Andrew's X19 restoration

Thanks a lot for the comments guys!

Ovi - I will make sure to take some more close ups next time I'm in the shed. I spent 12 hours there today so Im a little tired to do it right now, but I'll make sure to remember tomorow :)

Eastep - the R32 is a nice car... and the seats are so nice. My friend has taken me for a few rides, and it certainly goes like a rocket and sounds amazing to boot. Although I still dont think the Volkswagen 3.2 V6 has the soul of the Alfa V6. If it were my money, I'd probably spend the same dough on a clean used Alfa 147 GTA.

Ulix - you are right this part is fun. It is incredibly frustrating sometimes, but you cant beat the feeling of acheivement when something works. Ive decided to go all out on the X and make it as close to perfect as I can. I have a friend who has rebuilt his Alfa 33 16V to a super high level, and I've gotta make the X as good as his car! He comes around to my place at least once a week and gives me all sorts of crap if I do something dodgy - its good fun and good incentive. This is the engine bay of his Alfa, so this is what I am competing with and aiming for here :)
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Rupunzell - leading on from Ulix's comments I am going to make sure to do this as well. I have copies of all of Carroll Smith's books and am trying to follow his advice where possible. The biggest thing Ive learnt so far is his advice on fastners, the quality of them and their correct uses. I am trying to use only aircraft standard when I can. The car will be used on the track, so I want everything easily serviceable and clean so any new cracks or damage can be spotted before it becomes a problem. I am also going to try and standardise the head sizes of all the bolts to minimise the need for lots of tools which should reduce time in case we need to make any fast repairs at the track.

Emrliquidlife - well if your looking for a holiday theres always a bed here for you :) hehe

And back to the updates. I spent a good 10 hours in the shed today working on her, which kinda sucked as I saw 43deg on the thermometre at one point. Luckily we are only a short walk from the beach, so Ive been cheating and ducking down for a swim every few hours. You certainly get some looks when you hit the beach in dirty work shorts with smears of grease on your face lol. So far Ive found that the biggest problem is my own inexperiance. Ive never done serious work on cars before, only helping Dad out here and there. Sometimes I simply dont know what to do or how to do it, and I waste a lot of time waiting for Dad to get home from work to show me how to do something. Today I decided to take all the wheel bearings out and strip the whole suspension to prepare it for sandblasting, and it darn near took me all day - a job Ive seen done in 2 hours or less. I had to call Dad at work 4 times and even then had a pile of 5 dead ends for him to solve when he got home! Im not a mechanic, and I guess its a learning experiance and I certainly am learning a hell of a lot by reading the shop manual, figuring things out and using the old trial and error method of getting things done. I guess this all means that the next car I restore will take half the time :)

My first job was to sort the wiring loom out. In previous photos above you can see its just a mess of wires and god knows what (or the "hairy Italian genital area" as one of my friends called it). I sorted all the wires out, cleaned them up with soapy water and then retaped everything. I dont understand electricity very well (my knowledge is little more than "stick this plug into the socket and the light works now") so I wanted to make it as simple and organised as possible to give myself half a fighting shot at making it work. I then strung the loom back into and around the engine bay and around the front boot. Theres better pics somewhere that I'll stick up later.

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"I dare say Cadbury, this new hand held monocle is a simply smashing idea... it saves me from having to use my opera glasses at the most in-opportune of times"

My work today consisted of stripping the entire suspension down to its last components. I am using a mix of 1300 front hubs and 1500 rear hubs and arms. It took me ages, but I got everything out and now need to drop the hubs at a friends workshop so he can press the bearing races out. My plan is to get all the big parts sandblasted and then powdercoated either gloss or satin black. I will then get all the nuts, bolts and small brackets nickel plated. It seems pointless and frustrating, but these little details will really make the car when its done. So I can remember how it all goes back, Ive started to take photos like this one showing what components make up an assembly, and how they come apart. My camera is hating the greasy hand useage, but I'm sure these photos will be invaluable when I cant remember how it all goes back together in a few weeks time!

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So progress is being made, albeit slowly. The real fun will start when I get all these parts back from the powder coaters and nickle platers.. then the suspension and brakes can go on... cant wait!
 
Thanks very much for the comments, and Glenn the nationals are my due date for the car :)

Over the past few weeks Ive been fiddling around, doing bits and bobs here and there when time permits. Heres some random shots of the goings ons...

First up, heres some more closeups of the body for Ovi. Unfortunatly my camera doesnt take the best shots in the challenging lighting conditions of the shed, so I might have to convince a friend to come around with a DSLR and take some better ones!

