Restoring the Door Sill, Part 1 - Alfa Romeo GT

[@Matteo_Licata]

I've just seen my channel on your "featured" section... Thank you very much for this honor! I realized I didn't have that section on my channel yet... Well, now I do, and of course you're included :)

[@GreasyFingers]

Thank, Matteo!

[@red4hed]

Loved your 911 videos, but I'm glad the Italian beauties are back :)

[@GreasyFingers]

It’s so cool to slowly understand the differences of these two epic designs (105 and 911).

[@tunepatrol]

Jethro Bronner sent me here. Awesome work!

[@GreasyFingers]

Thanks, mate!

[@Matteo_Licata]

We shall all keep the Steel Ruler's memory in our hearts, as it generously sacrificed itself to the noble cause of preserving a classic Alfa Romeo. :)

[@GreasyFingers]

😂😂😂😂

[@GreasyFingers]

📏 ⚰️

[@65Alfaromeo]

Deine Videos sind interessanter als jedes Fernsehprogramm, die schauen sich mittlerweile sogar meine Oldtimerbegeisterten Kinder an.

[@GreasyFingers]

Cool, wenn ich zum Heranbilden von Oldtimer-Nachwuchs was beitragen kann! Privat habe ich da total versagt.

[@65Alfaromeo]

@@GreasyFingers Frage des Verkäufers im Spielzeugwarengeschäft beim Kauf einer Carrerabahn: Wie alt ist der Bub denn? Ich: Meine Frau ist im 3. Monat schwanger mit ihm. Noch Fragen? :-)

[@GreasyFingers]

@@65Alfaromeo 😆😆😆

[@davedavidson9996]

I like this channel. The music is well done and you are working on some cool cars. The important repairs that need to be done are taken care of.

[@GreasyFingers]

Thanks, mate, that’s a wonderful statement.

[@lillorebaudi7858]

I dream to have a friend like you that can restore my giulia. Thank you to Jethro Bronner that hallowed me to discover your channel. Great high quality video and work. The human kind needs guys like you to to show how a propper restoration must be done.

[@GreasyFingers]

Thanks, Lillo. I’m in regular contact with Jethro and I genuinely love his channel. Tell me more about your Giulia please …

[@lillorebaudi7858]

@@GreasyFingers Hi Greasy Fingers (What's your name?) I really appreciate your work, in both restoring and filming, and I thank you for the excellent service you give to the people that like you have the passion for restoration of classic cars, with quality tutorials filmed in the way where you can really understand the meanings of the job you need to approach and the problems related to it. Coming to your question, I just bought a 1970 Giulia 1.3 ti, one of the latest ti produceded. Coming from a northern city of Italy has several rusty problems, which I don't know yet the gravity since I haven't strepp the car down yet.

[@gearhead9828]

Your buddy really is a lucky guy to have a friend like you! It is so satisfying to watch you doing your magic, thanks a lot.

[@GreasyFingers]

Thanks, mate! Yeah, he looks quite happy these days. I give him two weeks to relax now and then I tell him what’s waiting for him at the left side.

[@paulgillard2258]

Like your philosophy and high level of skill. I’m not a car restoration person but I am hooked on watching the process. Fascinating how they manufactured the sills allowing such a good home for corrosion.

[@GreasyFingers]

Thanks, Paul. Yeah, it appears like a tutorial about how to not build door sills.

[@davidgray5583]

More great content. I find when I am having a bad day at work, a quick Greasy Fingers video provides my brain with the necessary CTRL + ALT + DEL. Thanks !

[@GreasyFingers]

I‘m really glad my vids have this effect on viewers.

[@remcotissink]

I love the way you go about things methodically. Very inspiring...

[@GreasyFingers]

Thank you, Remco. Many mishaps mark the path that brought me there.

[@MLC...]

Supercool! Thanks. I have to work now, but my plans for tonight.....

[@GreasyFingers]

Thanks again!

