Alfa 156 sportwagon - Broken already ALFISTI PLS HALP

[stripped fred]

I admire you sticking with this. The majority of people wouldn't but this is autoshite and we like to save old cars when we can. Hopefully it will prove a reliable car when sorted and as you say another more expensive example would probably need money spending on it.

[Dave_Q]

Thanks, but its fate isn't decided yet, I'm about 80% sure I will have a crack at the welding, but if it turns out to be beyond me then it's probably eBay the interior + cartakeback time.

[Al Bundy]

Most metal on a car is 0.6 isn't it (or possibly even thinner on some modern stuff)? If I'm doing chassis work I might use 1.0. If I was making a tank I might use 1.2.

 

Its never the metal you are grafting in that's a problem, its the stuff you are attaching it too that will blow anyhow of its a bit shit.

 

Although I made up my welding skills as I went along so could be completely wrong on this.

1mm for chassis ?if you were making a roll cage what gauge would you use?

[stripped fred]

1mm for chassis ?if you were making a roll cage what gauge would you use?

Hi Al, long time no speak. Are you still up to your eyeballs in old car renovations? Hope it's going well.

[HillmanImp]

1mm for chassis ?if you were making a roll cage what gauge would you use?

I have never had to make a roll cage, why would I. I'm pretty sure Dave_Q doesn't want a roll cage in his family saloon so not sure why you are asking?

 

Is this some subtle way of showing off that you've made a roll cage or something?

 

I'm honestly lost on the relevance of your question?

[Dave_Q]

Yeah I'm probably not gonna put a rollcage in, need to be able to get children/child seats in the back.

 

I guess the exact gauge of metal doesn't matter too much, I'm thinking around 0.8-1mm so it will be easier to form.

 

To be honest I'll end up with whatever I can get my hands on, I expect the floors are thinner than the sills for example, so a mix of offcuts could work well.

 

There's a sheet steel place on my way home from work so might pop in Monday.

[The Reverend Bluejeans]

I use 40 gauge for chassis repairs using cold fusion technology.

 

[Eddie Honda]

Last time I bought sheet steel it was no more than 30 euro monies a sheet. Arse-ache transporting 8x4 sheets though.

 

I got 0.9 zintec, 1.0 and 1.2 CR4 sheets in the shed.

[Dave_Q]

Last time I bought sheet steel it was no more than 30 euro monies a sheet. Arse-ache transporting 8x4 sheets though.

 

I got 0.9 zintec, 1.0 and 1.2 CR4 sheets in the shed.

 

I (hopefully) won't need anything like that much, if I bought that much 90% of it would sit in the garage for years going rusty and getting in my way.

 

 

I use 40 gauge for chassis repairs using cold fusion technology.

 

No way have you ever bought "Liquid Sills" in a tub that small.

[Joey spud]

 

I use 1.2mm zintec sheet on body repairs,it's easy enough to form and you can wang the power up and get some good penetration on the weld without blowing through it.

 

http://www.ebay.co.uk/itm/car-body-panel-1...725.m3641.l6368

[Eddie Honda]

if I bought that much 90% of it would sit in the garage for years going rusty and getting in my way.

Err, umm.

 

[Al Bundy]

I have never had to make a roll cage, why would I. I'm pretty sure Dave_Q doesn't want a roll cage in his family saloon so not sure why you are asking?

 

Is this some subtle way of showing off that you've made a roll cage or something?

 

I'm honestly lost on the relevance of your question?

Well what im saying is if youre repairing a chassis with 1mm or less it isnt strong enough the same as you wouldnt build a cage with 1mm or less,they are both structural as is a sill which you are telling this lad to repair with bean tins

[Al Bundy]

Hi Al, long time no speak. Are you still up to your eyeballs in old car renovations? Hope it's going well.

Yes mate,old jag keeping me busy at the moment,hows the fleet?

[Bren]

Zintec is easy to cut and form as well as having that nice coating to stop rust.

[stripped fred]

Yes mate,old jag keeping me busy at the moment,hows the fleet?

All going well at the moment but I've got to mot the astra soon so might be giving you a call!

[Al Bundy]

No problem mate

[Dave_Q]

Some progress on the Alfa this afternoon.

