Alfa Romeo Giulia (105): Restoration of the Doors, Part 1

The doors of this Giulia were in truly bad shape, but that's no surprise with an Alfa Romeo 105. Here's the first part of their restoration. I used self-made repair panels to do the job, a lots of metal shaping, butt welding and hard soldering.
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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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[@GreasyFingers]

Deutsche Untertitel jetzt online.

[@caspardelint3511]

Very tranqilizing and satisfying to watch. A Bavarian working on Italian metal.

[@klausschollmeier-sc9jo]

What i can see , the work of my first year 1983. You have Potential!.

[@Desertduleler_88]

You must really love Alfa's..... Great presentation, marvelous effort and perseverance with your efforts well done.

[@GreasyFingers]

Thanks very much. Perseverance and resilience is really what you need with a project like that.

[@manjit9445]

Thank you for another excellent video for both subscribers and visitors to the channel. Great to view the work detail and the audio explaining the process. Learning from your channel. Keep going !

[@GreasyFingers]

Thanks, Manjit. ☺️

[@kennyray116C]

It's very satisfying to watch you fabricate and problem solve.

[@GreasyFingers]

Thanks, Kenny!

[@Retiring34]

Superb attention to detail!

[@GreasyFingers]

Many thanks, Simon.

[@titanus49]

It takes true dedication,perseverance and absolute love for these iconic cars to be restored properly. I have a 1971 Giulia Super 1600 Biscione, (RHD),and fully appreciate your dedication to the restoration process.. I shudder to think how many of these cars were destroyed in the 70s, in order to make pointless and stupid police car chase movies in Italy.

[@GreasyFingers]

Many thanks, mate. That’s very motivating and an obligation to continue with the same commitment. What colour does your Biscione have?

[@bertone83]

A hell of a lot of work! I would have found it too time comsuming and would have looked for a different solution. However, I clearly admire your skills, patience and the result of course!

[@GreasyFingers]

Thanks, Mylord. Much appreciated. An awful hell of a lot work that was!

[@raisingjunior6389]

Fantastic video, this is a difficult repair so its normal to have to try a couple of different ways of making it. Sometimes its worth it to restart with a new piece of steel like you did, the second time its easier! Well done :)

[@GreasyFingers]

Thanks very much! Your feedback counts as 10. @all, please check out this channel if you haven't already: kzbin.info/door/8ltRW4KR7WzTiNj8Xy6C4A

[@Silva6667]

Ohne Worte....tolle Arbeit !!!!

[@GreasyFingers]

Danke, sehr nett!

[@hubechen4982]

I love your videos ..you do a good job and I wish I can do this all on my own .

[@GreasyFingers]

Thanks for the feedback! Much appreciated. May I ask: where are you based? I’m always interested in where on the planet people are watching.

[@ScuderiaUsignolo]

Recognizable problem with the sheet metal getting too thin;) Be carefull with grinding off the weld and dont hit good (new) metal. And also pay attention to the heat generated in the sheet metal with grinding (and welding). Use copper behind a hole, works great to closing up a hole! You can buy some copper weld tools. You can make nice sheetmetal patches! :)

[@GreasyFingers]

Scuderia Usignolo Thanks, mate. Copper plate: 11:07, 17:07, etc ☺️

[@freakboy3786]

Never give up. Good work 🤩

[@Kai77884]

Hallo ein schönes Video und super Arbeit 👍👍👍das kann nicht jeder😉Mit freundlichen Grüßen aus dem Ruhrgebiet 👋👋👋Kai

[@GreasyFingers]

Danke, Kai. Was man alles lernt im Lock down. 😊

[@Kai77884]

Greasy Fingers 😂👍

[@paulnorris7270]

Very nice work. I'm enjoyoing your videos

[@GreasyFingers]

Many thanks, Paul. Your feedback is much appreciated.

[@andynixon2820]

I also have a 105 giulia super . I'll be doing this work on all four doors , sills , floors , arches , wings , boot floor , bonnet edge . . . . Luckily I love the car and I haven't even included the seized engine .

[@GreasyFingers]

It’s good to meet guys out here who are about as wacky as myself. And I know exactly what you mean when you say you love the car.

[@GreasyFingers]

What colour is yours?

