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Thread: Project Phoenix an Alfasud sprint is reborn

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    Project Phoenix an Alfasud sprint is reborn

    good friend of mine Greg Pye who also races in DTRC in a silver Alfa sudsprint bought a second alfasud to race while his number one sud was having serious and seriously long winded engine rebuild with an alfa specialist, although mechanically fairly std the car performed well until that too suffered an engine failure, not wishing to loose his number 2 car for over a year (told you his other car was having a long winded engine rebuild) sent the car up to me to sort the engine and do a bit of welding.

    the car turned out so rotten it was beyond repair! floors innner/outer sills, chassis rails, inner wings, front chassis rails, screen pillars, bulkhead, inner and outer A pillars, infact the only thing holding the car together was the rollcage, so i stripped the car and scrapped the shell.

    fast forward 18months!!!!, greg finds a shell in a breakers yard it was an insurance write off, having been subject to a fire, which took out the interior and most of the wiring loom, and lots of under bonnet bits.

    now you see where the project gets its name its climbing out of the ashes literally.

    the plan was for a simple reshell, but although far better than the first shell this car still needed a considerable amount of welding.

    project aim from gregs view point,
    on a tight budget build a tidy, cheap spare race car from parts we already had.

    project aim from my view point,

    on a tight budget build a strong race car which is faster/better than gregs number one car, which might be a tall order given its being built out of cast off bits, but unlike the no1 car this wont be road legal and so will be lighter, and to be honest i'm not sure the set up on the no1 car really suits gregs driving style

    below are pics of the origonal shell, looks good you would of never known it was a death trap structurally, apparently it handled well, but i think that was merely the body flexing allowing perfectly flat cornering
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    Re: Project Phoenix an Alfasud sprint is reborn

    i actually started the car in late april early may, so intitally you will be seeing progress quicker than it really happened, as i said the main aims are keep it cheap, make it strong, this will be a pure race car so whilst it needs to be presentable the finish wont be upto the normal turbosport resto standards

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    Pole Position Decade Plus User NorthernBloke's Avatar

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    Re: Project Phoenix an Alfasud sprint is reborn

    Cool, I look forward to seeing this one as I've had a few Sud's in my time, the favourite being a 1.5 Cloverleaf in black
    Andy


    If it doesn't break it's not modified enough
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    Re: Project Phoenix an Alfasud sprint is reborn

    Good luck with the build Graham, will we see your number two (ooer) this season?

    Look forward to watching the build updates


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    Re: Project Phoenix an Alfasud sprint is reborn

    heres the back of the engine bay / heater plenum / battery tray master cyl area, after all the melted heater assembly wiring etc was removed.

    silver paint as seen in lots of the pics is a zinc based weld through primer, which is handy as you can spray it on before welding, and thus get some rust protection on the back of your repairs
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    Re: Project Phoenix an Alfasud sprint is reborn

    some interior pics, note the smoke staining! the big rusty patch on the floor was later cut out,
    pic 3 shows the o/s/r inner arch from inside the car, note the huge hole which was filled with fibreglass
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    Re: Project Phoenix an Alfasud sprint is reborn

    this is the rusty bit of the n/s/f floor seen from underneith
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    Re: Project Phoenix an Alfasud sprint is reborn

    at some point someone did a good job of fitting new outer sills, unfortunatly they forgot to rebuild the middle sill memberane so heres the n/s repair
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    Re: Project Phoenix an Alfasud sprint is reborn

    Excellent Graham Dont all die of shock but I like these

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    Re: Project Phoenix an Alfasud sprint is reborn

    heres the other side of the huge hole in the o/s/r inner arch at a couple of repair stages
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    Last edited by Graham; 14-08-2006 at 18:46.

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    Re: Project Phoenix an Alfasud sprint is reborn

    n/s/f floor repairs
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    Re: Project Phoenix an Alfasud sprint is reborn

    the alfa body shell is a bit strange, most of it is waffer thin and non structural, those bits have mainly been repaired using 22 swg galvanised steel, hense the somewhat splattery looking welds, all the structural bits have been done in 16 or 18 swg mild steel.

    some of the factory thin bits such as the floor in the area of the roll cage feet i've replaced the origonal thin sheet metal with thick stuff
    Last edited by Graham; 14-08-2006 at 19:31.

