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First Season: 1997  » Teardown  » Rebuild: Body     Etcetera

Chop! Chop! Now the really long hours and mess starts. Looking over the pictures as I prepared them gave me momentary chills even a year later. The images here are again just a few of many. Ask Me about any others, though I won't promise they might be any good. Fortunately I have another camera and more of a clue...

Some photos are from Warren.

1 9 9 8 Winter
Floors

Cut, Clean (Brush, Grind), Fit, Weld, Grind, Surface. These three shots represent a lot of hours, noise and dust. I cut and cleaned the holes just ahead of Sunny, he made patches or prepared the new panels and welded them in, I ground the welds and he surfaced.

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Passenger-Rear. Watch for brake lines attached to the pans with metal tabs.
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Passenger-Front. The oval at the top-end of the floor is in a pan underneath the floor that's open to wheel spray.
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Done! All pans press-fit neatly into the holes with only trimming for coverage I didn't need.
4 pans from Rob Martel
We used a braced scissor-jack to press the fore end of the front panels onto the frame members for a tight fit. Pans are welded in from above and below.
The Rest

More of the same along the sides and front. The car had been rumpled in spots and the divots filled with body-filler or in a few more-recent places patched roughly with sheet-metal and then filled level. Sunny pulled dents with a uni-spotter (a gizmo that welds a pullable pin to the metal) and hammered to "close". Sunny used three different types of filler. It will take years for a regular Alpine to be worth any more effort. There were two small structural reinforcements: bracing for the lower part of the front valance and across the underside of the trunk flip-up.

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D-side Rockers. The thin vertical strip in the "before" shot held the fender in place until we were ready to commit. It's a leaded seam.
2 rockers from Rob Martel
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The front had sustained a non-trivial impact and had been roughly welded and encouraged into some shape, then filled over.
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Sunny and I pulled the front into better shape and used a fibreglass filler, after hammering, where needed on deeper spots.
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Both hoods had been whacked.
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Attention to detail can be fraught with difficulties.
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Some days the job seemed to loom a little larger.
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Tools used, all from Sunny.
Clockwise from left: Hydraulic body puller for front; butane torch for removing lead; body sander; small and large slide hammers; body hammers; air chisel, cutoff, die-grinder and sander; crowbars for pressing and leveraging
1 9 9 8 Spring
The Tub is Etch-Primed and Sealed

It's starting to look more like a car again. Etch-primer bites into bare metal and resists rust. All bare top-side metal was prep-washed and double-coated. The tubs were done first so I could apply a flexible seam-sealer to every seam, fold, crack and hole.

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tub primed.
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tub primed - floors.
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tub sealed
Covering it All Up

Now it looks more like a car again. Sunny did all the priming. I hope this is the last time I see bare metal on this car for a long time.

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Bagged front axle. Since it wasn't coming off, the whole steering system had to be masked, as did the brake and clutch hydraulics.
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Bare metal was etch-primed, then the whole topside was covered with a high-solids primer.
Now some Real Colour!

What a relief to finally see something like 39: Carnival Red on the car again. Specs:
RS628N : SpectraMaster Red
DuPont ChromaPremier SS
850J Brilliant Red 48.1% 453.2
884J LS Red Oxide 6.0% 56.6
864J Magenta 2.4% 22.2
801J HS White 2.0% 18.8
52320N Binder 41.5% 391.0

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Inside areas are painted (doors and hoods too).
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The lighting brought out the orange in the paint.
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Painted inside firewall. Truest Colour
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In Henry's garage.
1 9 9 8 Summer
Small Bits

With summer on and the car too far from complete to make a season, only seemingly-little things get done, most of them unphotographed.

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Parts hanging from the ceiling of my garage.
Clockwise from top: "Hot" (engine) pieces primed: some become high-heat black, others red. Gearbox and misc pieces primed for hard ("roll-bar and chassis") black. Exhaust headers in very-high-heat white.

Every piece was washed in Varsol or Naphtha and bead-blasted. Before priming the piece was cleaned with metal-wash.

1 9 9 9 Winter
Small Bits

Now I'm onto all the small bits that seem inconsequential except when considered en masse. There aren't any photos yet, but here's where most things are happening for the meantime.

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My office work areas.
Clockwise from top-left: The machines I use to create Jerome's Sunbeam Pages. My workbench has a two-tub sink to the right, and the white pad is actually a long apron that covers me and the table. The fridge box has several resealable openings, a filtered fan-driven vent, some racks and a light (note the mask lower-left, still prudent when spraying).

First Season: 1997  » Teardown  » Rebuild: Body     Etcetera

Help Previous Page Up a Level Next Page Attachments   3.4.3. Rebuild: Body
JOY/CVP/YSEV/0.31 - November 7, 1999