1973 Alfa Romeo GTV - Restoration Begins - Page 5 - Alfa Romeo Bulletin Board & Forums
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post #61 of 97 (permalink) Old 06-29-2016, 06:56 AM Thread Starter
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The reason for showing these photo's is to continue to document all aspects of the repair process.
What I found is that this window is probably the most difficult piece of angles to fabricate, and cutting very thing metal, shaping it, welding it and now (not photo'd yet) grinding the welds back to smooth will be my next challenge. After all that, it will then get a skim of seam sealer then some epoxy paint, then a coating of cavity wax inside. All in an attempt to keep this area from rusting again.

Here was the progress at the end of last night.

Rear quarter repair Alfa Romeo GTV by Ian Bennett, on Flickr
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post #62 of 97 (permalink) Old 06-29-2016, 07:03 PM
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The Eastwood seam sealer is good stuff and dries hard but still pliable. Also their HeavyDuty Anti Rust is great for the inside areas. Keep up the good work. Everything you do will be better the next time you do it, at least it was with me.
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The passenger seat is 15 miles an hour faster than the drivers seat.

currently
2017 Giulia Q4
74 GTV restored daily driver
71 Berlina in 2L restored driver
the ones that got away:
1959 750 series Giulietta Spider Veloce
1962 Giulietta Spider normale
1965 Giulia Sprint normale
1972 GTV
1974 GTV
1974 GTV
1977 Spider
1974 Spider
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post #63 of 97 (permalink) Old 07-11-2016, 06:00 AM Thread Starter
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A bit more progress...
Realized that I am paying more for welding gas than I would for the entire panel to just be replaced!!
Keep this in mind for all those people who are deciding on welding up and fabricating your own repair, sometimes it's more cost effective to buy the finished panel (if you can) than to keep hacking and welding stuff together with your own DIY panels/parts.

Finally though, the drivers side floor is done.
Alfa Romeo GTV rust repair by Ian Bennett, on Flickr

Alfa Romeo GTV rust repair by Ian Bennett, on Flickr

Also spent time again on the C pillar window channel
Alfa Romeo GTV rust repair by Ian Bennett, on Flickr

Then replaced a section behind that in the rain channel for the rear window. (cut-out is here)
Alfa Romeo GTV rust repair by Ian Bennett, on Flickr

1/2 finished is here.
Alfa GTV rust repair - rear windscreen by Ian Bennett, on Flickr

Thinking about trying a waterproof filler product for these really bad rusty places after it's all welded up.
Attempting to prevent this repair in the future!
Evercoat Fiber Tech 635 - Reinforced Body Filler | O'Reilly Auto Parts
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post #64 of 97 (permalink) Old 07-12-2016, 05:39 AM Thread Starter
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Keeping up the thread with some additional photo's and progress from last night.

Alfa Romeo GTV rear windscreen repair by Ian Bennett, on Flickr

Alfa Romeo GTV rear windscreen repair by Ian Bennett, on Flickr

The 'gold' color in this photo is brass brazing and is really frustrating to encounter!! Welder hates brass!

Alfa Romeo GTV rear windscreen repair by Ian Bennett, on Flickr
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post #65 of 97 (permalink) Old 07-12-2016, 08:00 AM
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Keep on truckin' one step at a time. You've tackled a giant project and that in and of itself is impressive. POR, press on regardless
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The passenger seat is 15 miles an hour faster than the drivers seat.

currently
2017 Giulia Q4
74 GTV restored daily driver
71 Berlina in 2L restored driver
the ones that got away:
1959 750 series Giulietta Spider Veloce
1962 Giulietta Spider normale
1965 Giulia Sprint normale
1972 GTV
1974 GTV
1974 GTV
1977 Spider
1974 Spider
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post #66 of 97 (permalink) Old 07-14-2016, 08:34 AM Thread Starter
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Quote:
Originally Posted by gigem75 View Post
Keep on truckin' one step at a time. You've tackled a giant project and that in and of itself is impressive. POR, press on regardless
Thank you for the support Gigem and everyone else.

I keep on POR and decided to take some big cuts last night out of the swiss-cheese spare tire wheel well in the trunk. Fabrication is fun when you kinda figure out what the F* it is your supposed to do for what.

Almost looks like a 'real' part vs what I have been doing replacing little patches everywhere.
I will also say that my wheel well spare will no longer be curved, but flat-ish due to me not wanting to take on that complex curve without an english wheel.
So it will be a little rough, but I am thinking about panel bonding it back in vs welding it all back in, just to try out the panel weld for the wheel arches.
we'll see what happens when I get it all fitted up and ready for weld or the 3m panel bond.

