Duetto; Motivate me

[craig_m5]

The Duetto has sat, accumulating dust and additional microns of rust for 12 months now, whilst i buy the odd shiny thing from Alfaholics & ClassicAlfa etc.



It's not (really) a matter of money.. more a case of time management and me wanting to be involved in her (??) rebirth. I've sourced OEM panels to replace anything with a dent, rust or hysterical welding (all floors, nose, that arch, the boot).

I stand at the crossroads of paint removal.

Complete dip immersion (Alkaline) by Redistrip in NSW (est. $3K) or a professional sandblast for the chasssis and dip anything that bolts off here in Qld.. it's about twice as much for the redistrip ($not an issue), more a logistical get it to Sydney thing. Some people hate dipping, personally i like the idea of converting all rust in the seams to metal and etch coating the #uck out of anything that was joined.

And then what colour.. i hate red.. somebody give me a 60's sky blue (maserati) metallic that will pop the curves (a bit like the BMW x5?!). Do i flick the original 1600 twin carb for a 2L twinspark (already bought).

too may reds tonight
should be doing the 2012 OP plan.
or shagging a gradaute

[Jim Bookie]

you like pinot?

[craig_m5]

*L*.. it's a french Bordeaux.. no doubt something to do with me faffing about with the whilte balance on the camera (neon1)... see, still procrastinating !!

[craig_m5]

Some progress. I pulled apart the drivers door as it had a large dent and kilograms of bog upsetting the delicate balance of the vehicle. I hand prepped the frame but was unhappy with the flash rust in the cavities I couldn't get into. I had the frame (alkaline) dipped then lightly blasted. The skin (new original tooling) was hand prepped before everything was epoxy primed.

I'm chuffed to bits, looks great.
I'm planning on using 3M epoxy to put this back together.. Just like a big airfix




This is the paint I am working with... and the reason we're going back to metal for those of you who said "roll it as it is".. It's been rolled, passed to the left and smoked for far too long, trust me.



Bonnet and scuttle are off for the same treatment as the door.
The nose and wings are next although they're spot welded on.
... I need to update Ways "what have you bought thread" with an spanking new AEG sawzall

[mdt]

Yes to the twinspark. You'll no doubt miss the 1600, but the electronic ignition will make the car much easier to live with.

That door looks awesome. If you can finish the whole of the car to that standard, it's going to be a cracker.

[Lima]

That door looks awesome. If you can finish the whole of the car to that standard, it's going to be a cracker.

I concur.

[mikinoz]

Just keep plugging away at it. I've pulled the Imp out and will get it registered for the first time in 4 years, excited me just doing a shakedown around the block.

It will improve your life to go for a drive now and then in this!

I like your approach!

[craig_m5]

Princess Amidala, your '66 Alfa Duetto awaits.



Looks cool in polished metal.. Maybe I should go all Harrods Sheik and paint it in that Mercedes liquid metal (stuff).

No damage in this door (yay)
some damage above that wheel arch (yay)

Kilograms of bog gone.. silicosis here I come

[craig_m5]

More bits back from the dipper today, scuttle looks new
Bonnet on the other hand appears to have been bump parked and/or shagged on for 46 years
Looking to replace with new if I can find one.

[Aussie_Golfa]

Princess Amidala, your '66 Alfa Duetto awaits.



Looks cool in polished metal.. Maybe I should go all Harrods Sheik and paint it in that Mercedes liquid metal (stuff).

No damage in this door (yay)
some damage above that wheel arch (yay)

Kilograms of bog gone.. silicosis here I come

You are wearing dust masks (or at least a hankie) aren't you

And those lovely rims need to come off and go under the bed until all of the grinding, tool dropping, liquid splashing is finished, stick some old runners on it for the resto.

Are you going to glue the door panels together?? Is that a new tequnique (for this car) or is it a modern improvisation????

Lovely to see, keep the updates coming.

[Super 180s]

*L*.. it's a french Bordeaux..

Just as well you clarified, we could have become confused that it was a Peruvian Bordeaux instead...

[craig_m5]

Yep, using a mask.. and glasses, of sorts. The thongs were a bad idea..

Glueing (epoxying) panels on is a modern technique. Originally the car was held together with numerous spot welds, lead wiped between joints and of course factory rust in all box sections (no primer!).

I've got some 3M epoxy for the skins and will seam weld everywhere for strength. The epoxy glues come in different strengths etc and can be stronger than welding in some cases (my welds for instance ). I'll probably do a mix with the wings and nose, pretty sure they're not (too) structural. In fact I was planning to epoxy in/on all panels, floors etc and the seam weld. Although this might affect front and rear crumple zones... Yes, this car is Alfas first car to be designed with crumple zones (on purpose )

Yes I'm making it all up...

Have ordered two new front wings and outer sills. Might as well do this properly

[craig_m5]

Which have now arrived, lines so sharp i promptly cut my freakin finger (bastard)
wonder if I can get this done before Lima gets his car back



Oh, and I tracked down an original perfect boot/trunk lid, these are made of unobtanium..The most expensive bit yet (yay!)

Merry Christmas - nobody tell Cathy

[craig_m5]

.... and a new bonnet to replace the original which had been abused and slathered with bog by a bastard '70s panel beater, perhaps i could wrap it in carbon fibre






Side by side shot - they changed the frame structure after mine. The OCD alfanazi purists will have a fit that i'm not reskining this with recylced original russian steel hand stretched by italian virgins... can't afford them - all this is getting out of hand (could have bought a Panerai by now).