[@GreasyFingers]

Yes, exactly!

[@gerardscheffer8848]

Found your channel by Jetro. Love it!

[@GreasyFingers]

Thanks, Gerard. Glad you like it. Enjoy your time on the channel, and if you like it, I’d much appreciate if you recommend it to friends.

[@oacumulador]

In this video, the welding sound sounds better than the firsts ones

[@GreasyFingers]

The guy who taught it to me said it needs to laugh.

[@oacumulador]

@@GreasyFingers good one

[@sjoerdvandermaaden]

Again a VERY good reason to like, comment and recommend... Thank you...

[@GreasyFingers]

Thank, Sjoerd!

[@Alfa-209]

Keep the dream alive. Good job 👍🏼

[@rodneynelson3862]

"Decisions Were Made" -- Great Video. I just finished replacing the rocker panel on my '72 911. Looked about the same!

[@GreasyFingers]

Thanks, Rodney. When I look at the panels that I sometimes cut out of my cars, I seriously ask myself: what are you driving around with?

[@alastairwatson3201]

Hello. I sent you a comment the other day with a link attached, not realising that might have been seen as advertising. Sorry about that. I do recommend the use of fish oil for rust-protection but don’t endorse any particular brand. Moreover, I’m not a representative of the fish oil industry. As I said, great channel. I enjoy it very much. Cheers from Australia.

[@GreasyFingers]

Thanks, Alastair and no problem at all. When you say fish oil, I can’t help thinking the word „smell“. Is there anything about it of that kind that we should know?

[@alastairwatson3201]

@@GreasyFingers , according to the description on the can, it’s deodourised fish oil and acetone. However, it does smell vaguely fishy until it dries in a day or so, depending on the temperature. It penetrates very well and sets without completely drying, so that it remains sort of plastic / pliable. It can be coated with compatible primers and top coats. As I said before, Australia is a more benign environment for cars, probably akin to California or South Africa, but I do often take my cars to the east and west coasts of Tasmania, where there is a lot of salt spray and both of them - a 1978 X1/9 and a 75 Mitsubishi Galant hardtop - have only ever had minimal rust in the many years I’ve owned them.

[@GreasyFingers]

Sounds good! I like the idea of processing otherwise useless organic material. Fluid Film e.g. is made of sheep’s wool grease.

[@hilbilchillbil]

Just love a 105 looking forward to the next instalment

[@GreasyFingers]

Thank, Paul!

[@natjes6017]

This stuff will distribute across the workshop.... and I kid you not, you will find traces of it in your bed 😁😁 Subbed!! Awesome repairs, fantastic work!

[@GreasyFingers]

Nothing but facts. 😆

[@alexbrown1995]

Made me laugh out loud 🙂

[@blackwell1384]

I enjoyed this video series. I am currently watching them for a second time to help me plan my work on my 1967 gt sprint. What does the center sill section add to the structure? What if it is left out? Thank you again

[@GreasyFingers]

Thanks for commenting! I don’t think you should leave the middle sill panel away. It wood probably be an advantage in terms of corrosion, but strength-wise it’s there for a reason.

[@IVANRUFFINI]

Faggio 516. My favorite color ever.

[@GreasyFingers]

Yes, I love it too.

[@raquettebois8242]

Good job greasy

[@GreasyFingers]

Thanks, Raquette. 😀

[@paulofariapaulofaria4326]

Nice work, very clean and professional. Paulo faria Portugal 🇵🇹

[@GreasyFingers]

Thank you, Paulo. Are you aware that a significant amount of GT‘s was built in your country?

[@paulofariapaulofaria4326]

@@GreasyFingers yes, i have two friends who have three alfa romeu 105, two 2000 gtv and one 1750 like new.

