Alfa Romeo Giulia (105): Headlight Restoration

The restoration of my classic Alfa Romeo Giulia continues.
The headlights, though working without issues, were in too bad shape to go in again. I restored the headlight bowls, replaced the headlights, adopted the front mask repair panel by but welding in the fasteners of the inner pair of headlights, zinc coated all small parts and fitted the whole lighting system back to the car.
Here's the link to my partner where I get my spare parts:
www.myalfagrou...
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I bought this '72 Giulia Super 1.3 in the internet, without seeing her before. Then I went to Napoli by train and transferred her home on wheels.
You say that this is all wrong? Yes, I know.
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#Alfa105 #ClassicAlfa #restoration
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[@tik888]

You do a good job! When butt welding iron plates, there is a method of leaving a gap of about 0.8 mm to 1.0 mm. With this method, it is possible to firmly melt to the back side with a single welding. It is efficient to insert a flat-blade screwdriver into the butt surface as a guide for the interval.

[@tik888]

Also, of course, it is necessary to cut out the iron plate piece on the premise that there is a gap of 0.8 mm to 1.0 mm.

[@GreasyFingers]

Thanks for commenting. I can see where you’re going, but wouldn’t the (steel) screwdriver melt into the weld?

[@tik888]

@@GreasyFingers Insert a flat-blade screwdriver into the gap and leave a space so that it will not be affected by welding. Then you're okay! Since there is a gap on the butt surface, it melts to the back even if it is welded at a low voltage. I will show you a link of a Japanese work video that is actually welding in this way. He is doing it here. kzbin.info/www/bejne/eaOcl32bpJdpn9E This is the person's main channel. kzbin.info/door/rr4pkk-gzxvEadRHlp5vUg

[@GreasyFingers]

Thanks, mate. Looking forward to watch …

[@tik888]

​@@GreasyFingers It seems that there are cases where a gap of about 1 mm is left on the welding surface, and there are cases where welding is performed by sticking without leaving a gap. He seems to use two methods depending on the location.

[@oleoppenheimer2399]

Schönes Video wieder, erinnert mich von der Machart ein wenig an Jethro Bronner aus Südafrika ... mach weiter so 👍 beim Blech stumpf einschweißen empfehle ich übrigens lieber etwas „Luft“ zwischen den Blechen zu lassen (1mm). So hat das Blech die Möglichkeit sich etwas auszudehnen und verwirft sich nicht so sehr ( auch mit Druckluft kühlen wie du es machst) .... ist zumindest meine Erfahrung 🙂

[@GreasyFingers]

Danke, Ole. Ja, Jethro war immer ein Vorbild für mich. Wir haben inzwischen regen Austausch und irgendwie kommt’s mir vor, als würden wir uns gegenseitig pushen (auch wenn sein Kanal viel größer ist). Zum Schweißen: das Blech dieses Autos hat eine starke Neigung, einfach weg zu brennen, insbesondere das alte Blech. Es ist eine ständige Gratwanderung zwischen zu eng und zu weit. Ich müsste meinen Drahtvorschub noch erhöhen, dann wär’s wahrscheinlich besser. Geht aber nicht, bin schon auf Maximum.

[@oleoppenheimer2399]

@@GreasyFingers ja kenne ich 🙂 ich versuche mich immer an dem Nachbarschweißpunkt „anzulehnen“ 😀

[@gearhead9828]

Deeply impressive as always. Can't wait for the next video. Will there be engine work required as well? Ciao 🙋‍♂️

[@GreasyFingers]

Thanks! With the workshop moved, I hope I’ll be able to pick up the pace from earlier this year.

[@goofballgarage]

@@GreasyFingers The pace is perfect .... it is a labour of love ....... and you cant hurry love ;-)

[@rainerdorwin311]

Another great video - impressive to see this absolute attention if not addiction to detail - Chapeau!!! Well, maybe better: Tanto di cappello!

[@GreasyFingers]

Thanks, Rainer. That’s extremely kind from you. I’m trying to continue doing my best ...

[@MLC...]

