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Discussion Starter #1
So i finally decided to make a restoration thread for my GT Junior,

So first of my name is Felipe but you can also call me Flip. I'm a 22 year old engineering student from the Netherlands who bought this alfa 2 years ago from South-Africa.
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The pics are from almost 2 years ago. In the mean time the car was fully stript and put on a rotisserie, the next step is to remove the undercoating which i'm busy with now.

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Here some pictures of the progress from the undercoating.
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removing it is done by using a steel wire brush on a drill. For the stuff that doesn't want to come of with the wire brush I use a towel and thinner which works surprisingly good. As the car will go to bare metal anyway i don't mind that it takes the paint with it. Will let you guys know soon what the plan is with the heart of the car.

Flip
 

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Another single headlight Junior??? If so great will watch with interest. Regards John...
 

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Discussion Starter #4
Today i went to the workshop again to continue removing the undercoating.

The progress on the front wheel arches. Still a lot to do there.

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After taking a closer look i found some strange welds there...
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I find it strange that someone welded these spots as the area around it looks quite normal to me. Especially in the first picture i can't find a reason for the welding there. If some one can tell me why the previous owner did this as i'm quite curious.

I have these kind of spots also on the rear wheel arches where I can't point my finger on why someone would make them there:
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Anyway, I went on removing the undercoating on the floor as well.
The car has some wacky repairs at the front floors which a first thought were welded really badly but are actual soldered.

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Discussion Starter #5
After removing some more of it i started finding some of the holes this car has after almost 50 years

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To be honest i does't look to awful for a car that is almost 50 years old. I'm quite sure i will get some new floors for the front of the car. But the rear looks quite repairable. Here is a before and after photo:
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Flip
 

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Somebody has definitely been there before as the sill/rocker vertical seams between rocker and guards are missing.

In regards to those other welds, are you sure they are not Alfa Romeo welds? Not all welds were spot welds, and their welding was shockingly bad
Pet
 

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Discussion Starter #7 (Edited)
Time for an update again,

So after working on the underside i got a bit sick of removing the coating. Because of this i decided to focus on the removing the paint from the body.
The first method i tried was using chemical paint remover. This process works great on the paint,
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but under the layer of paint there was bodyfiller... quite a lot of body filler...


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The paint stripper doesn't work on the body filler thus i decided to try my luck again with wire brushes on a drill. This got the body filler off but was also a really slow process. While doing this I got a few surprises on the way.

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The outer sill has been replaced before. It is riveted from the underside, and (correct me if i'm wrong) it is brazed from on the top side. Beside this there were places where there was more the 2 cm of body filler

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I continued my journey and found under the body filler that it is rusted through on the bottom side of the front fender. The previous owner just threw body filler on it.
 

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Oh dear. Thankfully you can buy very good quality repair sections for the guards and new sill/rocker panels from the usual sources (AlfaHolics, Classic Alfa, etc.)

Pete
 

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Discussion Starter #9
This was the result after 2-3 hours of removing body filler. The rear fender was great, It was a nice smooth panel and only had some strange spots.
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Some one gave me a tip on using a scotchbrite wheel for the angle grinder. First i was a bit afraid of using it because it might create a lot of heat but after hours with the drill i decided to give it a try.
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So i bought myself a wheel and began to use it. After 30 min this is the result:
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These wheels work great and fast. As long you keep moving they create no heat at all. Only problem with them is that they produce a **** load of dust. As a result the workshop was also under the dust.

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After cleaning the workshop i got the message that it is better to not do this at the workshop. I got the tip to get some friends and try to finish this in a day outside, and hope that the neighbours wont complain about the noise. Thus i did. Armed with 3 angle grinders me and two friends began stripping outside. It worked great til we stopped after 20-25 minutes. There was a little breeze and as a result the dust was flying away to the neighbours in the ally where the workshop is located. We decided to stop and started cleaning the ground. We cleaned the cars that where parked off with compressed air. I thanked my friends for helping me and even though it was not a long time this was the result of it:

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The right side of the car looks to be in alright shape except for the rust at the front fenders. The left side however has quite some dents. No big ones but you can feel them when you go along the surface with your hands.

Here is also a photo on the progress of the underside of the car:
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At this moment i'm trying to figure out how to go on. On the one hand i want to keep going using the scotch bride wheels as i still have 2 unused and 2 in good shape left. But inside the workshop isn't an option and outside as well. Any suggestions are welcome!
 

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Discussion Starter #10
Oh dear. Thankfully you can buy very good quality repair sections for the guards and new sill/rocker panels from the usual sources (AlfaHolics, Classic Alfa, etc.)

Pete
Yea it is indeed not that great. I'm quite curious on what i will find in the inside of the sills/ rocker panels. Thank god that there are company's reproducing these parts!
 

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Felipe, if you can get a string vacuum to take out the dust maybe one used for wood working machine with a large hose say 100mm diameter, this will remove the dust, make a custom shroud to fit on the grinder, it will be less accurate to handle, but clean.
Tim
 

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Yes I agree with Sebastiaan, the heat gun is efficient, when you use the scraper grind the edge to 90 degrees, it is far better than creating a bevel edge, I have done more heat stripping than many and this is what has proved the best profile, straight across the grinder wheel while supported on the tool rest, you can create a radius also so the blade is slightly convex, this will lessen the chance of catching on the corners. Takes a while to get the feel of it but not hard, a scraper with a long handle is better too, less chance of hands becoming burned and more control.
Tim
 
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