I was in the pit doing an oil change on a friends Honda and saw the X from this angle - thought it looked almost evil :devil:
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Meanwhile, the camber plates and top perches arrived from Jim at G Force the other day. This is the final piece I need for the suspension puzzle, and once the suspension pieces are beed blasted and painted I will be able to get the suspension in. Im guessing there is going to be much celebration when the X is on its wheels for the first time :woot:
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I got happy with the Armorall and spent a few evenings in the shed rubbing away. The plastic was so old and faded that it just soaked so much of it up, but its very rewarding work and I'm happy with the way it turned out. I rebuilt the left tail light with new seals that I sourced from Clarke Rubber and I cleaned all the dust and muck from behind it. I have 3 spare right taillights, and believe it or not all 3 of them are broken in the same place. So, gotta find a replacement.
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The biggest problem I'm now facing (apart from being perpetually broke but thats another problem lol) is sourcing replacement suspension parts. I am finding it quite difficult to get most of the busches and ball joints, and I'm not exactly sure what to do. I had grand plans of renewing every suspension busch and ball joint in the car as everything else will be brand new, but this plan probably isnt going to happen. I went to The Spare Place and Turin Imports in Adelaide and purchased everything they sell suspension wise and a new set of wheel bearings front and rear, so I guess I'll do some poking around and see what the internet has to offer. If anyones got any ideas of what to do, let me know!
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Ive spent ages rebuilding the pedal box on the X. Its been quite a learning curve as I dont exactly remember how it came apart and the photos I took arent much good, but I'm getting there. I pulled it right back and sanded and repainted the main housing and pedals - they are far from perfect but you'll never see them anyway. From the spares Ive got I selected the best and least worn of every part and started rebuilding with fresh grease all round. Ive ended up using mostly parts that came off the car in the first place - they were hardly worn at all which further leads me to think that this car never did all that many k's. Dad and I are going to buy a flaring kit and make new lines for everything (with the good calipers I'd hate to have crapply old lines) and I put new master cylinders in. Dad and I only replaced them about 2 years ago, but its such a bitch of a job once its in the car that I decided to replace them anyway!
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I ended up buying these 6 wheels and tires off a friend. They are performance superlites in 13x6" size, and I intend to use them as the track wheels and get Panasports or something for the road. Guy was using them on his Fiat 124 Tarmac rally car - this is why there is 6 of them and they are fitted with Yokohama Advan semi slicks. There is still about 60% tread on them, however they have done a Classic Adelaide Rally and some shakedowns and are a little old so I dont expect them to be terribly sticky anymore as theyve had quite a few heat cylces. However, they will make fine shakedown tires for the car (its not going to be quick out of the box so trick tires probably wont make much of a difference while we are testing suspension and brake settings). I test assembled the brakes onto a hub and they just fit by about 3mm - close but it looks awesome as the brakes fill the entire wheel :excited:
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Well, thats enough of a break for now. Back to the shed for more head scratching and confusion
 
Keep going Andrew:thumbsup: What size tires are they? BTW, maybe it's just me, but I've found the 032(Advan) to have quite a bit of grip even to the wear bars. Are they the softs or hards?

Money, I hear you, I've already budgeted my next $5,000, just have to earn it now:wall:
 
Love what you're doing...

Especially with the shiny new hardware. That car will be a collector's item when you're finished!
Money? Don't worry about that... Think of it as an investment in what makes you happy. Priceless!
 
I think you'll find that the Yoko Advans will still grip aplenty. Since the X is such a light car, you won't wear them so bad. I get approx 7-8k miles from them on the street.

Looking great.

Ed
 
I really love the colour

I almost painted mine that colour. I decided to stay close to original.

Looks amazing Keep the pics coming.
 
Angelo - the wheels are 13x6" and they are fitted with 205 tires. I'm fully expecting that they might rub and have clearance issues, so I might not be able to use them anyway. But the plan at the moment is to get the car on its wheels, and just see if they fit or not.

Robert Moose - I did think long and hard about the color. I thought of changing it (it probably wouldve been red) but, like you, I decided to keep it origional and go with the green that the car came with. I quite like it anyway, amongst my friends I'm known as "that guy with the green X19" and I think its very cool in a bad taste 70's porno kinda way. I'm changing the interior color to black, but when it had the brown vinyl interior it was just so 70's it was awesome!

A few weeks ago I went and picked up the engine cover from the body shop. I decided to use a Series 2 engine lid as I might need the extra height it affords for carbies and air filters etc.

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Excuse the dust on it, I was too scared to wipe it down for fear of scratching it. I picked this engine cover up from the U-Pull it wreckers and it was remarkably free of rust, so it didnt need a huge amount of work to fix it. I got the guys to paint it satin black in an effort to replicate the finish it has from factory.

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I read somewhere on Xweb that removing the rain tray can reduce underbonnet temperatures by up to 30deg. The car is going to see some track work in up to 30-35deg C heat and heatsoak is always a big problem. The carbies also wont have a choke, so I need some way of combatting vaporisation. Also, it would be really cool to be able to peer through the engine cover and see the big carbies and air filters etc. The obvious choice was to remove the rain tray!

