It begins...

[dave.armstrong]

It's looking great!

[Kegsti66]

Looks very good, but one thing that came into my mind:
Aren't the calipers mounted the wrong way? I think the hoses should point forward. Mechanically it shouldn't make any difference.

Colin, you won't be able to get to the hand brake adjusters either, sorry.
Coming on well though, engine ready to go back in.
Will you be needing any / much paintwork or is it all fine?

[Alfamet]

Looking good chap ! Nasty surprises ? It's an alfa . Of course there won't be any

[Alfamet]

Looks very good, but one thing that came into my mind:
Aren't the calipers mounted the wrong way? I think the hoses should point forward. Mechanically it shouldn't make any difference.

Colin, you won't be able to get to the hand brake adjusters either, sorry.
Coming on well though, engine ready to go back in.
Will you be needing any / much paintwork or is it all fine?

That picture is of the trial fitting of the calipers when it was realised that they were the wrong hand. That's why you trial fit things before bolting them together. Now corrected and right as rain but good spot you guys!

A full respray is on the cards. Credit cards that is

[Alfamet]

looking great mate.
nice to see they've put coppergrease in with the new clutch slave, they are a bugger for seizing in the housing.

looks a perfect blend of restoration

Euan 's old school Kev.
That's why I thought of him when deciding who to entrust the Sprint's restoration to.

[junior]

The pictures have been very helpful thank you as many bits on mine are still at the looking at and wondering have I fitted this on the

right way round, right bolt, and not in the way of the next bit, or worse still the last bit.

Oh yes and will put copper grease on the slave cylinder, thank you Kev!

[KevJTD]

without the grease between the slave and the alloy housing corrosion soon sets in.
I've had to literally smash them out before.
this was one on my 33 that took a stab or two with the angle grinder then a hacksaw to split the casing of the slave.

[Alfamet]

To be scientific and a bit of an anorak, it's called galvanitic or dissimilar metal corrosion and it's caused when two different types of metal and/or alloy react with each other at an atomic level. The resulting corrosion is as good as a weld!

The grease creates a barrier between the different metals/alloys and prevents this happening.

The same principle applies to the water pump on Alfasuds. When replacing the pump, smear the mating surfaces between the pump body and the recess in the engine block with copper grease or similar to make it a cinch to remove next time.

[Alfamet]

Progress continues. I hope to have more photographs soon.
This for me is a lifetime ambition being realised. Ever since my first 'Sud in the '80s, I've always wanted to restore one. Circumstances prevented me from doing that until now.
It is for me motoring utopia. I hope that you are enjoying the ride as much as I am....

[KevJTD]

i'm sure I speak for everyone on here col, we're loving it almost as much as you are

gives me inspiration to keep pressing on when seeing others doing the same

[alfasuddriver]

Progress continues. I hope to have more photographs soon.
This for me is a lifetime ambition being realised. Ever since my first 'Sud in the '80s, I've always wanted to restore one. Circumstances prevented me from doing that until now.
It is for me motoring utopia. I hope that you are enjoying the ride as much as I am....

Always great to see an Alfa being restored to its former glory and with such enthusiasm from it's owner!

[Alfamet]

Well, my Christmas present is coming along nicely...


Overhauled driveshaft and hub with new bearings fitted


Suspension stripped revealing front inner wings in good condition


Front strut disassembly ready to receive new inserts


Components inspected for wear and replaced with new where necessary


Front subframe and anti-roll bar re-bushed and repainted


Strut leg and turret cap cleaned, degreased and repainted


Existing coil spring removed with new KYB spring ready for installation


Split boot to be replaced


Work starts on rear suspension overhaul

Happy Christmas everybody!

[dave.armstrong]

I remember getting mine back from the paint shop on 22nd December 2006. Can't believe it is 9 years ago today. It was the best Christmas present I've ever had. (Don't tell Pam though). Had a great time putting it back together over Christmas.

How do I post photos?

[Sud 145]

The 4 bushes on the anti-roll bar are the only ones I've Superflexed. The rest are staying rubber because I want it to still handle like a Sud. Is my thinking correct Colin?

[Alfamet]

The 4 bushes on the anti-roll bar are the only ones I've Superflexed. The rest are staying rubber because I want it to still handle like a Sud. Is my thinking correct Colin?

Bang on Tony.
All the rest of the suspension bushes are to be replaced using genuine Alfa Romeo rubber ones because of their compliance.
The rear suspension arm bushes in particular were always designed this way as the rubber bush was designed to give a little in use and this feature actually led to a degree of rear wheel steer that contributed to the legendary handling.
Fit the unforgiving rigid neoprene bushes and you lose this and the car won't handle as a Sud should.

[Alfamet]

More progress today and a little bit of a problem; or maybe not...

