Replacing the sills and floors in a Spider - Alfa Romeo Bulletin Board & Forums

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post #1 of 7 (permalink) Old 04-19-2017, 02:58 AM Thread Starter
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Replacing the sills and floors in a Spider

The floors of my Spider have been crudely repaired in the past and the remaining original metal is badly rusty. The inner parts of the sills have been replaced by a 100 x 50mm box and the outer replacement members have been lap welded in place. The only members worth keep are the upper door sills. Hence, I'm planning to replace most of the sills and the cabin floors.

I know I'll need to weld in bars across the door opening plus a few more to triangulate across the body to keep it dimensionally stable. And I'll be building a suspension cart to support the body during the work.

I'd appreciate any advice and experience on which parts should be welded in first and the order in which the floor and sill panels should be spot welded together.

Regards, Mick

Fulvia 1600HF, Fulvia Sport Zagato (project), Giulia Spider Veloce (project)

Last edited by OMWattsy; 04-19-2017 at 03:10 AM.
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post #2 of 7 (permalink) Old 04-19-2017, 09:39 AM
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I can discuss how this is best done, but it gets into a long complex post here. I could send you a e-mail with techniques and options more easily. Send me a PM with e-mail contact information if you wish.


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post #3 of 7 (permalink) Old 04-19-2017, 03:40 PM Thread Starter
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Gordon, thanks for the offer
PM sent

Fulvia 1600HF, Fulvia Sport Zagato (project), Giulia Spider Veloce (project)
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post #4 of 7 (permalink) Old 04-20-2017, 02:57 AM
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Quote:
Originally Posted by OMWattsy View Post
I know I'll need to weld in bars across the door opening plus a few more to triangulate across the body to keep it dimensionally stable. And I'll be building a suspension cart to support the body during the work.
Mick, here's my trolley for my Sprint, which might also work for your Spider - it combines a swinging frame for suspension point attachment and a base on jockey wheels. Everything's adjustable height-wise via jacks and screwed rods and the jockey wheel attachment arms (orange) can be slid out and turned over 180 deg to give another 5-10 degrees of tilt. The body can be held to the swinging frame by either the turnbuckles (attached to a bar that fits inside each jacking tube) or the suspension point attachment posts (not shown here - we welded these on after the car was on the trolley and checked for squareness).

There's less need to cross-brace a Sprint than a Spider (because the Sprint's roof acts as a reinforcement) so we've only used two braces for each door opening. Instead of being directly welded on, each brace is bolted to a tab welded into the edge of the door opening, making them easy to remove to access the cabin - not an issue for a Spider, I guess.

Maybe it's a Sydney restorer's thing, but my Sprint also had lots of plating-over of the rusted sills courtesy of the (expensive) mid-1980s 'restoration'. Some of the replacement metal appeared to be cut from an advertising sign. Even though it was galvanised, rust never sleeps ... so it has to be cut out and thrown into the Pits of Hell.

Cheers
Geoff
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post #5 of 7 (permalink) Old 04-20-2017, 08:53 AM
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Send a message via AIM to Erik
I've got lots of pictures of restoring the sills and lower front and rear wing of my Spider S2 1970.
Send me an e-mail to erik@loye.eu and I sent you numerous photos of the job both sides.
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post #6 of 7 (permalink) Old 04-20-2017, 09:11 AM
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That is one nice tool Geoff!! It would work fine with a spider IF one studied the structure and made measurements before any metal removal, possibly best comparing at least one known GOOD car.


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post #7 of 7 (permalink) Old 04-20-2017, 03:46 PM Thread Starter
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Hi Geoff,
I like the flexibility that your trolley offers.
i can see many possibilities of being able to quickly tilt or rotate the body to work on it.
I'm just wondering whether the underbody frame would be dimensionally stiff enough to rotate a Spider without it distorting?
Regards, Mick.
PS: My current plan is to build one of HooliganSuper's suspension carts with a possible extension to pick up the trailing arm brackets.

Fulvia 1600HF, Fulvia Sport Zagato (project), Giulia Spider Veloce (project)

Last edited by OMWattsy; 04-20-2017 at 03:58 PM.
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