[@andynixon2820]

@@GreasyFingers my car is a 1970 super in hollandaise blue . I bought it from a dealer - only one owner from new and stored since 1983 . It was only on the road for 13 years but in that time it already had lots of bad rust repair panels + lots more hidden rust . Luckily I do some metal fabrication for my living so just time and a little money for door skins + front floor panels . I am very much enjoying your videos , you are not alone in loving giulias !

[@GreasyFingers]

Sounds great, Andy. Please keep me posted as your project develops. It’s a hell of a lot work, but it pays back with huge satisfaction.

[@stevewuertz3598]

NIcely done. Thank you. I feel your pain on burn throughs on thin rusty metal. I'm saving up for a TIG welder as I believe the temperature control is more accurate and better able to deal with sheet metal. Curious-are you applying Solder or is that Lead applied with a torch? Also for non structural metal with pitting, ( you still need to neutralize any trace of rust) you might look at a product called AllMetal. Its a skim filler with a significant portion content of metal (I think its Aluminum) that is more durable than a bondo.

[@GreasyFingers]

Thanks, Steve. Much appreciated. I think you're right with the TIG welding, but when it comes to pricing they play in a different league. The soldering material I used is so-called silver solder, or to be precise AG106 L-Ag34Sn AG134 (34% silver). It melts at 700+something degrees and gives good adhesion and strength. Thanks for the tip with the AllMetal. I was planning to use Brunox, but I'll do some research on it ...

[@thetumanshow]

Great video. What are some basic tools you suggest for someone who wants to start tackling some old rust?

[@GreasyFingers]

It always ends with welding. Yeah, unfortunately.

[@ScuderiaUsignolo]

very nice work! Nice video also :)

[@franky19541]

Greasy fingers? I'm gonna call you " Magic fingers Surgeon "

[@GreasyFingers]

Thank you, François. No magic, just hard work. ☺️

[@conceptalfa]

👍👍👍

[@fabrigala2714]

Ottimo lavoro! Anche io ho una giulia, una 1300 ti, presto farò restaurare, mi piacerebbe lavorarci da solo ma mi manca lo spazio e le attrezzature. Vederti lavorare sembra facile! Che tipo di saldatrice usi? Grazie al prossimo video

[@GreasyFingers]

Grazie, Fabri. Lavorare da solo sulla macchina per me e come una piccola vacanza. La saldatrice e una tedesca “Stahlwerk”. Buon prezzo, comunque prestazioni medi.

[@gintonicmunich]

Respect ! with that harmonic steel drum sound it looks so easy going but its not ! Also respect for that hundreds of video perspectices, clips and editing and cutting into a story. Also I fell in love with your finger thick sand grinder - a fine tool. Where can I order one ?

[@GreasyFingers]

Thanks, Gin! That is a electric file from Makita. It took me a minute to fall in love with it. I buy all my tools at matoopa.com

[@gintonicmunich]

That company provides good quality products and service

[@remcotissink]

You use those small cubes to line up the panels nice and flush before welding. What are those called ?

[@GreasyFingers]

Hey Remco, can you point me on a time stamp?

[@GreasyFingers]

Here ya go: www.amazon.de/dp/B087LPFH34/ref=cm_sw_r_cp_api_glt_i_EJ75Q1647KSNVTYFYNXE?_encoding=UTF8&psc=1

[@GiulioSerra88]

great great job!!!! I also own a 69 Giulia Super under restoration, I'll follow you with pleasure. greetings from Sicily

[@GreasyFingers]

Thanks, Giulio. What colour is yours? Engine 1300 or 1600?

[@GiulioSerra88]

@@GreasyFingers biancospino 013, it's a 1600,low pedals called in Italy "Giulia Super biscione"

[@GreasyFingers]

Wow, awesome! Called Super Biscione in the rest of the world too, I guess. That’s the hottest Giulia of them all, cheers!

[@markusmahn3209]

Wieder tolles Video Johannes! Warum hast den Kupferblock nicht untergelegt beim Löcherschweissen? Der lag ja schon im Hintergrund rum. Nimm dir die Hitze vom Blech und das Schweissgut läuft nicht durch.