Alfa Romeo Wheel Well Repair by Ian Bennett, on Flickr

Alfa Romeo Wheel Well Repair by Ian Bennett, on Flickr

Alfa Romeo Wheel Well Repair - restomod car by Ian Bennett, on Flickr

Alfa Romeo Wheel Well Repair - restomod car by Ian Bennett, on Flickr

Alfa Romeo Wheel Well Repair by Ian Bennett, on Flickr
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Last edited by IanB; 07-14-2016 at 08:36 AM.
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post #67 of 97 (permalink) Old 07-14-2016, 01:33 PM
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That will work! I've often wondered why I even carry a spare. Nowdays a can of fix a flat will get you home and there are a lot of possibilities for that space up to just covering it or using it for amps, luggage, or even a flux capacitor.
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The passenger seat is 15 miles an hour faster than the drivers seat.

currently
2017 Giulia Q4
74 GTV restored daily driver
71 Berlina in 2L restored driver
the ones that got away:
1959 750 series Giulietta Spider Veloce
1962 Giulietta Spider normale
1965 Giulia Sprint normale
1972 GTV
1974 GTV
1974 GTV
1977 Spider
1974 Spider
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post #68 of 97 (permalink) Old 07-18-2016, 07:19 AM Thread Starter
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Updated photo's below.
As you can see, I am racing Gigem and losing!

I need less kids under 7 (right now I have 3!)
Anyway, here is what happened this weekend.

Epoxy on the steel that was starting to surface rust from the **** humidity in the summer time. I was fine all spring and winter, but come July, apparently you need to get some paint on **** or it starts to go/re-rust!
Here is the continued progress.

Alfa Romeo body in epoxy by Ian Bennett, on Flickr

Alfa Romeo body in epoxy by Ian Bennett, on Flickr

Alfa Romeo epoxy primer after finishing some sheet metal street-racer style restoration by Ian Bennett, on Flickr

Alfa Romeo epoxy primer after finishing some sheet metal street-racer style restoration by Ian Bennett, on Flickr

Alfa Romeo epoxy primer after finishing some sheet metal street-racer style restoration by Ian Bennett, on Flickr

Had the paint in the gun, so I grabbed a wheel and taped it up quickly! Kinda 'porsche' in look with the polished lips and black centers, but was still fun to just see how much more work I need to do with filler to bring the wheels up to 'paint ready'.

Alfa Romeo epoxy primer after finishing some sheet metal street-racer style restoration by Ian Bennett, on Flickr
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post #69 of 97 (permalink) Old 07-18-2016, 06:33 PM
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I'm a retired Grandfather and can send them back to their mother
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The passenger seat is 15 miles an hour faster than the drivers seat.

currently
2017 Giulia Q4
74 GTV restored daily driver
71 Berlina in 2L restored driver
the ones that got away:
1959 750 series Giulietta Spider Veloce
1962 Giulietta Spider normale
1965 Giulia Sprint normale
1972 GTV
1974 GTV
1974 GTV
1977 Spider
1974 Spider
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post #70 of 97 (permalink) Old 08-06-2016, 03:50 AM Thread Starter
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1973 Alfa Romeo GTV - Restoration Begins

A quick note to anyone putting on large pieces of fiberglass on any car. Fit meant will not be the hallmark of these pieces.

I am struggling now with how much 'tension' I should put in these fiberglass pieces while they are on the car. They can't just lay on the car because the mold wasn't super accurate, but they can me squished a bit, tucked a bit, massages to fit all the body lines. How this may be what your supposed to do, massage them on while the 3M panel bond sets up, but I have no idea.

Anyone have an opinion?


Last edited by IanB; 08-06-2016 at 03:53 AM.
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post #71 of 97 (permalink) Old 08-06-2016, 07:59 AM
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That's unfortunate.

One method you may wish to consider is using self tapping screws. Very easy to screw through the fiberglass into the sheet metal, holding the piece where you want it. Obviously, upon set up, pull the screws and finish with normal body work procedures.

Bob

Everyday is a school day. Learning something new all the time

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You're kidding, another one?! 1984 GTV6 Maratona
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You didn't...oh yes I did. '73 Berlina graduate course in rust repair. No thread yet, don't want to piss off the GTV

You didn't...oh yes I did II. 1995 164LS 5 speed, awesome when it runs!!!

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post #72 of 97 (permalink) Old 08-06-2016, 06:53 PM
I would advise against using self tapping screws. Review my post #24. Get yourself a bunch of Cleco claps from Summit Racing. Pre drill the fiberglass and the metal fender, fit, adjust, fit, adjust,fit adjust. Apply the panel adhesive and Cleco clamp the fenders in position. After they cure you can install rivets before or after final paint.

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Last edited by gprocket; 08-06-2016 at 06:56 PM.
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post #73 of 97 (permalink) Old 08-06-2016, 07:04 PM
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I've also done that. Works quite well.

Everyday is a school day. Learning something new all the time

View my '74 GTV restoration at:
To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.


View my '91 164s adventure at:
To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.


But wait there's more: View my 164LS thread, now parts car status:
To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.


You're kidding, another one?! 1984 GTV6 Maratona
To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.


You didn't...oh yes I did. '73 Berlina graduate course in rust repair. No thread yet, don't want to piss off the GTV

You didn't...oh yes I did II. 1995 164LS 5 speed, awesome when it runs!!!

Musings on shop related items:
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post #74 of 97 (permalink) Old 08-07-2016, 07:14 AM Thread Starter
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1973 Alfa Romeo GTV - Restoration Begins

What's another 25$ right? Cleco's are on the way...cross fingers...

Last edited by IanB; 08-07-2016 at 07:20 AM.
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post #75 of 97 (permalink) Old 08-07-2016, 08:53 AM
You'll find that's the best $25 investment you could make.
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