Anything that does not fit into other topics.
KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

Nearly two years have passed and the car is 99% complete. The car has stood in storage in its incomplete state which as lead me to do quite a few items again . Cars don’t like standing in storage !!! Sadly my father passed away over a year ago and we shared this project and the only time I get to work on it is when I leave the UK in winter and spend a month out in South Africa warming up. I have taken quite a few pics on during my last visit. I have only put three juniors together and I’m still convinced the GTV6 is still much easier to put together and less fiddly but having said that the good thing is you can buy all the parts for a 105series .
Over the next few weeks I will update the pics and at same time update my GTV 6 2.5 restoration pics .
KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

The intention was never to have a concourse car but I thought I would redo the entire brake system. The is originally a very low mileage car at 71000km only so most pipework on the brake lines was in relatively good shape . Having said that I decided to replace every brake line ( rubber and steel ) , remove boosters again and send for testing and then remove the already serviced clutch and brake cylinders to be checked for rust as been standing now for 5 years.
KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

This is the before pic
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

I borrowed a set of pipe benders and started the long process. Eight hours later the brake and clutch lines were complete . It was so much harder with engine in but still totally doable .
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

Upon testing my booster we found it to leak .Problem was corrosion !!! You can see the pit marks that created the leak ! Once sorted then vacuum tested again then it was back home to install. At same time if had all the rubber brake hoses remade ! Now every part of the brake system is new or refurbished.
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

Was very difficult to source proper vacuum hose but we got an importer of US pipes so was lucky there. Can’t use any pipe as will collapse ! Also got pipe specific for brake fluid for the bottles ... not easy to find either.
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Last edited by KevinR on Sat Jun 08, 2019 3:14 pm, edited 1 time in total.
KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

Brakes are all sorted and no leaks ! Clutch feels great as well ! In testing electrics I found the heater unit struggling so I decided to pull the heater box back out again and strip it down. Took quite a few pics incase I forgot how it went back together :)
Idea was to clean all debris’s out, test motor for long period of time, pressure test heating radiator, replace sponge around unit and where it fits up against bulkhead .
As the car is such low mileage the heater radiator was perfect but heater valve gaskets inside had perished.
Quick call to Tom at Classic Alfa and new steel valve was sent out to Johannesburg. Unit is back in with new heater hoses.
Pics show the rubbish that has been collected over the years and jamming the fan. :(
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Last edited by KevinR on Fri May 31, 2019 2:30 pm, edited 1 time in total.
KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

All back together all refurbed
KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

Had problem above downloading pics as it was duplicating.
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

I'm going to post pics of my GTV 6 2.5 which I'm also busy with renovation under "restorations and renovations" . As their is an "Other" section I thought it's not to inappropriate posting my Junior restoration here .

So moving along :) After re checking all my door mechanisms and window adjustments I have now cut the plastic to protect the door cards. The drains holes inside the doors were rechecked and the doors coated with anticorrosin spray.
I found the doors were not closing properly due to door cards been fractionally to long so out with the saw and staple gun !
I have used black nylon cup washers that don't cut into the door cards to help fasten the door cards . Yes I know it's not original but it needed to be functional.
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

The GTV which is currently under resto parked next to the junior .
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

While I was redoing the heater unit and the dash was out my mate suggested I redo the wooden veneer as mine was sun damaged and faded in areas. He had these wooden inserts lazer cut in two colours but I stayed with the original colour. The chrome work got a polish and the lights cleaned up. Hardest part was connecting the vent ducting without slicing your hands to bits on all the sharp edges !
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

Fuel tanks are always a source of nightmares on restorations as so many people do not redo or or reline them . There are various methods around but I went for a tried and trusted epoxy coating that's been in use for over 10 years here in SA . The product is from USA. I had to cut the fuel pick up by 5mm due to extra lining in tank ! Tank is back with all its screws and a rubber sealing gasket . Even with newly refurbed tank I put an extra temporary inline fuel filter for start up to save my carbs . This is will be removed after a few starts as it does affect delivery pressure .
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

I decided to go through every electrical connection and replace terminals that had corroded or were in bad condition . Luckily as mentioned before this is a low mileage car that's been in a dry climate so it was not a difficult job. The wiring diagram was pretty good . I have realised my eyes are fading as out came the magnifying glass ! I labelled all the wires in and around the dash and cable tied the groups together as I knew gauges will be going in and out few times .
A real pain was putting in new wires for the door lights. This often overlooked when headlining goes in so I had to pull wires to the rear first as only way to get them down the roof posts ... What a pain ! Thanks to Kevin Strapp at Ak classics for all help on sourcing bits and bobs locally for me and for wiring help on the wipers !!!
I had my original column stalks refurbished by Highwood Alfa . I prefer these refurbed type as the wiring is so much thicker on the originals. It is noted a relay for headlights should be installed if using the newer type.
Similarly this is the same with the reproduction ones for the GTV6 .
Note the original Kilometres on the clock 71855 km.
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KevinR
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Re: Our 1600 Junior restoration

Post by KevinR »

The car is now ready to fire up after five years . I bought new cap, leads, points and condesor from Classic Alfa to make sure my electrics are all fresh. I then found I was missing parts to my oil filter so only available filter in SA was a King from ATS Motorsport. This i fitted while the carbs were off again !!!! I had an electrical issue with the horn wire which was jammed in the steering column . The only acces to the jammed cable was through the bottom of steering box so carbs had to come off. After six hours of trying to push the broken bits of terminal out the refurbished steering column / box with coat hanger wire I final dislodged the jammed terminal .
Carbs were put back on and with temporay exhaust the car was ready to fire up. While I was priming the oil I noticed a drip of water from the water pump which never had an issue back then. Some times when you don't run engine for ages this happens but after a while of running the seal rebeds itself . This did not happen so back on phone Classic Alfa to import this water pump . It's not a common type and was lucky they had in stock .
This arrived in few days. I managed to get the old one off without removing the pulley which was relief . With everything back together I got the engine fired up. Initially there was a bit of smoke but this soon cleared up. Most of it was from the oil I had poured down the barrels to preserve the engine ( yes I did get this out prior to cranking with plugs in :))
Now the car is ready for and exhaust !
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