Restoration of 1600 Jr Z - 3060346 - Alfa Romeo Bulletin Board & Forums
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post #1 of 134 (permalink) Old 07-08-2012, 08:26 PM Thread Starter
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Restoration of 1600 Jr Z - 3060346

Thought I would start a thread to document the restoration of my Jr. Z. I bought the car from a long time friend last year. He imported it from Italy in the mid-80s along with a 1300 Z. So I'm the third owner and it has the grand total of 23,000 miles on it. The original owner raced it in Italy so many of those miles were hard ones. He put an Autodelta 2 liter in it, so Ziggy gets along pretty well. The car has a few bits of surface rust so overall, I consider it rust-free. The second owner had the interior redone and the car repainted in 83 before leaving Italy, so its not the first paint job.

1973 Alfa Romeo Junior Zagato 1600 Images. Photo: 73-Alfa-1600_JR_Zagato-DV-11-CI-02.jpg

I bought the car after it sat under car covers in the driveway for 10 years. I started with rebuilding the front end and other sundry mechanical issues. My wife and I drove it to Monterrey for the Concourso. I had less than 200 miles on it as the new owner and been towed home twice before starting the long journey from San Diego to Monterrey... The car ran really well but used/leaked 4 qts of oil in 1000 miles.... After 40 years its time to really go through the Zagato.

My goal is not to go as far as Brian is with his 1300 but I'm sure he'll have a STUNNING car when he's done.

Chassis: The interior is very serviceable and with some clean up and repairs it will be fine. My ultimate goal is to send the dashboard to LA for recovering; we'll have to see how the funds hold out.
The exterior has a few dings and surface rust spots, so a complete new paint job is necessary to include the engine compartment. All new gaskets around the windows have to installed since the original parts are dry rotting. All of the stainless steal is serviceable. Under the car, I'll clean it and re-spray the undercoating were appropriate. Like Fred, I have some door locks to repair.

Mechanically: The entire front end has been rebuilt already. It still sags on one side so I have four new springs. I'm going to pull the rear end out to replace the trunion since the spacers are rotted out. I found a NOS still in the bag trunion last year. It also gives me the opportunity to clean up the rear suspension and replace the springs.
The big ticket items are the engine and transmission. Both are being completely rebuilt and I'll save the details for my next post.
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'73 1600 Jr. Zagato, '73 GTV, '12 Fiat 500 Abarth

Last edited by mjlang; 07-17-2012 at 07:34 PM.
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post #2 of 134 (permalink) Old 07-09-2012, 12:19 AM
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What a gorgeous car......

Alister
1973 105 GTV (Alfa #6 of 19 owned)
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post #3 of 134 (permalink) Old 07-09-2012, 06:53 AM Thread Starter
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Pictures make the car look far fresher than it really is. Up close, the cosmetics don't hold up so well and the motor leaked oil EVERYWHERE. I do have a beautiful canvas on which to paint my masterpiece.

'73 1600 Jr. Zagato, '73 GTV, '12 Fiat 500 Abarth
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post #4 of 134 (permalink) Old 07-09-2012, 08:18 AM
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Wow. You're setting the bar high for me

That's a nice looking car you have there - the angles all look extremely straight and the shut-lines are perfect. You're already so far ahead of where I was when I started!

I'm generally not a fan of yellow on any car but the particular yellow orange on yours looks great. Is that close to original?

The rockers on my car were blacked out like yours. I guess that would happen when folks sprayed rocker shutz - maybe to hide the texture? It's sort of a shame - the rocker lines have a nice curve to them that get's lost when painted dark colors.

Brian OKelley

'69 Junior Z (AR1800015)
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'87 Milano Gold - troop carrier
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'71 145 Volvo Wagon - Alfa engine transport
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post #5 of 134 (permalink) Old 07-09-2012, 09:47 AM Thread Starter
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I don't know why Ed had them spray the black stuff on the rockers. There's no rust on the car since it came from southern Italy and has lived in Escondido for the last 30 years. I keep watching your adventure with Pat's old car and think its really cool.

That is the original color; Giallo Oro Z... Its my favorite on the Zagatos so far. The other color that would look stunning on the car is a Porsche stone gray from the late 50's 356s. I saw one in town, it has greenish tint to it. I won't change the color of mine, not worth the effort, but if I was doing a full "go crazy" like you; I'd think real hard about it.

'73 1600 Jr. Zagato, '73 GTV, '12 Fiat 500 Abarth
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post #6 of 134 (permalink) Old 07-09-2012, 10:24 AM
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Gray does look really good on these cars. I'm going to go with the light-silver/gray - it shows off the lines really well.

You knew Pat? Excellent dude. It was great to get to hang out with him. Went to his place a few times after I bought the car to chat and drink beer. Great conversation.

Brian OKelley

'69 Junior Z (AR1800015)
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'67 Giulia '1750' Super - rally car
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'71 145 Volvo Wagon - Alfa engine transport
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post #7 of 134 (permalink) Old 07-09-2012, 10:27 AM Thread Starter
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Yes, I knew Pat for 25 years and miss him very much. He would be mortified if he know how much work you're having to do on this car. It was their driver car and it always ran. There is a dove gray that Ford put on Mustangs that would be really cool on this car. I always wanted to paint a GTV with that color.

'73 1600 Jr. Zagato, '73 GTV, '12 Fiat 500 Abarth
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post #8 of 134 (permalink) Old 07-09-2012, 12:13 PM
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Yeah. I hadn't intended to go so far with this car but the rust was just so extensive, there really was no choice. The front sway bar mounts were completely separated from the body, the inner sills were completely gone, the tail was rusted away from the frame, stuff like that.