I'd always been in half a mind to replace the rear beam axle with a galvanised unit for longetivity so had allowed for this possibility in the rebuild.
Well, the rear suspension was dropped complete with springs and arms but leaving the dampers in situ. This is when it was noticed that both of the spring seats on the beam axle were in bad shape with a bit of cracking around their bases.
More worryingly was evidence of a botch job having taken place previously as a repair had been attempted using car body filler! Unbelievable but regrettably true.
So, for safety's sake the beam axle will indeed be replaced with a galvanised one after all, which I ordered today from John at Justsuds.
I can't understand the logic around this scary and unsafe botch job. One question; why?

Pictures here:


Rear beam axle dropped complete with springs and suspension arms but leaving the dampers in place.


Cracking to the base of spring seats on the beam axle. And yes, that white chunk you can see is a piece of the body filler used for a previous attempted botched repair.

Ah well. Onwards and upwards.

[Kegsti66]

Enjoying your thread Colin. I have also been thinking of new KYB springs. Are you using their shock inserts or something different?
I understand you plan to keep the car close to original spec, is that correct?
Cheers.

[Alfamet]

It's all been reasonably straightforward - so far! - and I'm glad you're enjoying the thread.

The KYB springs are the closest spec that you can get to standard height and loading these days. Reference numbers are:
RA1003: Front
RA5167: Rear

I bought the new springs all round about three years ago from a dealer's liquidated stock. I think however that they're still available from http://www.buypartsby.co.uk?

The front inserts I'm using are factory NOS original items. I acquired them about ten years ago and then sold them in a job lot to John at Justsuds. I then got them back from John a few months ago!

The rear dampers to be fitted are again NOS SPICA original items that I bought at the same time as the springs but I've seen them since on a German website offered new: http://italiancarparts-shop.de/epages/0 ... ageSize=36

I set off the restoration trying to keep everything as close to standard as possible subject to parts availability etc and so far I've managed to achieve it.
More progress pictures soon.

[Kegsti66]

Thanks Colin, some useful links there.

[dave.armstrong]

Looking forward to seeing the progress Colin.

Do you have a Sprint Speciale brochure?

If not I will scan mine and email it to you.

Hi Colin

I have eventually found it and scanned it and emailed it to you.

Enjoy it!

Dave

[Alfamet]

Looking forward to seeing the progress Colin.

Do you have a Sprint Speciale brochure?
If not I will scan mine and email it to you.

Hi Colin
I have eventually found it and scanned it and emailed it to you.
Enjoy it!

Dave

Got it Dave. Many thanks.

[Sud 145]

Just checking that the Sprint is save and sound above water level-watching the news. If I remember you had to wait to collect her because she was cut off by floods when she lived down this way.

[Alfamet]

The Sprint's miles away from the floods Tony but yes; I did have to wait a long time before I could pick her up from Surrey when I bought her. I had to wait weeks!

[Alfamet]

With further inspection, it seems now that my decision to replace the rear axle was the correct one.

Metal fatigue and a partially seized bush had caused cracking around where the suspension arm connects to the beam.

Could have been nasty!

[Alfamet]

I'm glad that the botched repair to the rear axle was spotted.
The spring and rear shock absorber could've gone through and come away from the axle at any time. It doesn't bear thinking about really.
The same goes for the suspension arm, which could easily have become detached while on the road.
Best to be philosophical. Rather I found this now than at 70mph on the motorway. The consequences could've been dire....

Anyhow, further progress:


One of the new re-bushed OEM rear shock absorbers alongside an existing one removed from the car.


One of the rear suspension arms re-bushed and etch-primed awaiting top coat.


Another rear suspension arm on the bench stripped to bare metal awaiting new OEM rubber bushes, etch primer and top coat.

It's getting exciting now.

[Alfamet]

More progress pictures:


Engine and gearbox reunited on the bench.


And then positioned under the car ready to be bolted back in place.


New engine and gearbox mountings fitted before installation


Getting there. Note new alternator.


She's in!


Refurbished driveshafts connected with new inboard brake discs also installed.

Waiting now for the galvanised rear beam axle to be delivered from Justsuds and the rear suspension can be rebuilt.

[dave.armstrong]

The attention to detail is fantastic and I am really excited about seeing it.

[Alfamet]

The attention to detail is fantastic and I am really excited about seeing it.

Me too Dave!!

[Kegsti66]

and me !!

I may be biased, but I think the Alfa boxer engine bolted to the gear box is a fantastic looking piece of engineering art.

[Alfamet]

and me !!

I may be biased, but I think the Alfa boxer engine bolted to the gear box is a fantastic looking piece of engineering art.

No. You're not. it is quite simply a sublime piece of engineering at its best. End of...