[@GreasyFingers]

Danke, Markus! Nett von Dir. Das Kupferblech bringt m.E. nur was, wenn’s ohne Spalt fast anliegt und wo das möglich war, hab ich’s auch verwendet, siehe 11:07 und 17:07, etc. Auf konkaven Flächen wird‘s schwierig. Da müsste man sich für jeden speziellen Fall eine Blech mit einem bestimmten Radius biegen und sich irgendeine Vorrichtung bauen, die es dagegen drückt. Oder übersehe ich was?

[@markusmahn3209]

Greasy Fingers Ich meinte die Stelle bei 12:00 Das sah gerade aus. Vielleicht täuscht aber die Perspektive.

[@GreasyFingers]

Ahhhh! Ja, da hätte ich sie verwenden können. Irgendwie war mir vorher schon klar, dass da ein neuer Türboden rein muss, der Versuch das zuzuschweißen war ein Free Ride, um ein bisschen Erfahrung zu sammeln.

[@cybersurfer2010]

When welding thin plate back it up with a piece of copper bar...

[@GreasyFingers]

Thanks, mate. See 17:20 ... sometimes it helps, sometimes not. If the backside is curved, the copper plate thing has its limitations.

[@ActionM]

Johannes,where is the Alfa?

[@GreasyFingers]

You mean the Giulia? Tomorrow the GT will be picked up by its owner then she’ll go back on the lift.

[@rudigerkrebs5954]

Ja zefix! Du bist ein Künstler! Kann man bei dir in die Schule gehen?

[@GreasyFingers]

Ja, zefix! 😆 Kommst hoid vorbei, dann schraum ma zam!

[@rudigerkrebs5954]

@@GreasyFingers Ja sofort! I bin a kloana Pfuscher auf der Suche nach Besserung

[@GreasyFingers]

@@rudigerkrebs5954 Wo wohnst Du denn und um welches Auto geht’s?

[@lieberfreialsgleich]

Wird das Auto in Diessen restauriert? Ein Onkel von meiner Frau wohnt da. Walter Wehner, Johannisstraße. Er ist Fotograf, seine frühere Frau hatte ganz genau so eine Giulia 1300 super.

[@GreasyFingers]

Ja, ich arbeite in Dießen. So ein Zufall! Vielleicht fahre ich mal vorbei, wenn sie fertig ist ...?

[@lieberfreialsgleich]

Greasy Fingers er hat mehrere alte Busse und Paketwagen, mit denen er Retro Fotoautomaten zu Veranstaltungen fährt. Auch schon Oldies. Da gibt es auch öfter Arbeit.

[@jobeucken640]

I don't understand at all why you don't weld these self-made parts in autogenously??

[@GreasyFingers]

Could have done, but the amount of heat would have induced additional deformation. Don’t you think so?

[@jobeucken640]

@@GreasyFingers Use a welding nozzle of 0.5 and weld max.1.5 cm. Take one sheet metal hammer and bag and knock the weld flat. Then you weld another 1.5 cm and knock the weld flat. Continue these steps until the whole is welded. This method only works if you can reach it from the back with the bag! This way of working knocks out the stretch that arises during welding. An additional advantage is that you do not have to grind the weld seam after welding.

[@GreasyFingers]

@@jobeucken640 Thanks, mate. Very good advice.

[@jobeucken640]

@@GreasyFingers 👍👍

[@klausschollmeier-sc9jo]

You need only professionell Tools!.

[@Bertausmuc]

Oh mann, dein Schweißgerät ist nicht besonders.

[@GreasyFingers]

Da hast du leider recht. Ich sehe es als Handicap-Training.

[@GreasyFingers]

Da hast du leider recht. Ich sehe es als Handicap-Training.

[@Bertausmuc]

@@GreasyFingers Warum auch einfach wenns auch so geht. Trotzdem sind deine Videos sehr hilfreich. Super Danke.

[@Jotadjota574]

Una vergüenza no veáis el video muchísimos anuncios

[@GreasyFingers]

You're right, man. I didn't even know that the mid roll ads were on. Turned them off.

[@Jotadjota574]

@@GreasyFingerslos videos me gustan son una pasada

[@klausschollmeier-sc9jo]

You make to much welding points. Its the mistake from not professionell doing allways.