[@paulofariapaulofaria4326]

@@GreasyFingers in Portugal 🇵🇹 there were many alfa 105s but now there are very few and they are very expensive

[@sameagle988]

"Ragazzi! What have you done?" Battle cry of the Alfa Romeo owner. Cheers to you-

[@GreasyFingers]

Thanks, mate! It’s such a well designed car if only they have had corrosion in mind a bit more when they did the sills (instead of oversizing them by factor 18).

[@sameagle988]

@@GreasyFingers Yes, but you know you love something when you are charmed by the imperfections. (And you are willing to get wax-oil in your hair to tend to it)

[@GreasyFingers]

@@sameagle988 😂

[@kenty2831]

Craftsmanship + passion + education rare commodity this day. The mention of rust distribution reminds me of dog hair

[@GreasyFingers]

Thanks, mate. Yes, dogs hair!

[@kenty2831]

@@GreasyFingers my pleasure, instead of visiting the local art gallery in san diego, I watch your metal work as a form of shaping metal vs marble

[@Sigurd924]

Das Markenzeichen dieses hervorragenden „Schraubers“ , die Schutzpappe bei der Arbeit mit der Spritzpistole“ 👍😀

[@GreasyFingers]

😆😆😆 Gut beobachtet, Sigfried. Abkleben ist immer ein rechtes G‘frett.

[@ericbovenkerk7608]

Really admire these great skills and honest craftmanship. Thanks a lot, Amsterdam

[@GreasyFingers]

Thanks, Eric. Much appreciated. Please recommend the channel to friends.

[@uniqueaustraliandestinatio1352]

Football (Rugby) off because of Covid-19, but Mr. Greasy Fingers comes along to save the evening!

[@GreasyFingers]

So cool to read this. 😀

[@TonyBrQ]

I have only just discovered your channel, through my Giulia Super addiction (from the 70s when I could not actually afford one) and I have to say it is totally addictive! Your skill, determination, creativity and knowledge is outstanding. And anyone who can take an angle-grinder to the sills of what looks like a very nice Alfa GT is much braver than me! One other thing - I was considering investing in a Giulia Super (1.6, of course) but I will be much much more careful than ever, in assessing any potential cars, after watching your videos...;-)

[@GreasyFingers]

Thanks for the feedback, Tony. I love it! When I bought my Giulia, in hindsight I have to say I was a greenhorn. Today my standpoint is: there’s no such thing as a 105 with okay sills. One is either before or after their restoration. Hoping to get one which is good enough to remove the topic from the agenda is kind of the wrong approach. This viewpoint of course excludes the ones that have been professionally rebuilt, but you can’t do that with a budget below 50k. When I did the Faggio’s sills an idea came to my mind to fully galvanise them next time I do this. I’m very excited about it and in my mind thoughts are maturing …

[@TonyBrQ]

@@GreasyFingers - I have just noticed...you have another unsung classic...a Philips fan-heater from the 70s! They work forever, no restoration needed!

[@vijaywaingankar8352]

Good work

[@andygtv]

Great work👍😀

[@GreasyFingers]

Thanks!!

[@meXicossie]

Hey this is some meticulous work…love it, what is the spray you used before welding?? 15:20

[@GreasyFingers]

Thanks, that’s Inox spray.

[@gezdickinson8850]

Such a cool and interesting channel, love it!

[@oiygfdxssfgg]

Nice work

[@GreasyFingers]

Thanks, Raffaele!

[@rognoso72]

Very good job.I'm just wondering how to spot a rusty car since I'm planning to buy an used Duetto since these hidden sides under the fender can be checked only removing the external part

[@GreasyFingers]

That exactly is the doom of the world of Alfa Romeo ownership. You don’t know how bad they are before you’ve cut them open. Sorry I have no better news for you.

[@ActionM]

Magic... Well done my friend..

[@GreasyFingers]

Thanks, Pantelis!

[@peaktraveller]

Great work as always.

[@DataSpook]

Impressive, great work!