However, this opens up more problems, the biggest being protecting the engine from rain. Whilst I will never intentionally drive this car in the rain, it wont be a daily and it will never be parked outside overnight, its inevitable that it will get wet at some stage (ie if we're at the track and it starts raining I'm still going to keep racing it hehe). So, I had the idea of putting nutserts in the engine lid so that we may screw the rain tray on if need be. Eddie at the body shop welded these little nutserts in when he was doing the rest of the work, so this way we can have the best of both worlds!
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I mentioned earlier that I robbed (or raped as some people are saying lol) a wrecked X19 to get all the small rubber grommets and clips. Ive spent many hours cleaning them (some were caked in grease) and they have come up like brand new. This little pile took me nearly 5 hours:
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Heres one of them closeup - this is the one I am most proud of. All of the holes were totally filled with grease, and before I started I thought that both sides of this were completely flat. After much cleaning and a bit of armour-all, it came up brand new!
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Ive also made a pile of parts that I delivered to be silicone bead blasted this morning. As soon as I get these mostly suspension parts back I can paint them and hopefully get the car on its wheels!

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Well done young man...

Andrew: Your attention to detail belies your youth.
A most impressive job by any standards.
That it is your first resto is doubly impressive.
Few of any amount of experience match quality of your work.
I stand in awe of your dedication and first class narrative.
Keep the updates coming!
MM/Oregon
 
As the Ole Rascal says...

Your work belies your youth... we are envious!

Coupla things will make your life easier...

1. Raintray... I've run without one over 8 years through many a downpour with the stock Bosch EIU in the right hand pocket. Make sure your drains are CLEAR!

2. For all your RUBBER, VINYL and PLASTIC revitalization... clean with paint thinner or lacquer thinner... then use DUPLICOLOR Vinyl and Fabric spray in FLAT BLACK on all the flexible parts... and DUPLICOLOR TRIM BLACK on all the hard plastic or rubber components. If you clean and paint everything front and rear... all will appear to have popped fresh right out of their molds!

Now... after about 8 years... I'm having some of the Duplicolor flake and bubble off of some of the exterior components since I've had the car outside in the COLD (32F, Cold for SoCal) yet covered.

Looks like I'll need to freshen them up again for another 8 years...

Keep up the great work... all my best!
 
Dedication, thy name is Andrew:) As Tony said, I've never had an issue with the rain train in my 9 years with it off, slalom, car wash, street drive whatever.
 
I appreciate the work

The attentionto details and the thorough commitment.
Keep us posted and enjoy your work.
 
thanks very much guys!

htfx19, the say no to rice thing... no doubt you wouldve seen what we call the "ricer" cars - small near stock Japanese sedans with big wheels, tiny brakes, loud exhausts, big stereo's and lots of stickers. Similar to the 'say no to drugs' campaign we came up with 'say no to rice'. It could extend to any Japanese car, although theres a few we like so we'll leave it where it is :shh:
 
For some strange reason I decided to go on a crusade to get the front suspension in this Easter. With a bit of luck, hopefully it should be in by tomorow night.

The first step was to get everything silicone bead blasted. I got this done at a local radiator shop and the parts came up really well. I elected not to have them profesionally painted, but rather to buy good quality spray cans and paint them myself. In the end I gave all 19 parts 3 coats of primer and 2 coats of gloss black and saved a good deal of money in the process. As you can see I decided to build a high tech spray booth specially for this job!

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The next move was to drop all of the nuts and bolts to be dipped and zinc plated. In a rather scary move, after taking many photos I combined all my small bags of nuts and bolts into two bags and hoped for the best. All up I had 10.5kg worth of hardware. I am over the moon about how well they came up, when I dropped them off they were all old and greasy and they came back brand new!

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The next job was to sort them all out to try and make some sense of where the hell they all go! Ive decided to sort them into piles of like nuts and bolts and keep them in their set piles. When I then need a 10mm nut or a certain bolt, they'll all be together. I was very happy with the cost as well, it only cost $43 to have it all done, including some small assemblies such as boot latches and hinges.

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For a bit of a change of scenery I decided to assemble the struts, strut tops and top perches. Now I know how they all work, and its just a matter of putting them into the car. Cant wait!
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The freshly painted parts:
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I just finished painting the hubs, and I'm pretty happy with how they came up. In hindsight I might not have chosen gloss black (maybe a satin or something) but they still look very nice. The gloss black will nicely offset the gold color of the zinc plated hardware.

I pressed all new wheel bearings into the hubs and that was a learning experiance. Ive never done it before, so I decided to do it myself. Garren from the Fiat club showed me how to do the first one, and then left me to my own devices. To cut a long story short I've now ruined 2 perfectly good brand new bearings (pressed a dust seal in the wrong place that caused the flange to bind up on the front and I forgot to put the locking ring on the back before pressing the flange in on the rear). We had to press the bearings out to fix the problems which ruined the bearings - ah well lesson learnt!

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Happy Easter indeed!

Wow, that is a lot of effort Andrew. The car will no doubt be a thing of beauty when you complete it. Keep the updates coming, I really enjoy watching your progress. I do not have the energy to go through this type of resto.

Just simply an outstanding effort Andrew. Thanks for sharing.
 
WOW!

The nuts and bolts turned out great!

Fantastic job on this. I am really impressed. I wish to heck I had some of your resources around me.

Can't wait to see how it ends up.

Keep up the great work.

Eric Armstrong
 
Great fun to see and read your progress!
Love your attention for detail.

And that color, fell in love with it the first time I saw it, especially with brown interior...from the decade that taste forgot!!! :happy:
 
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