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    Re: Project Phoenix an Alfasud sprint is reborn

    oooooh yes mate , i love the italian cool motors like these , well done for saving her , i really miss my old fiat 128's ( sad old git )

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    Re: Project Phoenix an Alfasud sprint is reborn

    as you can see the o/s floor was in just as poor shape as the n/s
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    Re: Project Phoenix an Alfasud sprint is reborn

    Quote Originally Posted by mk1 gaz View Post
    oooooh yes mate , i love the italian cool motors like these , well done for saving her , i really miss my old fiat 128's ( sad old git )

    cheers, just had to keep reminding myself this was a better shell, it really was by about 500%!

    i learnt to drive in a driving school fiat 128,
    although it was a boring one not a funky 128 3P

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    Re: Project Phoenix an Alfasud sprint is reborn

    rear of o/s sill with outer repair patch removed, th eouter repair looked good, its just a shame the 3 skins behind it werent doing anything except rusting
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    Re: Project Phoenix an Alfasud sprint is reborn

    n/s wasn't any better
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    Last edited by Graham; 14-08-2006 at 20:13.

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    Re: Project Phoenix an Alfasud sprint is reborn

    the really worrying thing about this car is that it was until recently on the road with an MOT

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    Re: Project Phoenix an Alfasud sprint is reborn

    just a minor repair, bottom of n/s A pillar/inner wing
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    Re: Project Phoenix an Alfasud sprint is reborn

    even the top"c" pillar/roof needed somewelding on the inside
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    Last edited by Graham; 14-08-2006 at 20:31. Reason: posted wrong pic

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    Re: Project Phoenix an Alfasud sprint is reborn

    Fair play Graham.
    That's a big job you have done there. Is that the worst done, or is there just as much to do?

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    Re: Project Phoenix an Alfasud sprint is reborn

    rear lower quarter panels and arches needed some attension too, rear valence which is double skinned had a collection of holes too, repair panels are available at silly money, so tha answer was just to cut them off!
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    Re: Project Phoenix an Alfasud sprint is reborn

    Quote Originally Posted by Dave_Roberts View Post
    Fair play Graham.
    That's a big job you have done there. Is that the worst done, or is there just as much to do?

    very kind of you to say so dave, not sure its much in comparision to your own efforts,
    actually i have finished welding in metal now, i'm just bringing you all up to speed

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    Re: Project Phoenix an Alfasud sprint is reborn

    time to tackle a biggie, rear shock mounts they were a huge collection of assorted rusty plates, so out with the trusty angle grinder and the rust was gone
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    Re: Project Phoenix an Alfasud sprint is reborn

    Quote Originally Posted by graham bahr View Post
    not sure its much in comparision to your own efforts,
    Well those pictures of rust gave me some flashbacks

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    Re: Project Phoenix an Alfasud sprint is reborn

    i had a plan for the rear shocks, the ones on the old shell were fairly shot, but after a bit of meassuring i realised the shocks which last year were on the back of my race BMW, which were actually rover 216 spax adjust to which i added adjustable platforms would fit, making spring swapping and set up easy (the alfa wasn't orogonally coilover)

    so a made some brackets, thick enough to take the suspension load and pass it directly into the chassis
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    Re: Project Phoenix an Alfasud sprint is reborn

    i didnt do it all, my son and daughter both spent a day each scraping out old sound deadening pads, which often exposed more rust!

    heres charlotte in action
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    Re: Project Phoenix an Alfasud sprint is reborn

    rear quarters also gave issues round the window areas, the car was to be fitted with polycarb windows, the easy way to do it is fit them in the origonal frames and lower mechanisims, but leaving the frames and mech off would save loads of weight, so they were removed, to expose two problems, yet more rust, and i found the surfaces that the window would have to screw to were actaully on 3 different levels, welding in some 10mm square steel stock followed by a bit of filler fixed both problems
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    Re: Project Phoenix an Alfasud sprint is reborn

    that makes dave roberts's escort look clean !!!! ..........P.S. i've had tons of rusty italiain motors , i just love em

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    Re: Project Phoenix an Alfasud sprint is reborn

    as i said this was the GOOD shell, and it wasn't long agao it was driving around with an MOT

    i do have a spot spot for old itailian motors, not ferrari's and stuff, down to earth, fiats, alfa and lancias, my first loves were lancia fulvias

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    Spam Man mk1 gaz's Avatar

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    Re: Project Phoenix an Alfasud sprint is reborn

    my mate had a new one and it snapped at the windscreen/bulkhead when it was 5 years old after a few wet winters !!!! ........