[@GreasyFingers]

Thanks, Luis! Please recommend the channel to friends. 😊

[@hugogreen4916]

Watching you retain the integrity of the original structure by nipping and tucking seems so sensible. But I have to say, as a layman counterintuitive. I always thought new panels and replace the old was the preferred restoration way. But now I can see the light. Some time soon - if I can find someone with your skills- I am going to have to have someone look at my 116!

[@GreasyFingers]

Thanks, Hugo. There are good reasons for both ways. 116 are very cool cars. Every year that passes makes them more attractive.

[@DustyPearl-13]

Absolutely FANTASTIC job! I Keep up the GREAT work! Auf wiederhören!

[@GreasyFingers]

Thanks, Aziz!

[@D...M...A...]

Hold the mig in place as she cools to let the argon gas do its job , nice work

[@GreasyFingers]

Thanks!

[@alfagreg4108]

One of the best channels. Love to see a spider being done given the challenges of not having a roof. My 76 spider has rust issues. What I do not know is how inherently stiff the body of the spider is with solid sills and floors. Excellent video and channel Greasy. Anxiously waiting for the next installment.

[@GreasyFingers]

Thank you! Most of the 105/115 stiffness results from the inner and middle sill. If those two and the A- and B-pillar are good, I think you can safely remove the outer sill. Maybe an endoscopy will help you making the right decisions?

[@alfagreg4108]

@@GreasyFingers ....I was thinking the same. Some nice ones that work with your phone. Thanks!

[@fearghalmurray9579]

Would you have a link for the “Enoch” rattle can paint you mention, 15 mins in?

[@GreasyFingers]

It’s Inox spray, aka weld-through primer.

[@fearghalmurray9579]

Inox Spray Schweißprimer L234 perhaps?@@GreasyFingers

[@GreasyFingers]

amzn.to/4cpU4cT

[@mertozyurek7169]

wir warten sehnsüchtig auf deine Bertone-Restauration. Viele Grüße

[@GreasyFingers]

Ja, da habe ich etwas zu früh auf die Pauke gehauen damit, aber spätestens im Sommer tut sich da was …

[@gordontweston]

Hallo aus Irland! Excellent work. A satisfying pleasure to watch your methodical and surgical approach and those virtually invisible weld seams. The dry wit adds to a great production :D My poor 1600 Junior undergoing work at the moment. I’m trying to keep to original nos outer panels. What’s your opinion on that regarding the gauge and fit please?

[@GreasyFingers]

Thank you, Gordon. Generally fit of spare parts isn’t too good. I’m therefore trying to save as many original panels as possible, though it becomes a bit of a Frankenstein car.

[@rickeverett3304]

how many days to fix the pillar rust and replace the sills?

[@GreasyFingers]

8-10

[@francescodamore3393]

Great great job! Dreamcar ❤

[@GreasyFingers]

Thanks, mate!

[@torwereen7481]

Good work here. Realized after doing as you started, with trying to keep as much as possible from the original sill, but then realized after removing a part, that the real thing had a small pice of tape sayin 1993, and there was a rest from the original one. Unfortunatly they hadn't done anything to the middle sill, so about 70 mm of the bottom is missing.... So, now new parts are on its way. BTW, the tin replacement you are using. Brand? Hope to get my sills in place before end of the month.....

[@GreasyFingers]

I‘m realising the same at my Giulia these days. The brand is Teroson. It’s a recommendation. Fingers crossed for your project!

[@torwereen7481]

@@GreasyFingers Thanks, will test it. Looking forward to see how you solved it on your Giulia in a comming video.

[@sergeanthorvath]

What strength are those magnets you use?

[@GreasyFingers]

Nothing special, just Amazon board magnets.

[@drblast]

You should have media blasted that inside area, ask me how I know...I have some GTV videos of the work I have done...have to dig deeply to get it all out.

