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Discussion Starter #1
Just what the BB needs, another Super project!

This my project I picked up in Sebastapol, CA 2 years ago. In retrospect I am not sure this car should have been saved but its mine now so here we go. Updates and progress will be pretty slow. My goal is a CSRG vintage racer that can be street legal again if I choose. This car is way too rough to restore fully (IMO) but I have tried to do things the best I can as a home hobbiest.

Before you say it, Andrew has the serial number already....

Isnt she lovely....
 

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Discussion Starter #2
It ran... somewhat

So I had to know it if would run.

Changed out the starter (burnt up)
rebuild the webers
new fuel pump

It tried to start but was struggling. Eventually some beating on the muffler loosened up about a million acorns and she coughed to life. Actually sounded pretty good but a pop out of cyl 1 and hard starting had me suspicious. compression test
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pulled the head and there is a little corrosion problem. My pro welder buddy has since fixed this right up. However this was just for fun, the bodywork really needs attention before the engine.
 

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just a bit of bondo right....

So this is by far my most advanced car body work I have ever tried. Done a bit of reading and other guys on the BB inspired me to give it a go. This car has been hit in front, repaired poorly with a lot off brazing. It was then hit again and partiallly repaired and left in the rain for years. I found a front passenger fender at APE, unfortunaltely the driver fender was terrible and the lower valance and radiator support are very poor on the APE piece as well. But its a start and you dont find parts for these very easily anymore.

Man it takes a lot of drilling to break out all the factory spot welds on the fender....
 

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bumper horn and subframe

Unfortunately the driver side frame area where the sway bar attaches and lower radiator support attaches is totally rotten. Passenger side is fine. Seems much like Porsche 914's battery acid runs down into the frame and wreaks havoc. The Ape clip donated the replacement horn which i seam welded in place. I tried to overlap tabs as much as possible. I treated the inside of the frame rail to rust-mort and por-15. Was not fun trying to wire brush the inside. I suppose the only perfect way to fix this car would be a complete subframe dis-assembly like Daron does but thats way out of my budget and skill level.
 

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Discussion Starter #5
more parts..

I got a new valance and lower radiator cross member from Classic Alfa. Great folks to work with. I cannot believe how fast they get parts to California. They always reply patiently to my questions and emails. They are reasonable on shipping, parts are top quality. I get status emails on my orders with tracking numbers. The US vendors could take a lesson on how to run a biz....

Borrowed a spot welder and this saved a lot of time installing the cross member and the lower valance. Plug welding is time consuming at my skill level.
 

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Discussion Starter #6
cont...

On the top radiator cross member I had to seperate the inner and outer shell to be able to straighten it well. Its a meld of the original and the donor clip from APE. Some of this sheet metal is very thin and tough to weld without blowing holes. I am slowly getting better. Lots of grinding!

Once I had the crossmember on and test fitted the the lower valance and the hood along with a bit of measuring I seam welded the pass. fender back together and plug welded all the original spot welds...

The fenders did not line up at the lip but a bit of sectioning on the blue fender fixed that. Was much easier than I thought it was going to be. The stuff you think will be hard is always easy and via versa....
 

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a little dash work

I took a break to rebuild the instruments. They are a really pretty piece. spray on stripper took care of the outer bezel and I disassembled the gauges to clean the glass, paint the silver bezels and polish the rust out of the chrome as best I could. I had a local shop reupholster the pad. I am really happy with this result.
 

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a complete front end...

I did a big push this last weekend and got the big welding complete on the front end. Rebuilt the headlight housings and polished the 1 piece grill. The car originally had the figure 8 headlight bezels but I like the 1 piece grill. The stuff that came with the car was totally mangled anyway. I bought the 1 piece grill from the BB and got it for a good price but its very warped. It polished up nicely but is actually pretty pretzeled (twisted) from end to end. Stainless steel does polish up nicely but does not like to bend back to shape.

Next is the rear fender arches and rust holes in only one door ??? Why only one? A few holes in pan to fix and it should be relatively hole free. Suprisingly the lower side longs are rust free. No rhyme or reason to some of this rust action. I also got the rear fender arches from Classic Alfa, this area is trickier than its look. There is 3 layers here.

Anyhow its nice to drive into the garage and see a face on my Super, Its got such a nice smirk. Must be one of the coolest front ends in auto history.

Probably take a bit of a Alfa break now. My 914-6's engine needs some serious attention. My 7 year old is finally "into" cars and my only running sports car start spewing oil like the Valdeez.

Promise to update when thing happens. Appreciate all the info on this BB

cheers Daron
 

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Just what the BB needs, another Super project!
No need for tongue in cheek on this one. Of course we need to see more Super projects! Its keeps sewing the seed of covetousness in the hearts of all spider and coupe owners!:D

Very ballsy to cut off all that metal on the front. It'll be a fun car when you are finished. Keep up the great work.
 

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Wow that was a lot of work. My super just had some rust on the sway bar mounts. I didn't bother with fixing it and just fixed the outer sheet metal since I went with a rear mount front anti-roll bar. It acts as a chassis stiffener too! Sooooo much better !
 

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Discussion Starter #16
Some Updates on the Super

Time moves on and slowly we do a little work here and there. I coach a comp soccer team for my 12 year old which consumes an amazing amount of time. But here is the latest!

Heater box was previously a home for elderly mice. Needed a new core, motor, control valve, hoses and a complete disinfect/rebuild. Found nice matching screen material from home depot (gutter screening) Classic Alfa supplied the Alfa bits
 

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Discussion Starter #17
Pedal Cluster Ready

Almost all the clevis's and pins where oval'ed. Some welded and re-drilled and found some matching bits in my porsche parts collections. The pedals would not even move. It all polished up nicely. Ordered a brake master rebuild kit for the ATE but does not match. Apparently I have the one that they dont make a kit for anymore so will have to get a replacement unit.
 

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Discussion Starter #18
Back Seat Re-upholstered

Got a rear seat only kit from Re-Originals. A local upholstery guy quoted me like $1400 just to do the rear seat!!! Got to love California prices.

Was quite a battle and the Arm rest makes it a little tricky but also happy with this result. Had to do a little welding and clean-up on the wire seat frame. The lower Pirelli brand seat foam was in good shape. The Horse-hair back rest was rough. Had to cut some off the top and make a foam top and use lots of passing. Replaced the rotten material between seat and frame with a nice canvas.
 

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Discussion Starter #19
Motor Update

Got the block and head back from Del's Machine in Sacramento who are a great resource and I always have good results with this business. I gave the head the mild port and polish via the Greek fellows book. Most of my rebuild stuff comes from Spruell's who where good to work with on the old school way of making calls and actually talking to someone.

I have the crank in. Just had it polished and checked clearances. All looks good. For a filthy abused and neglected car some parts are in very good shape after you clean the years of crud off them.

I had to spend a lot of time cleaning corrosion out of the inside of this block. The head needed welding where corrosion has eaten away at the surface. This little car was not well cared for.
 

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Discussion Starter #20
Tires and Wheels

Well not really needed yet but could not resist putting some nice new Michelin vintage tires on my Minilite wheels I set aside for this car. I put a coat of paint on the wheels and changes out the front left hand thread studs with some off a parts car I have. The rear axle will be replace with a later LSD unit that will give me normal threads to accommodate the special shank-nuts the Minilites require. The offset seems just right for the Super.
 

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