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    Re: Project Phoenix an Alfasud sprint is reborn

    fortunatly the front end of the car needed next to no welding
    i merely had to make some room in the front panel for the oversized rad using my trusty air hacksaw, i then went on to turn the slam panel and front valence into bolt on panels,

    why?

    because to take either the engine or gearbox out of a sud, you have to remove the front suspension and lift the car up and drop the whole lot out the bottom, which isn't very repair friendly, but seeing as these panels have no structual purpose, making them bolt aon allows easy engine removal through the front of the car
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    Re: Project Phoenix an Alfasud sprint is reborn

    at this point i had had enough of welding, so turned my attension to something else, this is an early sud, which had diabolical inboard front discs, which crack and overheat, and have the smallest brake pads you've ever seen on the front of a car, 2cv's have bigger front pads

    so the plan is to swap the front suspension for alfa 33 which is almost the same but has vented outboard discs and thankfully bigger pads
    whilst swapping the front end around i poly bushed it, fitted some uprated strut inserts and turned the front legs into adjustable platforms, which is much easier said than done, as it actually involves cutting the legs up, turning bits up in a lathe and welding it all back together, hoping the inserts still fit, one was rather tight but did go in with a little help from some sandpaper a die grinder and hammer, the 2nd one was perfect (practise i guess)
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    Re: Project Phoenix an Alfasud sprint is reborn

    for the most part i'm only showing you repairs to one side of the car, two reasons, i did it one side at a time, and the second side merely mirrors the first, and i couldn't be bothered taking so many pics! i was only taking pics in the first place so greg could get a better idea of progress, not as a way to document the work as such

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    Re: Project Phoenix an Alfasud sprint is reborn

    when it came to the rear arches they were predicably full of rust and filler, nothing i couldn't fix with my trusty air hacksaw and welder, i simply cut the rusty arch off and later welded the inner and outer skins back together,

    remembering this is a budget job on a race car, the arch would be replaced with rivited on GRP ones, thus saving a huge amount of time filling smoothing blending with filler etc, it also mean a minor tap on track can be repair by riviting a new arch on as i've got about 20 arches to fit in stock.
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    Re: Project Phoenix an Alfasud sprint is reborn

    a couple of bits of filler and its ready for some paint

    not much filler required, as the rear arches will be rivited on without blending, just a bit of tidying where the sills meet the rear quarters, one corner of the o/s/r valence (whats left of it that is) and a bit around the rear windows, the o/s one needed most as extensive welding to the inner arch badly warped the outer bodywork
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    Re: Project Phoenix an Alfasud sprint is reborn

    at this stage i fitted the 6 point cage and door bars, the whole way along i had left the doors on as a way to ensure the shell wasnt going out of shape by constant door gap checking, as a way of light relief i now attacked them with my saw to save some weight, if you look carefully you will see i have been seam welding the shell whilst doing repairs
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    Last edited by Graham; 15-08-2006 at 09:27.

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    Re: Project Phoenix an Alfasud sprint is reborn

    primer and paint, with a quick splat of some stone clip in the car and a coat of 2K primer all over, i hit the interior with a nice bright coat of Ford Radiant red
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    Re: Project Phoenix an Alfasud sprint is reborn

    thats it your now upto date, 4 months of spare time inbetween work, racing and mending my own race car and all manor of other jobs in the interim,

    the rest is now real time

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    Spam Man mk1 gaz's Avatar

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    Re: Project Phoenix an Alfasud sprint is reborn

    looks great , will be smart and too good to smash up racing !!!! ......

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