[@stevewuertz3598]

Thanks for the best Alfa Sills treatment video ever done. Sills (all 3 of them because to say both of them wasn't enough) are the bane of all Alfa owners. I have a field find 73 GTV that I know is worse than this one. OK-i can live with that-I bought it that way. I need to find the courage to put a boroscope in my seemingly pristine GTV that the Previous Owner paid to have a high end shop fix. Not today. Great tip on the magnets-I found a set on Amazon today. I have a collection of welding magnets too large for tight spaces Fantastic tip on the INOX spray! Curious-why did you select MIG over TIG? I like the hi intensity narrow flashlight to enable more accurate wire tip placement on the MIG!!

[@GreasyFingers]

Thank you, Steve. Yeah, these sills are a nightmare. They could be improved a good bit in terms of corrosion with just slight design changes but I guess during its production, making new tools was out of budget. I am tempted a lot to get my CATIA out and do some design work. TIG is on my list, but yet I neither have the skill nor the gear.

[@stevewuertz3598]

@@GreasyFingers I bought a used TIG 2 weeks ago but haven't started working with it. My MIG is 30 plus years old and did not allow for making fine temp adjustments-Low and High settings.

[@GreasyFingers]

I think I’ll finish the Giulia with the equipment I have and then follow your way.

[@raisingjunior6389]

That' a really good looking GT...Superb video but do you have enough magnets to hold the ruler? :)

[@GreasyFingers]

Now that you’re saying: I should get some more. 😆

[@jamesdecross1035]

Q: what do you use to protect the inner panels?

[@GreasyFingers]

You mean the product I use towards the end of the film? That’s Fluid Film Liquid A.

[@macwiz1333]

Endlich wieder ordentlich Bleche betschen und schweißen. Grazie, raggazzi ;)

[@stevewuertz3598]

Had to come back for a second viewing-it was that good. Fitzee likes .024 wire for sheet metal. Considering you are welding to the inner sill which is a thicker gauge than ordinary panels, what gauge do you find sufficient for this task? Thanks Also, are you on 100% Carbon Dioxide gas?

[@GreasyFingers]

I‘m using 0,8 mm which would be 0.031 inches. I guess it has not much to do with the final result but how much grinding you have to do. Gas is 80 CO2 and 20 Argon.

[@armourpiercer]

Respekt 👍👍

[@mertozyurek7169]

yeah la macchina delle emozioni ♥

[@xzvxzv4358]

I own a 1750gtv , took me 8 years of restoration, mat Grey and brown leather classic racing look, but I'll put a v6 vortex engine and transmission and keep the original engine in my living room..

[@GreasyFingers]

Wow, that’s a project! Will you be using it for racing?

[@xzvxzv4358]

@@GreasyFingers no.. not for racing.. for the driving experience and unique expression in .. but no long a v6.. now a ls1 v8 ...

[@dinohuss9054]

excellent

[@GreasyFingers]

Thanks, Dino.

[@diewerkstattschraubt]

Und wieder Mal ein Kniefall von mir. Ich hoffe, dass ich annähernd solche Fertigkeiten erreiche 🙏👍👍👍

[@GreasyFingers]

Danke sehr! Das kann jeder, der Lust dazu hat.

[@alfabio147]

Sehr interessante Videos, ich werde mir in den nächsten Tagen mal alle anderen anschauen. 👌 Der Bertone ist einfach ein absolutes Traumauto😍

[@GreasyFingers]

Danke, Fabio, willkommen auf dem Kanal und viel Spaß beim Gucken.

[@grumpymealey2441]

Love the videos keep up the great work

[@GreasyFingers]

Thanks, Christopher.

[@raypurchase801]

I wonder if there are ANY GTVs still on the road with all-original panels. That's not a hostile comment. I've got a 1750 which my father bought in 1974. I know what I'm talking about.

