Classic Alfa Forums

Wow, I'm a few weeks away from putting the flapper wheel/ grinder near the same sections....best get ready!!!

Btw....after saving berts photo to my never ending sud pics, then I'd definitely keep the yellow. Looks great with the black trim.

Interesting thread there, I can see this car coming back to life. Loving the attention to detail...

I managed to get a bit more work on this windscreen pillar over this last week, so here is an update......

I have made up the outer vertical section, welded it in slowly to prevent any distortion which is the problem with these type of areas, I usually use a wet rag to help to take the heat out of the metal after welding.
Then I spayed a load of etch primer in from the inside of the pillar while I still had good access knowing that some would burn off but not all especially if the area is cooled straight after welding, I then cleaned it off from the outside.

Door gap so far looks good....

The next job was to make up that outer pop riveted on closure panel which was a complete nightmare due to the shape

I made this in 2 pieces

The next photo shows the inner flange in place and some spacers in place to maintain a door gap....

.... and the outer flange that I had already made up was tacked on and when I was sure it was correct more and more tacks were added from both sides and the panel was cooled as I was doing it with the old wet rag method

...... and after about 4 hours of of bench work, linishing back the welds, filing the welds etc. I ended up with this:

Once I was happy with this I added some etch primer and then some sealant and pop riveted it into place as it left the factory

Looks good, the next photo shows the outer edge.....

If I told any of you how long it took to make this panel up and get the shape right no-one would believe me......

The next job is to complete the top of this panel to the roof in the rain gutter area and the front face of the pillar

I have now made up and fitted 3 of the 4 sides of this pillar and the inside strengthening panel so I'm getting there!!! I think

vecchioalfa wrote:Looks good, the next photo shows the outer edge.....

21614 006.JPG

If I told any of you how long it took to make this panel up and get the shape right no-one would believe me......

I'd say if it turns out this well Adie, what does it matter?

If time is what it takes to make the outcome as good as possible, so be it, and in this case mate you've done sterling work again.


I would believe you by the way, i know how tedious and time consuming apparently simple profiles can be, but to get right, really right, can take 3/4/5 times longer than you think, but hey, it'll be straighter than alfa ever made it by the looks of it, so stop clock watching and carry on! lol!


nice one

........I have a transport job for you coming up Shrew, I have bought another series 1 alfasud, coming from abroad, it leaves Sydney Australia next Saturday, I got the car at a good price but the shipping cost has killed me , big time!! it arrives in Southampton port but I think it could take up to 60 days to arrive in Southampton, if you want to do this let me know

its a long long way and day, but yes, of course mate, i'm in!

just holla as soon as you get an idea of possible landings

cheers mate

Great work there chap, never a quick way of doing anything . We always think it"ll be a five minute job. But it always turns into a day

Ok chaps....
O/S front screen pillar work is now complete......

The next problem now is that there is nothing to fasten it to at the bottom, the pillar is currently tacked to badly corroded metal which will all need replacing.

So, starting at the bottom of the 'A' post I need to work upwards to meet the bottom of the windscreen pillar, most visable areas of the 'A' post didn't look to bad but I know what will be inside

The inner wheel arch - inside of the 'A' post is the 1st. area to repair, I cut all the corrosion away and made up a new piece, tacked it in in stages to keep it all straight & flat, the last photo shows the metal that was removed.

All the welds were cleaned back from both sides

Finally some etch primer was added, I know some of this will burn off as I move on with this repair but it helps me see the wood for the trees if you know what I mean

Wish i had these fabricating and welding skills!

Time for an update....
This 'A' post is turning into another big job

As the inner section was also corroded this had to go as well as the outer...
Inside looks ok, back to some rust free metal finally!

New piece made up and tacked in place
Inner piece welded in place and welds ground back, outer piece made up and holes drilled to spot weld through

Outer piece in place welded up and ground back, looks good...

As I am using 1.0mm sheet its going to be rock solid when finished and also means I can crank up the current on the mig
Last two photos show weld penetration form the inside

nice when you can use the figures further round the gauge eh Adi! Crank it up son!


sterling work again mate, and quite correctly, this will be a whole lot beefier than orignally tinned together eh


well done dude, great to see these bits getting sorted

Looks perfect!

Thanks lads
Looking forward to the day it goes away for paint.....

Lovely metal working and welding, an inspiration for the rest of us.

Lovely job

Thanks guys..... I am trying to rid this car of every bit of corrosion, I have kept all the metal I have cut out so far, its in the corner of the garage and its been getting bigger and bigger, must be about 30kgs by now, I will take a photo of it all at the end!!

that'll be an interesting excercise Adi!


you should then use it to make some sort of Alfa Scuplture or display, as a stark reminder of your efforts value!