As a Giulia Super owner myself, I find these videos fascinating. They are helping me get to know my own car, teaching me things that I have not discovered about Giulias in 24 years of ownership (rust free original unrestored South African car). I have bought a set of hammers and dollies that look like yours which I have started to make small repairs on 116 Giulietta. Thanks for the inspiration!

[@GreasyFingers]

Thanks a ton for this comment, Jacques. It really gave me a blush.

[@Kai77884]

Hello a great video and a perfect work 👍👍👍👍Mit freundlichen Grüßen aus dem Ruhrgebiet 👋👋👋 Kai

[@Matteo_Licata]

So glad to see you back on KZbin and progressing with the Giulia! The availability of new panels really is a godsend... I can imagine how difficult a restoration would be without these. By the way, are the new headlights modern repro units? I didn't know those were available!

[@GreasyFingers]

Thanks, Matteo. Yeah, I moved my workshop to another place, one more suitable for winter. Now films they’ll keep coming ... Regarding the spare headlights: I’m not quite sure, but I think they are authentic from Carello.

[@Matteo_Licata]

@@GreasyFingers New-Old-Stock then? Wow, that makes it even more interesting. Can't wait for the next videos!

[@jimmygrant3212]

They reproduce them but not entirely great reproductions. Some people have removed the lenses and glued their original Carello lenses onto the new buckets.

[@Matteo_Licata]

@@jimmygrant3212 Thank you for letting me know. Quality concerns are exactly the reason I asked, as the quality of repro parts often leaves much to be desired.

[@stevewuertz3598]

Another great one. Thank you so much. Especially like the detail to reassembing the little clips and fasteners. The time between disassembly and repair, plating and paint is so long that I often forget those details like the orientation of an adjusting screw. Olive green is a great color and I'm tempted to do my 66TI in that color.

[@GreasyFingers]

Thank you, Steve. I already incited Jethro to use the green on his GTV, so now we’re three.

[@freakboy3786]

Good job! Very deatailed one

[@villalji]

Great job Johannes, as usual, I love your attention to detail!

[@GreasyFingers]

Thanks, Jesus. It’s the sum of proper details that makes them stand out.

[@NikkoSalgado]

First! amazing job as always mate

[@GreasyFingers]

Thanks, Nikko. ☺️

[@richardtrias262]

Bella máquina viva l' italia

[@GreasyFingers]

Nothing to add. 😊

[@alessandromeyer4888]

Did you ever consider powdercoating yourself? It's relatively easy and with your level of skill would be an easy upgrade for sturdier paint.

[@GreasyFingers]

Thanks, Alessandro. Sounds very interesting. Tell me more, where can I find a starting point?

[@alessandromeyer4888]

@@GreasyFingers There's actually not that much to it: you need paint-powder, a gun, and an old oven capable of 180° C ~. Reasonable guns can be bought for a bit over 100€, 500g of reasonable powder costs as much as the next rattle can. And we just used an old Miele oven thats it:rock solid paint on the suspension parts of my GTV and Giulia. :-) I even coated the brake calipers without a problem. I enjoy restoring old rusty parts as much as you do. Hence I did my giulias suspension before any chassis metal work, which is why I am here now (und auch noch wegen allem weiteren was du so tust. :-)

[@GreasyFingers]

Now you got me hooked … Thanks!

[@brokenbonegarage8910]

I'm sure Master Fitzee woukd approve LOL Great job sir, watching you work, you introduced something in the way I work on the car I'm rebuilding, patience. Thank you!

[@GreasyFingers]

Thanks, Michel. I just recently came across the concept of patience myself and I have to say it really works.

[@FhVW]

great eye to detail! what color is this?

[@GreasyFingers]

Thanks! The colour‘s name is Verde Oliva Metallizzato.

[@franky19541]

Hi, After the Headlight Restoration is there other video of the 105 ? By the way I love your garage always well maintained, clean and of course i would like to give honor to the way you work and the patience you show. These are signs of a "Man with golden hands" If I had a car to be repaired I would give it to you blindly knowing the end result would be "Pristine" Congratulation Mister Greasy Fingers

[@GreasyFingers]

Bonjours François, you really make me blush. Thanks A TON! In the 105 Series, after the headlight video there’s the floor pan video. You find them all in chronological order in the according playlist.

