With the engine, major engine accessories, radiator, fuel system and exhaust all installed, this restoration can enter the phase focusing on the appearance of the vehicle. In this segment, some severe body rust is repaired, and the car is prepped for painting. After that, the vehicle is followed to the body shop for some professional body repair and a paint job. The objective is to restore the outward appearance of the vehicle as closely as possible to the way it looked when brand new.
Floorboard-Rust Repair
Note: Some of the steps shown in this segment feature specialized tools such as welding tools and plasma cutters for cutting away metal. If you are not experienced in welding or metal work, you may want to consider leaving major rust repair to professionals. Following is a summary of the repair as shown in the episode.
- The Alfa, though maintained reasonably well, did exhibit some major rust problems, particularly in the floorboard (figure A). Repair of rust in the floorboard is critical for a variety of reasons, including structural support, moisture prevention and avoiding the possibility of exhaust fumes entering the passenger compartment of the vehicle from underneath.
- The focus of this repair is the rust in the floorboard area on the driver side, near the pedal assembly. A wire-wheel brush is used to clear away some of the surface rust (figure B) to assess the extent of the rust damage.
- Once the main area of damage is identified, it is marked off with chalk to indicate areas that will need to be cut out.
- A plasma cutter is used to cut away the damaged metal (figure C). If you don't have access to a plasma cutter, you can generally achieve satisfactory results in a job like this using an air chisel, air nibbler or similar power tools.
- With the cuts made, a hammer is used to tap out the cut section of metal (figure D).
- With the hole opened up, a grinder is used to smooth the cut edges where the section of metal was removed (figure E). Use the grinder to provide smooth edges and square corners, as well as to remove as much rust-contaminated metal as possible. In that way, the surrounding area that's left will offer sound structural support for the replacement piece that will be welded in later.
- With the edges ground smooth, take measurements of the opening (figure F) to get the dimensions necessary for cutting a metal patch.
- A piece of replacement metal is placed underneath the cutout, and a marker is used to mark off the shape of the patch for cutting (figure G). You may want to cut the piece slightly oversized. Once the piece has been cut, excess can be cut away if necessary, but shortages cannot be corrected without cutting a new piece.
- With measurements taken and the outline marked out on the replacement metal, the piece is secured in a vise and braced with a piece of steel, and the patch is cut out using a plasma cutter (figure H). A plasma cutter produces temperatures of 24,000 degrees at the tip, allowing the metal to be cut quickly and easily.
- With the patch cut out, it is held steady using locking pliers while the edges are ground smooth using a power grinder (figure I). The replacement patch is ground and shaped until it closely matches the piece that was cut out (figure J).
- Using a magnet holder, the patch is positioned in the cut opening. The magnet allows the piece to be hand-held as it is tack-welded into place directly onto the floor-pan (figure K).
- Once the piece has been welded in place, a grinder is used to remove any raised spots left by the welding process. Grinding is done on both the bottom surface beneath the car (figure L), and on the top surface of the floor-pan (figure M).
- Further spot-welding and grinding may be necessary to achieve a good seal and flush surfaces, both above and below.
- Once the surfaces have been ground smooth and welding residue has been cleaned away, a primer is applied to the bare metal.
- After the primer has dried, a seam-sealer is used on the weld seams to help ensure a good watertight seal (figure N).
- After the seam-sealer has dried, a layer of black undercoating is applied to the surface (figure O).
In the segment that follows, the body of the Alfa is prepped for body work and painting.
RESOURCES :
Alfa Romeo Owner's Bible: A Hands-On Guide to Getting the Most from Your Alfa
Model: 0837607078
Author: Pat Braden
Order this book from Amazon.com
Bentley Publishers
Alfa Romeo Spider: The Complete Story
Model: 1861261225
Author: John Tipler
Order this book from Amazon.com
Crowood Press
Original Alfa Romeo Spider (Bay View Original Series)
Model: 0760311625
Author: Chris Rees, James Mann
Order this book from Amazon.com
Motorbooks International (MBI Publishing)
Essential Alfa Romeo Guilia & Giulietta Coupes & Spiders: The Cars and Their Story 1954-95
Model: 1870979591
Author: David Hodges
Order this book from Amazon.com
Motorbooks International (MBI Publishing)
Alfa Romeo: The Spirit of Milan
Model: 0750919582
Author: David G. Styles
Order this book from Amazon.com
Sutton Publishing
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
Model: 1557881944
Author: Jim Richardson
Order this book from Amazon.com
H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing
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