Did Liam get his car back yet - how much more time do i have

[mikinoz]

Side by side shot - they changed the frame structure after mine. The OCD alfanazi purists will have a fit that i'm not reskining this with recylced original russian steel hand stretched by italian virgins... can't afford them - all this is getting out of hand (could have bought a Panerai by now).

Did Liam get his car back yet - how much more time do i have

I think this is progressing very nicely.

Was the deadline Liam getting his car back or his house built. Either way, you probably will still have a bit of time up your sleeve.

(BTW - Imp is registered! Only needed new brake lines and grease the kingpins)

[J-Tim]

Side by side shot - they changed the frame structure after mine. The OCD alfanazi purists will have a fit that i'm not reskining this with recylced original russian steel hand stretched by italian virgins... can't afford them - all this is getting out of hand (could have bought a Panerai by now).

Did Liam get his car back yet - how much more time do i have

Yes, because Chinese steel is soooo much better!

Just kidding

[craig_m5]

Yes, because Chinese steel is soooo much better!

Just kidding

German steel actually.. they're the only people making good reproductions from the original dies.
Opened up the nose.. found ancient damage hidden and never correctly repaired.
Yay, more bits to find/buy/make

[J-Tim]

Ughhh that's nasty!

Good luck!

[craig_m5]

will make getting the engine out easier

[The Pork Hunt]

lol i was pulling apart one of my minis for parts the other day and made more than one discovery like that, though less of the "bad repair" more a "feature" of british steel in just about every nook and cranny of the car Also random question to anyone who cares, clubman shell, rusted to ****, surely not worth fixing? i really couldnt be arsed but its gonna be hard seeing her leave my life 16 years and being my primary mode of transport during the "golden years" hah


I know youre trying to save money/do it yourself for the love and all that but thats the best part about just taking it somewhere to be stripped and fixed properly, its sans the heartache of every reveal of something crappy you should have expected, but weren't

[sweatyworker]

You can buy a brand new clubman shell from the UK. NFI what the cost is though... Actually it's 6000 pounds sterling plus shipping

[mikinoz]

You can buy a brand new clubman shell from the UK. NFI what the cost is though... Actually it's 6000 pounds sterling plus shipping

Better off buying someone's car that they have done a full reto on at that point for 10-15k.

Craig you should have found most of the surprises by now right?

[irsa76]

There's a bloke on another forum restoring a 105 and every time he thinks he's found all the horrors, more rust is uncovered. He joked that he might as well cut the car in half lengthways and replace the entire driver's side.
But then again he daily drives a 164 and his mrs owns a Rover 75, not to mention has half a dozen motorbike "projects" so he's probably insane!

[craig_m5]

Yep, there are no new surprises for me here. I've had this car (on & off) for over a decade, I know all her secrets. It's all just a bit ugly when it gets out in the air. Continuing a theme, the dodgy front end and unknown repairs to front sills forced me.. Hope I can weld as well as I can cut



Somebody has been here before...

[Tank Engine]

Holy snapping duckshiiit Craig. I thought early model UK Fords were bad but I bow down to your perseverance.

[craig_m5]

The most sought after part in my history with this car arrived at customs today ... I'm excited!**
**opinion is obsessively mine only, readers may not be as excited, your results may vary no promise or guarantee implied




Slight bit of rust around the lower skin fold, will convert or wire off... NEVER DAMAGED (hopefully) still has a nice gloss and paint sticker (avorio) on it. The holes will be welded shut as they're not correct for my '66. I can't tell you how long I've looked for this and how hard it was to find this from Aust.

I'm also never talking about how much it cost to get here, we're officially no longer keeping count !!
Oh yeah, didi mention I cut my front wings off

Happy Australia Day People !!

[RichSawkins]

I can't tell you how long I've looked for this and how hard it was to find this from Aust.

I can imagine, I have an Italian motorcycle so I feel your pain.... I've been lucky enough to find a good source of parts in the US.

Keep up the good work !

[craig_m5]

It appears I can weld. No doubt down to the tools (digital Kempi miniarc)

Let the reassembly commence
Okay.. Cmmence the planning of the jigsaw that will be reassembly
Once I practice some more

I'm excited again





Blew lots of holes in that last one practicing wire speed and stuff (okay, i've no idea, it's hard)

[craig_m5]

15x4.5"....46 years blasted and powder coated new

[craig_m5]

Finally tracked down the eight pieces of silver that make up the radiator support cross member bit (tech term) from Germany, Belgium and the UK




And today...... YAY !! OEM Duetto nose... (alledgedly original part(s), i doubt it, v'old nonetheless)



Hysterically, after searching the world (boot lid was from Toronto), this was down the road in Brisbane. I already have some reproduction pieces which get stitched together to make this part.. will see which is the best/neatest/easist fit

[craig_m5]

negotiating panel assembly and paint.. my requirements/desire for finish detail is outside my skill/talent/grasshopper
I'm not ashamed
I have other skills
Besides, i'd rather drive this f#cker before I'm too old to hold a license


You're all going to polled for a colour choice.. I'm colour blind.. And NOT red.
Don't think your getting off easy here, I want serious retro consideration. Way?

Part of me is enamored with a late '69s 911/912... You only live once right ?

[sweatyworker]

That Lemon Yellow colour. Love it. No gunmetals no metallic at all especially not silver. Powder Blue is your only other option... Although the blue on the Montreal could be cool.

[Lima]

Agree, no metallics.

Those blue options are pretty good.

[craig_m5]

Metallic blue was an OEM colour !!
Okay, I know, I did ask

[skc]

You only live once;