25 year old Alfa 75 back from the brink (hopefully)

[Dcal]

Bit of a diversion, no welding but a bit of heat required.

Started on the upper wishbone

As removed from the car with the ball joint removed

After blasting but siting about for a while

Removing swivel arm and bush

And then trying to remove bearing

Not playing ball

So a bit of heat and persuasion required

And finality got it off

Assembly was a lot easier, then another blast and a few coats of epoxy primer

And two pack top coat

 

[jpmillermatic]

nice work...parts look good!

JP

 

[Dcal]

Passenger side next
Pretty much the same as the drivers side so no point in putting you all through the detail so just a few before, during and after photos -

Only real difference is i used Sherwin Williams epoxy on the P/S instead of the Jotan 87 I used in the D/S.
Only time will tell which works best
The front isn't painted as the front panel needs work

In fairness this side was probably worse, but turned out better.

I was quite pleased with the tiny repair on a punched hole that probably wasn't needed!

 

[jpmillermatic]

more great work...those welds look really tidy. well done

JP

 

[Dcal]

Thanks JP,
I welded this with a transformer mig and I really struggle getting consistent welds, some time its fine and other times it just eats the edges away, on the same settings and steel thickness. (all the welds are butts)

I've just bought an inverter based multi function machine from Hood (Rtech MTS 255S)
I haven' t properly got to grips with it yet but it has a few features which should help.
I'll see how I get on with it, I'm nowhere near to running out of Alfa tin-worm to practice on.

 

[jpmillermatic]

I hear you regarding the tinworm. I like your looking at it as an opportunity!

JP

 

[Dcal]

Hi JP, if I didn't look on the bright side not sure I would start.

The sills had a "bit" of rot at the jacking points, the front inner sill were fine and just needed a small patch about 6 by 4 inches.
This should be quick and easy.

The area in question on the PS before I started, the DS was pretty similar. Note the previous repair!

One point of interest (to me anyway) is there is a pressing in the sill close to the jacking point. This doesn't line up with the jacking point so whats going on? Checked the other side and that's the same. Checked the back but their too far gone to be any use for reference. I seem to remember from 30 years ago, my mothers Fiat 850 had a similar pressing which was for the jack. This car didn't come with an original jack so that didn't help. I could be totally wrong and it would have been easy to forget about it but decided to try and replicate it.

For a former I used a bit of 25mm scrap and some 20mm flat bar. Half an hour with a 5inch and die grinder and ended up with this

But not a great fit, need to grind more steel away or -

Instead built it up with a few runs

And after a bit more grinding I ended up with this

Which is a reasonable fit.

Shaped a bit of 0.8mm steel and tacked to the former. Then tapped it to shape with a small ball-peen hammer to get the finished patch.

Blast and a bit of weld through zinc primer

fit up and weld in place- with a bit of copper to help with alignment and welding

Then make and fit other patch to finish - Excuse the ropy welding

I could have gone to a lot of bother to replicate a dinge that might have been made by the careless placement of a trolley jack!

 

[Pigeon_Droppings2]

Nice work on the template...I imagine you might be able to start turning out repair panels for sale with that bit of kit.

Like the approach of using whatever you have....at the end of the day all people see is the finished repair....doesn't matter if you use a frying pan from the kitchen as a template!!

Great attention to detail as usual...well done.

 

[Dcal]

Started work on the front panel

Biggest issue was a bodge repair on the lower radiator support panel meant I had very little to work on

Stripped out the front panel



Did a search on the internet,
best info I got was from the workshop manual, which gave frame dimensions

Used that and the line drawings to make a new radiator support panel
Punched a few holes for the radiator mounts

Then made and fitted a couple of strengthening brackets

The front panel had next to no paint on it (especially the rear)

Gave it a blast to see what I had to work with

A few patches and see how it fits

Which gives me something to go on to repair the nasty hole in the inner guard

Turned out OK, I think

 

[Exuptoy]

Your work is an inspiration mate.......amazing. My dad has a P1800s Volvo to restore and he is always pouring over DVDs of Peach and Tommassini and Ron Covell and these guys make complete panels from single sheets of metal through wheeling and dollying or making hardwood bucks and all from paper templates. I am blown away by the talent of these guys. Have a look fella. I'm sure you'd find it interesting.

 

[Pigeon_Droppings2]

Dcal - amazing work....like what you did there....very methodical and precise.

Exuptoy...P1800 is my favourite car of all time...I was very tempted by a red one listed on ebay this week but it hit £13k and I just couldn't justify it.

 

[jpmillermatic]

man, that is nice work!....very inspirational....keep at it!

JP

 

[Exuptoy]

Exuptoy...P1800 is my favourite car of all time...I was very tempted by a red one listed on ebay this week but it hit £13k and I just couldn't justify it.

Dad paid a couple of grand I think but it's bad.

 

[Dcal]

Thanks for the kind words and encouragement lads, certainly need it at times.

Exuptoy, I think I like 80 and 90 Italian cars because they look like you would only need a folder to make panels. Never is that simple though.
I really struggle with curves. I have just finished repairing a rear arch which was a real pain.

I also marvel at the work real Craftsmen produce. (Should that be Crafts-persons?) I will certainly check out the guys you mention, thanks for the heads up.

I would love to go on a course with someone who has the kit and knows what they are doing.
Anyone know of a good one?

I made a foot operated stand for a a shrinker / stretcher which made it really usable, next job is to make a deep throat one which would make it even better. I could just buy one but wheres the fun in that.
I'm also in the process of beefing up and converting a cheap bead roller to power feed which should make it into another great tool. (Got the motor and drive on here)
I used it to set the relief in the radiator support panel and the difference in time it took in comparison to making a form and hand beating it was remarkable.
Another home made was a frame for an air hammer for planishing bits and it works pretty well.
Biggest issue I have is if you start stretching 0.8mm steel, you don't have far to go before you get foil! Mind you I'm probably overworking it and I did manage to form the patch for the front of the DS inner panel with it even though it was a disaster to weld in.

I've also thought of making an English Wheel, but I'm sure I would produce a awful lot of scrap until I get the wing of it so I'm holding back on that for now.

Starting to gather up the tools I need (want), just struggling to get the time to use them.
Maybe i should less time making / modifying tools and more time working on the cars.

 

[Exuptoy]

Regarding planishing, the wheel makes a far better job of it without making it too thin. My dad has one which he purchased with 1 set of wheels but my mate has made a full set for him. Also if you cover the flat wheel with a rubber inner tube material you can increase the radius as the rubber gives more. He also is in the process of making a motor driven swage.

 

[Exuptoy]

Peter Tommasini at work. This is just a taster. My old man has the complete set of 9 dvds following the car, start to finish.

 

[Dcal]

Wow, that's some skill.
They make it look so easy (As if!)

This could convince me that I really need a wheel, or it could just as easily convince me to give up.

 

[Exuptoy]

Haha. Another guy is Chris Runge. Started off making hot rods and his one off designs are now fetching $150k!!! Google Runge FF04 or FF01

 

[Pigeon_Droppings2]

Beautiful work....I reckon that panel must be pretty thick steel....if I hit my Figaro like that the car would just fold in half!

When I win the lottery (not if!) I'll get myself one of these...beautifully made I think.

 

[Dcal]

Yous have got me thinking now!
I quite fancy fabricating one
Seen a couple of brilliant ones on on the net

Whats it like to get the wheels and anvils?
And just to be clear, I don't have any room for more kit.
But... I could mod my planishing hammer frame for a wheel