[@steliosh3928]

I VE SEEN A LOT OF VIDEOS WITH THAT PROJECT .PERFECT JOB !!!. i MEAN THAT YOU WORKED SO HARD TO REPAIR EVERY DAMAGED PART IN DETAILS. I LOVE THAT YOU DONT LEAVE ANYTHING AT ALL REPAIRED PERFECTLY !!!!

[@GreasyFingers]

Thanks for the feedback! If you do it, do it right. 😊

[@pseudonym4957]

Good to see more progress, these videos are always so well done they're a pleasure to watch - I have a Toyota RT72 I struggle to get parts for so rebuilding is slow, but I fell in love with the verde oliva colour after seeing it on a 105 so everytime I see your Giulia being reborn here it gives me a bit of spark to keep building 😁 Thanks for sharing 👍

[@GreasyFingers]

Thanks a ton for your comment, mate. So encouraging. I very much like the RT72, keep it going!

[@bertone1805]

Nice work. A lot of work but very rewarding. Good luck with the rest of the Giulia. I will have a drive tomorrow in my own Giulia

[@GreasyFingers]

Thanks, mate. Enjoy your ride tomorrow!

[@joelpriestland793]

Hey. Just doing mine. How do you get the spring assembly off the inner light ring please?

[@GreasyFingers]

Hey. Just pull the plastic ring like in 1:30. The ring might be gone, it’s just plastic.

[@joelpriestland793]

@@GreasyFingers it’s the smaller light so like 1:43. Just pull?

[@GreasyFingers]

Yeap. Some anti rust spray, let soak in for a minute or two, then pull gently.

[@joelpriestland793]

@@GreasyFingers Nice one! Thanks mate

[@AlfredGaebeli]

Echt supertolle Videos. Hab bereits beinahe alles gebinchwatched. Angenehme Stimme und gutes Gleichgewicht von Geschwafel und Musik. Mehr bitte!!

[@GreasyFingers]

Danke, Alfred! 😊

[@berndcassel2581]

Sie arbeiten ruhig,präzise,handwerklich sauber,haben einen guten Humor Schön,dass ich Ihren Kanal entdeckt habe

[@GreasyFingers]

Danke, Herr Cassel. Ich freue mich!

[@imapadlock]

Fair play to you 👍😋🇮🇹

[@matzedias]

Amazing alfa restoration videos ❤️ Grüße eines Alfisti aus Tirol!

[@GreasyFingers]

Danke, Mattl. Bist Du in Ö oder I?

[@matzedias]

@@GreasyFingers Innsbruck, Bertone GT Junior 1600

[@GreasyFingers]

@@matzedias Cool, ich bin das halbe Jahr in Oberbayern und das halbe Jahr in Brixen. Da geht bestimmt mal was zam.

[@jimmygrant3212]

What’s the purpose of the levers to tilt the headlight up when you have a screw to adjust the height?

[@GreasyFingers]

Hello Jimmy. I have no idea. The lever had been without function in my car and it can be found only at the left main headlight. At the right side it once had an accident, so it had likely been replaced. I know that some period cars have the opportunity to switch the headlights from right- to left-hand drive. Maybe my car was originally equipped with this feature?

[@Alcalfa]

@@GreasyFingers It is to lower the headlight beams when you have a big load in the boot, to avoid blinding other drivers. Really there should be a lever on each headlight, so one of yours has gone missing at some point, or perhaps is a bowl from an earlier Bilux (only a guess). H4-equipped bowls should definitely have had the lever from new.

[@flyingarts6765]

Do you plan to close the two openings.

[@GreasyFingers]

Which ones you mean, George?

[@flyingarts6765]

@@GreasyFingers the ones under the grille

[@GreasyFingers]

Ahhh, I see. Yes, period correct means to close them, so I guess I will.