It reaches where you really have no choice but to do the work that needs to be done.

It's still going to be a driver. There's no question about it. I used to be able to keep up with Conrad Stevenson's SS in my car - it's a fast little bugger - Pat really knew how to build a 1750!

Brian OKelley

'69 Junior Z (AR1800015)
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'67 Giulia '1750' Super - rally car
'87 Milano Gold - troop carrier
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'71 145 Volvo Wagon - Alfa engine transport
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post #9 of 134 (permalink) Old 07-14-2012, 10:50 PM Thread Starter
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So things are progressing slowly, but I'm meeting weekend goals. So far I have the motor about half assembled. Pistons will take me an hour to put in this week and my mechanic has the head done. That's been an adventure... The original head was milled about 1/8 of an inch. They had this super thick head gasket and no pins in the head so it leaked like crazy. We also found the entire head was shot, valves, guides, seats, etc. My mechanic had a head and donated it to the cause. It only needed one valve and seats as well as the porting/polishing redone. The cams are high lift, short duration so with the porting and slightly oversized seats, it should work well. The bottom end was a whole different story. Autodelta did arts and crafts on crank and rods. Lots of metal was removed and its all balanced, a real work of art. I'm puzzled with the attention to detail on the bottom end and the crap head. This used to be a race car in Italy, so I suspect it was a fix in the pits... The rest of the motor looked like it has about 10k miles on it, nothing is badly worn but the head looked like it has 100K on it. The whole car only has 23K on it.

We spent today working on the transmission. I have all the parts ready to go to reassemble the entire unit next week.

I also spent an hour taking off the rear bumper or at least what they pass off as a bumper. As always, three bolts are easy, the fourth is pain in the ***. True to form, my Dremel tool failed half way through the job and off to Sears I went to get a new one.

Goal for next week, finish the engine and transmission build. Below are some before and after shots.
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'73 1600 Jr. Zagato, '73 GTV, '12 Fiat 500 Abarth

Last edited by mjlang; 07-17-2012 at 12:31 PM.
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post #10 of 134 (permalink) Old 07-16-2012, 11:34 AM
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"but the rust was just so extensive"

Real shame, as it had NO rust when we drove the car in 75. Hope to see it running again some day.

Del

Seattle

1989 Milano, Shankle Sport
1991 164S, stock
1994 164LS (~Q)
1972 Morgan 27

previously owned since 1964:

62 Morris MiniMinor 850, 67 Austin 1275 Cooper S (Downton 3/4 race), 64 Giulia Sprint GT (1st red one made), 72 Fiat 128 Sedan, 75 Alfetta Sedan, 78 Alfetta Sedan, 78 GTV, 81 GTV6, 86 GTV6
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post #11 of 134 (permalink) Old 07-17-2012, 03:32 PM
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Oh, trust me, you will.

You'll have to take it for a drive when it's back on the road so you can make a comparison between the stock car and the restored version

Sorry that it won't be through the French countryside. We'll have to make do with Seattle byways.

cheers,
Brian

Brian OKelley

'69 Junior Z (AR1800015)
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'67 Giulia '1750' Super - rally car
'87 Milano Gold - troop carrier
----------
'71 145 Volvo Wagon - Alfa engine transport
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post #12 of 134 (permalink) Old 07-17-2012, 08:01 PM Thread Starter
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Attaching some images of what's ahead...
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'73 1600 Jr. Zagato, '73 GTV, '12 Fiat 500 Abarth
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post #13 of 134 (permalink) Old 07-18-2012, 11:25 AM
Del
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"Sorry that it won't be through the French countryside. We'll have to make do with Seattle byways"

Ahhh, too bad, although I have decided that a spirited drive through Tuscany on their really great roads would be much better. Shame I didn't have it a couple of weeks ago when we were there. Just great open winding roads through the wheat fields and vineyards, and along the tops of the hills. Sooo smooth and picturesque.

Anyway, keep it going. These are great cars from the modern era creative days of the 60's and 70's of Alfa.

Del

Seattle

1989 Milano, Shankle Sport
1991 164S, stock
1994 164LS (~Q)
1972 Morgan 27

previously owned since 1964:

62 Morris MiniMinor 850, 67 Austin 1275 Cooper S (Downton 3/4 race), 64 Giulia Sprint GT (1st red one made), 72 Fiat 128 Sedan, 75 Alfetta Sedan, 78 Alfetta Sedan, 78 GTV, 81 GTV6, 86 GTV6
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post #14 of 134 (permalink) Old 07-19-2012, 01:04 PM
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Morgan,

Glad you are documenting this. I can't wait to see it when it is done.
Good Luck!

Dave De Rosier
1969 Spider, 1965 Giulia Sprint GT vintage racer
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post #15 of 134 (permalink) Old 07-19-2012, 03:20 PM
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It never even occurred to me that 1600 Z's are hanging pedal cars. Must be nice to have dual circuit brakes. I'm probably going to re-pipe my car while it's apart - when I pulled all of the plumbing out of it there was a decent amount of pitting. Definitely don't want to blow a hardline when you only have a single brake circuit...

I'm noticing that there are 5-6 decals on the top of the passenger inner fender. I don't suppose you could post a snap of those? Curious if the decals are the same between a 1600/1300. What's that big red sticker?

Thanks!
Brian

Brian OKelley

'69 Junior Z (AR1800015)
----------
'67 Giulia '1750' Super - rally car
'87 Milano Gold - troop carrier
----------
'71 145 Volvo Wagon - Alfa engine transport
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