[@GreasyFingers]

Hey! Not at all received as hostile. I personally can hardly imagine that the way the door sills are designed, a GT can survive more than 5 years rust-free, certainly not in a country with regular rain or even salted roads. I exchanged with Jethro the other day and we’re on the same line. I know a guy, however, a former owner of an Alfa Romeo dealership, who claims that his has never been welded and is without visible rust. The latter I can confirm. I’ve contacted the guy about making an “Is It Any Good”, let’s see whether this will work out.

[@Marie579]

What you’ve done to the car is excellent work, what you did to the ruler…… criminal! 😢

[@GreasyFingers]

Yes, this ruler has a very hard live.

[@ACSeazzu]

Absolutely wonderful work, your attention to detail is incredible and inspiring. Does your friend have an Instagram or something for the car?

[@GreasyFingers]

Thanks, mate! Here you go: instagram.com/jodornhofer?igshid=YmMyMTA2M2Y=

[@daos3300]

very good reasons. though the quality of work is perhaps more convincing.

[@GreasyFingers]

Thanks!

[@lieberfreialsgleich]

Eigentlich früher mal gut repariert.. nur da hat leider jemand am Rostschutz gespart. Gut das man alle Teile für die Reparatur leicht bekommt. Ich würde immer möglichst grosse Reparaturbleche an den Kotflügeln hinten einsetzen, die Radläufe gammeln nämlich wie die Schwellen. Die Konstruktion der Schwellen stammt meines Wissens nach von Karmann, nicht von den Ragazzi. Bei meinem gtjunior habe ich etliche große Löcher in den Mittelschweller gebohrt, damit man besser Wachs verteilen kann und Feuchtigkeit auch wieder raus kann.

[@bertone83]

Was hatte Karmann denn mit den Schwellen zu tun?

[@GreasyFingers]

Ja, das Design bietet einige Möglichkeiten für Verbesserung. Ich habe die Löcher, von denen Du sprichst von außen rein gemacht, siehe zweiter Teil. Man kann sie nicht sehen, wenn das Auto auf der Straße steht und ich hab keine Lust, die nächsten Jahre immer seinen Teppich raus zu machen.

[@antoniosprocati5050]

uuu !! quanto e bella!

[@GreasyFingers]

Si, irresistibile!

[@conceptalfa]

👍👍👍

[@kingcrunch85]

Kleine Empfehlung: Probiere einmal die Schweißpunktbohrer von Würth. Die sind um Welten besser als die Schweißpunktfräser mit den aufgeschraubten Kronen.

[@GreasyFingers]

Danke vielmals. Das werde ich definitiv probieren. Hast Du einen Link für mich?

[@kingcrunch85]

@@GreasyFingers Würth HSCo 8mm Schweißpunktbohrer, ich habe die vom nächstbesten Ebay-Händler bezogen. Es gibt die auch im 6mm, für meine Autos haben die aber leider keinen praktischen Nutzen, da die Schweißpunkte größer sind.

[@RubyMarkLindMilly]

You sound like an English bloke whistling away all that's missing is a mug of tea!!!

[@GreasyFingers]

Many viewers tell me that my English sounds like Werner Herzog‘s which I kind of like.

[@overbuiltlimited]

All this talk of corrosion makes a case for an all carbon fiber Alfa body. Of course you’d still have to deal with the sills, jack points and other problem areas of the unibody. Then there’s the cost of a CF body which has to be frightfully expensive.

[@GreasyFingers]

CF would certainly be an option for the front fenders and all hoods and doors. I’m also contemplating about galvanised sills and maybe I’ll try this out with my Giulia project.

[@overbuiltlimited]

@@GreasyFingers CF fenders would be nice! By the way just ordered a couple shirts to help the cause. Learned that Vereinigte Staaten is the US. ;)

[@GreasyFingers]

@@overbuiltlimited Thanks, mate! That’s the best way to support the channel.

[@jamesdecross1035]

DON"T cut your metal ruler - the one thing you want of a straight edge is for it be straight!

[@GreasyFingers]

Now the car‘s straight and the ruler crooked. Better than the other way round!