Classic Alfa Forums

petrolhead wrote: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!

..... now there's any idea........

Been thinking about a boxer engined based coffee table as well......

think you might want to DIP the final sculputre in rustcure and laquer to prevent it shedding its own weight daily in further rusting! lol!


and if you do make a coffee table type thing, remember to keep it original and not overly straight or level!

fantastically thorough job your doing mate, the only real way to be sure the rot has gone, but i admire your dedication to the task

an inspiration to us all

Thanks guys....
The praise keeps me going really it does....

Ok managed to get some more work done on this 'A' Post.
The next job was to make up a new outer face section, it took a long time to get it how I wanted it, made out of 3 separate pieces and welded together, captive nuts also added....
Then remove the old section which was hiding a lot of rust with water having got in through the screen many years ago
Luckily for once the inner section was very good, only needing 2 small areas of repair

Etch prime, drill holes in the outer panel for spot welds and weld in place and down the front edge too, carefully grind all the welds back and add some more etch primer to the outside and spray some in from the top between the 2 layers of metal using a probe on the nozzle....

Top work again mate,

I must drop in on you sometime adi, love to see it in the flesh how it is now if that'd be ok?

Top work again

petrolhead wrote:Top work again mate,

I must drop in on you sometime adi, love to see it in the flesh how it is now if that'd be ok?

Yes mate no problem, give me a call / txt next week

Wow! Great work!

Time for my family holiday in Ukraine to see my wifes' family, if I don't get shot or blown out of the sky I will catch up with you all in 2 weeks

I'm back!
Ok the next job on this post was the door hinge side, I firstly decided to beef up the overall strength by welding in 2 short pieces of angle iron.....

Then on to the lower hinge area........

The upper hinge area is next......
This is mess to be honest, it will all need replacing piece by piece....

The first bit to replace is this one I think......

Eventually managed to cut it out and make up a new piece......

........ and tack it in place.....

Time for an update on the old alfasud....

The bottom of the screen / top of the 'A' post are has multiple layers, one of the reasons it rusts so bad and it is all hidden from view only visible once you go looking

3 layers here, each one marked with a yellow dot
The problem is here that to rid the car of corrosion everything needs to be replace here and its difficult to work out the order to do it in and keep everything accurate and looking right

First job is to remove this bit....
Which reveals more corrosion, these early cars are only 0.7mm sheet and it is all rusted through so no option but to replace it all to do a proper job

As this area needs to completely cut away in stages I thought it would be a good idea to add a supporting piece to hold the bottom of the screen post in place so nothing can move....
Then I cut away the first part...
Rotten

This then shows the next problem.... deep surface corrosion to the back of the upper door hinge position, as this is double skinned it is bound to be twice as bad from the other side so that will need to be replaced or the corrosion will just keep on going through time
Problem is keeping everything accurate and in the right place otherwise the door will never fit correct

I decided to make up a jig to locate in the 2 holes in the retaining plate with to pins and weld it to the inner face of the 'A' post....
So when I work from the other side and remove the upper hinge area I have a datum to work too

Next job was to begin to repair that front section, its double skinned (as usual ) and this is the inner piece being made up
Cardboard template is always the way....
For some reason this piece is not welded to the inner upright piece originally, not sure why but I decided to weld it for more strength, I am also using 1.0mm sheet so much stronger than the original structure

Outstanding attention to detail Vecchio!

Yep, great workmanship

That is really, really good work. keep it going mate

Thanks guys I know I will get this bodywork done....... ........oneday

Hi Vecchioalfa,
Another great thread to follow.
Top work, you'll get there. Great detail to your work.
Like others have said, I think you should keep the colour.
Suds set standards in their day not just in the way they drove but breaking traditions. The 1970's liked colours as well.
It will be great if one day loads of us can get all our colourful cars together...... something for the future.
Keith.

Kegsti66 wrote:Hi Vecchioalfa,
Another great thread to follow.
Top work, you'll get there. Great detail to your work.
Like others have said, I think you should keep the colour.
Suds set standards in their day not just in the way they drove but breaking traditions. The 1970's liked colours as well.
It will be great if one day loads of us can get all our colourful cars together...... something for the future.
Keith.

Hi Keith,
Nice to hear from you mate, yes I am looking forward to getting my car back on the road but as we know due to the type of construction to do it right there is no quick option, takes time, a lot of time. I am going to try to get out to more events next year even though the sud won't be finished, I am hoping to have it ready for paint by summer though....... maybe.....
Your car looks great, in one of my favourite colours, I will be keeping this one its original colour as no others survive in the yellow as far as I am aware

They didn't like the colour at NAD !!

Kegsti66 wrote:They didn't like the colour at NAD !!

No accounting for taste