How crazy am I to think I can fix this myself? - Alfa Romeo Bulletin Board & Forums
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post #1 of 18 (permalink) Old 06-16-2018, 01:43 PM Thread Starter
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How crazy am I to think I can fix this myself?

Looking at a 72 that has a very solid structure but rear window rust. Obviously a window out job, but if I'm willing to spend a boatload of time and in decent with a MIG welder, am I naïve to think this is a DIY job?
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1966 Giulia Sprint $500 junk yard find. I probably overpaid...
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post #2 of 18 (permalink) Old 06-16-2018, 03:53 PM
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Hmmmm. Well, not one of us pops out of the womb with the skills to weld, fabricate, etc... So in that sense you aren't crazy at all, everybody has to start somewhere. If you have the time and an adequate space, and a willingness/desire to learn and spend some money on tools and stuff, then go for it.

However, while you may not be crazy in thinking you can tackle that, I can't help but wonder if you are perhaps a little more crazy to not believe that there is rust beyond what you can see. If there's rust there I can't help but wonder if there is other stuff hiding down in the rockers and places like that. I'd just suggest being VERY cautious in looking for other rot and at least going in with your eyes wide open, or be willing to walk away if it's more than you are comfortable taking on. I spent many weekends over the course of three years doing all of my metalwork, so ask me how I know...

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post #3 of 18 (permalink) Old 06-16-2018, 08:30 PM
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With time patience and will it is ALL diy. If you want the car and the project, do it.

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post #4 of 18 (permalink) Old 06-16-2018, 09:34 PM
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I did my rear window sill and learned a lot. Patch panels are available but there will likely be some custom fitting underneath. I started with some simpler projects first though for my first butt welds. And yes you should think about looking for other areas too. You should be able to find my posts on window sill and nose repair projects. I am still a novice so you will want to research others who are more skilled but maybe they will be inspiring. I did not take on anything structural and figured what do I have to lose?

Gene
'71 GTV 1750 USA SPICA
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post #5 of 18 (permalink) Old 06-17-2018, 05:34 AM Thread Starter
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Hi Gene, happy Father’s Day.

Where did you find the rear window patch panels?

Thanks!

1966 Giulia Sprint $500 junk yard find. I probably overpaid...
1971 1750 Spider basket case , 1972 GTV 2.0 L
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post #6 of 18 (permalink) Old 06-17-2018, 06:05 AM
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Most major suppliers should have this panel. Example here: https://classicalfa.com/products.php...SE-REAR-SCREEN

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post #7 of 18 (permalink) Old 06-17-2018, 06:10 AM Thread Starter
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Thanks.

Didn't find it on their mobile site, user error I suppose.

Thanks for posting that.

1966 Giulia Sprint $500 junk yard find. I probably overpaid...
1971 1750 Spider basket case , 1972 GTV 2.0 L
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post #8 of 18 (permalink) Old 06-17-2018, 08:02 AM Thread Starter
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So, basically;

1) screen out
2) wire brush like a mad man
3) sob
4) cut back to good metal
5) spend 20 hours fitting
6) tack weld and adjust
7) sob
8) finish welding
9) dress the welds and rust proof
10) drive

About right?
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1966 Giulia Sprint $500 junk yard find. I probably overpaid...
1971 1750 Spider basket case , 1972 GTV 2.0 L
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post #9 of 18 (permalink) Old 06-17-2018, 08:32 AM
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I think you've got the basic plan right. Something you'll need to be conscious of is that, once you've figured out where the rust stopped, you well be very close to the edge of where the patch panel extends, and right on the key styling line that runs the length of the car along the top of the door panel. So, it might be wise to have the patch panel in hand and mark exactly where it extends to before you start doing any cutting. It's probably a safe assumption that you'll also need to weld in some fresh metal around the window frame too for the inner panel. I formed these sections with a shrinker/stretcher and then test fitted the window just to make sure I kept the profile right. It's all very doable, just fiddly.

When I did mine I used the occasion to get POR 15 to any internal areas that I could possibly reach and then used a weld thru primer along the welded internal edges to minimize raw metal after the fact.
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post #10 of 18 (permalink) Old 06-17-2018, 11:46 AM Thread Starter
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Thank you for the detailed and thoughtful response. That picture also helps visualize it quite a bit.

1966 Giulia Sprint $500 junk yard find. I probably overpaid...
1971 1750 Spider basket case , 1972 GTV 2.0 L
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post #11 of 18 (permalink) Old 06-17-2018, 03:23 PM
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Hi
Classic Alfa and others have this repair section available
Name:  st029__93773_zoom.jpg
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Gone: 1970 GTV 1750 S2, 1990 164, 1991 75TS, 2000 2.0 GTV 1x 1965 Giulia Sprint GT
Current: 2006 166 V6, 1 x 1965 Giulia Sprint GT
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post #12 of 18 (permalink) Old 06-17-2018, 04:13 PM Thread Starter
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Thanks mate, appreciate it. Exactly what I'd need

1966 Giulia Sprint $500 junk yard find. I probably overpaid...
1971 1750 Spider basket case , 1972 GTV 2.0 L
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post #13 of 18 (permalink) Old 06-17-2018, 09:36 PM
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I purchased my sill panels from Alfaholics. Fast and professional.

Gene
'71 GTV 1750 USA SPICA
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post #14 of 18 (permalink) Old 06-17-2018, 09:39 PM Thread Starter
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Thanks - I have heard good things. My panels that GTA is installing came from them too.

1966 Giulia Sprint $500 junk yard find. I probably overpaid...
1971 1750 Spider basket case , 1972 GTV 2.0 L
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post #15 of 18 (permalink) Old 06-18-2018, 10:51 PM
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Quote:
Originally Posted by Trich View Post
I think you've got the basic plan right. Something you'll need to be conscious of is that, once you've figured out where the rust stopped, you well be very close to the edge of where the patch panel extends, and right on the key styling line that runs the length of the car along the top of the door panel. So, it might be wise to have the patch panel in hand and mark exactly where it extends to before you start doing any cutting. It's probably a safe assumption that you'll also need to weld in some fresh metal around the window frame too for the inner panel. I formed these sections with a shrinker/stretcher and then test fitted the window just to make sure I kept the profile right. It's all very doable, just fiddly.

When I did mine I used the occasion to get POR 15 to any internal areas that I could possibly reach and then used a weld thru primer along the welded internal edges to minimize raw metal after the fact.
Trich - where did you source the repair panel seen below the side window in your photo? Cheers
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