WFSZ16 04

Another week on the zagato. Not a lot of pictures but a lot has happened. I repaired the uppercorners of the firewall. Changed the side profile of the driversside to match the passengerside. Knocked out some dents and stretched the driversside a little bit. Then located every stresscrack, knocked it flat and rewelded it. Remade the lower 20cm of the firewall and the passengerside already welded in after connecting the sidepanels to the firewall.
Now the firewall is strong and firm again compared to the wobbly and bent thing it was

Another week on the zagato. I finished the welding on the firewall and put it back on the car. The tops of the sidepanels are connected to the sides of the dashboard and the inner Apillars with a little plate that curves a bit outwards. Both Apillars are rusted very thin so i fabricated 2 new inner and outer Apillars and the complete assembly that connects all parts together. To make sure the windscreen will fit perfect all the way around and especially in the lower corners i have to fabricate completely we made a fibreglass copy of a windscreen. Unfortunately that didn’t hold its shape enough so i made another template with steel profiles i shrunk and stretched and welded together to follow the curves and shape of the windscreen and hold that shape. The roofline is a little bit out of place but that will be corrected the next week

Finally another week on the zagato after my little accident with a grinder. I started the week with completing the Apillars and the windscreenframe. The passengerdoor opens and shuts perfect. Only the gap with the rearquarter closes up in the middle. The driversdoor is pushed forward on the Apillar. After carefull measuring and comparing the problemareas are the innerframe of the driverdoor is pushed in, probably when they welded in a firstseries Apillar and the skin of the passengerdoor is to long and the shutlines are wrong. The new parts on the car are all good and square. The doors need to be repaired anyway so i will deal with them later. I cut loose al the brackets, jackpoints and braces that need to be recycled. Made a few smaller improvements on the firewall for nicer fit and completed the floorsections. Then i took everything apart again for the last time. Next time every part will be primed and welded back on the car to finally start building again

Another week on the zagato. Primered every area that will be closed and assembled the entire nosesection. Found a little crack in the driversside innerwing so welded it up. Changed the seatbeltmountingpoints to the original ones with thread. Then i assembled the nosesection on a subframe complete with the towers to weld the nosesection together with the subframeboxes and the firewall. Then took it of the subframe and placed it on the jig in front of the car where it bolted right on without any tension and put the floor and innersills back in the car. Time to start building a car again

The zagato is one puece again. Made some minor adjustments on the innersills and the floor and welded them back in. The transmissiontunnel also. Then the seatbases and screwed the Apillars back in to check for the rearbody and the roof. Perfect the same on both sides. Then i made the reinforcementpanels for the innerwings/bulkhead/subframeboxes and welded them in. Made new bottom endplates for the rears of the innersills and the strengtheningplates for the Bpillars. Now i’m of to zandvoort for the annual trackevent from the alfaclub to have some fun on the track with my Alfa 33

Another week on the zagato. I started with a lot of measuring and found the roof of the car twisted to the drivers side. So i made a jig of the windscreenapperture of the red zagato to make sure everything will fit and line up. Welded in the sideplates between the Apillars and the firewall. The windscreenframe was a little bit bent down so i used the press to put it back in place and supported the edge while welding the sideplates and pressing the dashboard down again to make it straight again. Then some minor modifications on the Apillars to make it fit the windscreenjig and the doors. With the hydraulic press i pushed the roof back in place and capped of the Apillar and the windscreenframe

Another week on the zagato. Started with a bit of finetuning the hingelocation on the APillar until satisfied with the fitting of the door and made the top to attach it to the windscreenframe. Then i reinforced the Apillar like original and made cages to keep the threaded plates in place. Repaired the side of the dashboard and made a reinforcementplate like the original and welded everything to the car. Made the Bpillar reinforcement fitting nice and welded the corner of the rear innerwing and connected everything together. The leftside of the car is now strong again and everything in the correct position

Another week on the zagato. Started with making the reinforcements for the passengerside Apillar and welded everything in place after a lot of careful measuring and comparing with the driversside. Fabricated and connected the Bpillar so the car is now straight and strong again. Time to move on to the front innerwings Straightened the original rotten rearsection for a template and carefully drilled out the spotwelds of the original passengerside frontsection and straightened that also. Marked and cut out twice for both sides. Tipped the edge and shrunk the edge to fit and follow the curve amd clamped in place. Made the driversside outersill fit. Next time I will make the passengerside innerwing, trim the outersill and weld everything together on both sides again

Another week on the zagato. I welded the innerwing to the car and the reinforcements to the Apillar. Extended the bottom of the Apiller to join it to the outersill. Welded the sill in and extended the Bpillar to join the sill. Then i started making a new doorskin and taking thr old door apart. The windowframe is bend and rotten so i measured everything and made a drawing to have a couple of rollers made to create the correct profile. I also measured the lower part of the doorframe to be able to recreate the profile. The front part of the doorframe was bend and the lower part rotten so i made a new piece and cleaned the lower hinge. Next will be reassembling the doorframe and fit it in the car to locate the lowerhinge