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05-08-2008, 07:38 PM
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...in the Garage...
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Join Date: Nov 2005
Location: Oakville, Canada
Posts: 820
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....I've cut along a line below the upper flange. With the lower welds drilled off, the outer sill was easily removed. I also drilled 3/8 inch holes at 1 inch spacing where the plug welds will go.
I de-rusted it with wire a wheel, straightened it locally and etch primered it. It's all ready to go back on....
I've countersunk at each hole so that I have better access with the tip of the mig welder and also so that there is less thickness variation (for the weld) between the floor and the inner sill...this will hopefully make for easier and better welds.

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05-15-2008, 12:43 AM
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Registered User
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Join Date: Jun 2006
Location: Athens, Hellas
Posts: 15
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Great work Rossano! It looks that the outcome will be astonishing.
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05-19-2008, 02:12 PM
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...in the Garage...
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Join Date: Nov 2005
Location: Oakville, Canada
Posts: 820
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Finally finished off repairing the lower corners on the rear kick panel (cross member)..
The seat mounting point reinforcing doublers and the inner seat belt attachment point were not provided with these panels, I'll have to add these in next (before welding the panels in for good).
...and more pre-fitting....checking for contour mismatches and pre-drilling holes for welding plugs.
Pre-fitting the cross piece floor support which I still need to do a final bead blasting on to remove some light rust....I can hardly wait to weld these in for good....but I'll have to.

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05-19-2008, 02:18 PM
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Gettin ready for The Glen
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Join Date: Sep 2005
Location: In the garage working on something
Posts: 5,327
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Neat job. Make sure you Waxoil (or equivilant) that beauty on assembly to protect from  rust.
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05-19-2008, 02:58 PM
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AlfaBB Addict
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Join Date: Apr 2003
Location: Austin, TX , USA
Posts: 2,061
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WOW Rossano, really nice work!!!
__________________
Peter
Currently:
'67 Duetto
'69 Euro 1750 GTV
Previously:
'76 Alfasud Ti/'75 GT Junior/'87 Alfa 33
'91 Alfa 75/'95 Alfa 164/'79 Alfa Spider
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05-31-2008, 11:23 AM
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Registered User
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Join Date: Nov 2003
Location: So. Orange County, California
Posts: 7
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Inspirational Restoration Work!
Rossano,
Hats off to you bro! Very good detail work in your restoration. This thread is very inspiring indeed. I hope to acquire this type of skill with the restoration of my Alfa's. I had a 74 GTV (French Blue) that got crunched in a rear end collision so seeing your car brings back many fond memories of my old Alfa GTV.
I can't wait to see the finished product. Keep it coming mate.
__________________
"Play hard, live well, enjoy life, repeat."
71 1750 GTV|84 GTV-6
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06-01-2008, 06:28 AM
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Registered User
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Join Date: Nov 2006
Location: Brisbane Australia
Posts: 132
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gobsmacked, very pro work you are doing there buddy. keep it up
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06-02-2008, 05:54 PM
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...in the Garage...
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Join Date: Nov 2005
Location: Oakville, Canada
Posts: 820
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Lowmilage: I plan on using the cavity wax for sure...but after I've have all the welding finished.
Peter/ecuadude/mfroble:...thanks for the nice replies gents, I expect to keep my current steady pace going throughout the summer...and to keep regular updates coming...(humm...I hope the AlfaBB can cope with all these photos though)
This past weekend I managed to get some more work completed. Started by reclaiming the seat mounting bracket which luckily was pretty free of corrosion, but did require some slight reforming so that it matched the new pan's contour.
...followed by my usual hole treatment for the plug welds...
...welding completed....
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06-02-2008, 06:06 PM
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...in the Garage...
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Join Date: Nov 2005
Location: Oakville, Canada
Posts: 820
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06-02-2008, 06:21 PM
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...in the Garage...
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Join Date: Nov 2005
Location: Oakville, Canada
Posts: 820
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Last edited by 1750GT; 06-02-2008 at 06:33 PM.
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06-02-2008, 06:35 PM
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Registered User
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Join Date: Aug 2007
Location: Vancouver, Canada
Posts: 129
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Hey man, if you're ever out West here in Lotus Land, would you mind if you gave me a tutorial in restoration techniques? Your project is looking superb!  It's obvious you know what you're doing.
A good friend of mine is coming over this weekend to weld a few floor pieces into my '74 and he's going to teach me how to mig weld. Oh yeah,in one easy lesson but I'm a quick learner  I was talking to him last night at Happy Hour and he said Sat. morning so I'd better hold off the Appleton's and Coke 'till Sunday heh heh heh 
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06-02-2008, 06:50 PM
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...in the Garage...
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Join Date: Nov 2005
Location: Oakville, Canada
Posts: 820
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The original reinforcing used a thinner material (which at about .080-.090 inch thick just seemed to be a little bit too light). I used .125 inch thick material and extended the edge out to where the bend line transition is.
I want to add a large weld along this area so as the beef it up a lot more than the original which again seemed to be a little flimsy here.
..no worries about inadequate penetration with the MIG here.

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07-31-2008, 10:03 AM
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Junior Member
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Join Date: Feb 2007
Location: Cape Town,South Africa
Posts: 27
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Wow Rossano I have seen your thread before but I just checked it out again. I see what you mean about me being lucky with my car. But you have done AMAZING work! I wish I had your skill and ability!
Your car will be awsome when it's done and I will follow your thread with much interest.......
Steven
__________________
'74 ALFA GTV Junior...in the shop currently in pieces being rebuilt to fast road spec
'84 ALFA 3.0 GTV..My teenage dream car!! 
'72 Mazda RX-2..Almost finished fitting the 13b Turbo
'68 Maserati Mexico..4.2 rebuilt....Beautiful
'99 Subaru WRX..Huge performance upgrade almost complete... 
'08 Chev Lumina 6.0 Daily driver.. FUN,FUN,FUN!
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07-31-2008, 11:26 AM
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Registered User
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Join Date: Jul 2007
Posts: 9
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Ok Rossano, how much do you want when it's finished.
I need to get over to see your project. Mine is in getting sprayed... finally.
Looks really good!!
Roger.
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07-31-2008, 11:40 AM
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Senior Member
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Join Date: May 2003
Location: Oakville ON
Posts: 1,619
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Roger, What colour 
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Ken Lee
Oakville, ON
1974 GTV 2000 - Ruby (I'm never selling this one, honest!)
1973 GTV 2000 - Rowdy (or this one I hope)
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