 progress for a while, happy to report it is all done, there wasn't any last minute drama or anything.
Car passed the mot without issue.

Did a good few miles around the local area, car is great fun with only 45bhp so the twisties have to driven in the "maintain momentum" style
Quite a roly poly ride too, but better than my other Y10 as this one has new shocks and suspension bushes.
Love the colour if I do say so myself, really suits it, glad I also did the hatch in a gloss rather than matt finish.

As mentioned, I have another Y10, the GTie that I have had for a while, well it had a little while with Richard but is back with me now, so what do I do with this car?
I recently also got hold of a Lancia Dedra turbo, a car I loved when we had one years ago as a daily driver when the kids were small.
So the decision was made that as this car is fully sorted and an easy sell it would go. What price to ask though was another matter. The market isn't huge for the Y10 but surely the condition now would appeal.
Both Rob and myself are fans of the TV show Bangers and Cash filmed at Mathewsons auctions near Pickering, North Yorkshire so I thought it'd be a great car for them to sell. I went to one of their auctions in 2019, when we were still able to be on groups, and it was a great place with really friendly staff.
Spoke to them and they agreed they'd give it a go.
So a few weeks ago Rob followed me up therein his Suzuki and we left the little gem with them.
Was about 110 miles from our house to their place and the car ran faultlessly, idles perfect and no nasty noises, smells or leaks. Sits happily in trafic, really is a great little thing. Sort of regretted selling it but the decision was made.
We got to meet Derek the boss man and Paul, his Son who was busy running the Pickering warehouse where most cars are stored. A great day out.

https://www.mathewsons.co.uk/

Car available to view, or bid! on the above link.
They sell the first 100 lots on the Friday night so being lot 64 it will be around 7-30 to 8pm going through I'd guess. All can be watched live on the link on their website.

Made this simple devise, thought it worth sharing although I can't claim it's my idea!
A cylinder head is a funny thing to work on, damn things want to roll around and slide about while you're trying to work on them which risks damaging them.
Saw this somewhere so knocked it up from a few lengths of soft pine wood.


Just simply criss-crossed and screwed together. Leaving the ends squared off helps it sit stable and resist sliding.

The head can then be positioned at whatever angle needed without the risk of damage or sliding around.