 

Here it is, the heavy oil fired powerplant of Breadvan72's dreams.

 

 

First thing: Try to figure out why the washers don't work.

 

Locate filler - hidden next to header tank.

 

Apply screenwash and give it a try.

 

 

Success! That's one fail sorted, 12 to go.

 

Gears next. The linkage is down here somewhere.

 

There's evidence of an extensive oil leak in this area, possibly from the intake pipe which is suspiciously clean and scrapyard marked.

 

Battery tray needs to come out - this is covered in oil as well.

 

Now you can see the gear linkage a bit better.

 

This is the problem - this pivot sits in plastic bushes* and it seizes up.

 

The pin cleans up fine with a bit of wet'n'dry, then gets put back together with much grease and new bushes.

 

Success! All gears including reverse can be selected easily, although it doesn't self centre. It'll do for now.

[Guest Hooli]

Does the self centering come from the box or are there springs nearer the stick?

 

I've only ever had RWD boxes apart so not sure whats typical on a FWD.

[Dave_Q]

Pass on that one - there is a spring on the box but I couldn't quite see how it's meant to work.

 

I would have faffed more but it was chucking it down, it's not a top priority for now.

[strangeangel]

Yikes, how on earth did I miss this thread? Probably cos it said Alfa Romeo in the title I guess  

 

Sorry, but that fail sheet just says James Brown to me. GLWTWelding etc.

[HillmanImp]

Well what im saying is if youre repairing a chassis with 1mm or less it isnt strong enough the same as you wouldnt build a cage with 1mm or less,they are both structural as is a sill which you are telling this lad to repair with bean tins

Then why didn't you say that. I apologise for being deliberately obtuse but you were talking in riddles. I'm not trying to argue, I just thought 1.2mm was a bit thick. If the metal you are welding to is a similar thickness then use what you want.

[Dave_Q]

Firstly, I'm aware that I have 2 threads on the go mentioning this car, a thing I normally hate.

 

But I figure I'll keep this one up till it's tested then go back to my usual tat thread.

 

Anyway, who's ready for rust pics?

 

Most of them are a bit poor but you'll probably get the idea.

 

Skirt off -looking good.

 

 

Who needs sills?

 

 

Here is the highlighted bit of the floor, but it will probably be worse once poked.

 

Honestly I don't think it's too bad, most of the bits that need doing are fairly simple shapes, the inner sill looks good, the floor can be patched with flat sheet.

 

Could just do with some tips on what to do where the sill joins the floor.

[The Reverend Bluejeans]

I'd chop the whole lot out back to good* metal and just have two 90 degree flanges either side of the inner sill if it's still solid and can be cleaned up enough. I'd plug weld it here with seam welding around the edges. 

[Dave_Q]

Further mild progress, I've cut out the sill and floor and procured zintec sheet in 1.2mm, as well as some 0.7mm welding wire and matching tips. 

 

 

I've also scraped off all the shite underseal on the rest of the floors and lashed Vactan everywhere - I've got a big tin of underseal and plan to apply it to a "Somercotes Cortina" thickness in the hope of warding off rot elsewhere.

 

 

 

I've not made much progress so I'm going to have the day off work on Thursday in the (optimistic) hope that I can get it all done then and drop it off for retest Friday.

 

So does anyone want to come and help me? Someone with a clue on welding would be good, but any extra pair of hands would be great as I have other mechanical bits to do as well eg spring.

 

Ta.

[strangeangel]

Would, but my regular day off is Friday at the mo... not that I'd have been much use. My skillz are limited to burning holes in garden furniture with an arc welder, sadly.

[bub2006]

Not too good at welding but can wield a spanner. Spring compressors at the ready too. I'll check my rota for Thursday. What area you in?

[Dave_Q]

Ah yes, location would be an idea, I'm in Huddersfield.

 

Tis about 30min from Glossop, but you'd probably be best coming up the M1 to J38.

 

HD7 4AA is the general area for route planning/stalking/etc.

[bub2006]

OK I'll look into it mate

[bub2006]

I finish work at 1300 Thursday so will be an afternoon run. I'll check miles and time now mate

[chodweaver]

Might try to skive off work and show up if you're not already oversubscribed? Could even bring some tools...

 

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