Giulia Super 1600 Engine Rebuild...

Its been over 9 months since I last posted an update on my Giulia Super restoration. Yes, progress has been slow, but it must be remembered this is on a shoestring budget and tasks only get completed after I sell some excess part that I have to fund it! I have been collecting the parts for my engine rebuild for 6 years and I can happily say the rebuild is nearly complete. After realising that my car was actually going to come together pretty close to factory correct specifications I decided to rebuild its original 1600 engine. Most Supers seem to have been ‘upgraded’ to a 1750 or 2L engine but you lose some of the charm of the free-revving 1600 by going down that path. Besides the 1600 is plenty quick enough for me an the car’s purpose as a fun family outing car. The fact that my car still sported its original engine is testament to how reliable these engines can be. You must remember that my car’s odometer has been around the clock ‘at least five times’ according to the previous owner! I completely stripped the engine down the the bare block and all parts to be reused were completely refurbished. A list of things done to the bottom end of the engine include: All alloy vapour blasted Crankshaft tested and linished liner seats honed New pistons and liners Rods had to be balanced, shot peened and rebushed New main and big end bearings Oil pump rebuilt New waterpump Full gasket set The cylinder head I will be using was purchased a few years ago off a guy that had it rebuilt but never fitted to his never-finished project. It had a fair bit of money spent on it with new...

Alloy Engine Parts Vapour Blasted...

I’ve been sorting a few smaller bits out as I get ready to fill the engine bay back up. I had the Bonaldi booster rebuilt. A few little tweaks there that I will post about later. But as for some more photos, here are my engine components looking lovely and clean! I had them vapour blasted by Jason at Rust Busters. I felt confident to go with him as he and his father-in-law are very familar with Alfas, Fiats etc. Ardelve. Your first choice for parts cleaning equipment. Taken from their website: The process is applied using graded spherical glass beads in our Vaqua high performance aqua-blast machine, which simultaneously degreases and provides rust inhibition. With the Vapourblast process there is NO IMPREGNATION of the surface and no damage to sharp edges and precision surfaces I am very happy with the results. The block isn’t in the pics as there was a bit of corrosion on the #1 cylinder liner seat that is getting rectified. Also attached is a before photo! I have been collecting the bits for the engine rebuild for years so it is nice to know I have all the parts I need now including many NOS (new old stock) bits which always fit better than the reproduction parts. [slideshow id=18]...

Dynamat Installed

The carpet is now in. I also needed to install some sound and heat proofing on the floor pans since I had removed the factory stuff in able to coat the floors with a sufficient covering that would give me piece of mind with rust protection. I used POR-15 a couple of years ago and it is doing its job very well. It is extremely hard, almost ceramic, non-porous, has a bit of flex to it, and is self-leveling so you can brush it on and it will give a nice shiny finish. If you do want to remove the factory bituminous sound deadener don’t just try and scrape it off using a heat gun. Buy a bucket of dry ice pellets (very cheap) and sprinkle them over it, leave for 10 minutes, the sound deadener subsequently hardened to brittle level and I just chipped it off to the factory primer. Floor pans were squeeky clean 30 minutes later! Best not to try and grind this stuff off for another reason, and that is that it more than likely contains asbestos… The Dynamat went down very easily. It is an easy product to work with and is so shiny! Its a pity to cover it up. I sorta think Dynamat is as much about the branding as it is to have a little polo player embroidered on your pocket. I had a look at the local Jaycar electrical store and you can get a very similar product for a lot less. Hard to see that there could be heaps of difference between their performance when they use the same materials. You just miss out on all that Dynamat branding all over your floorpan! I got some underlay from a moulded carpets place in Underwood...

The GT Veloce in Papua New Guinea!...

I just received a few photos from a previous owner who had my coupe in the late 70’s/early 80’s. Some people were dubious that my car was in PNG considering it was sold new in Sydney but here’s the proof! The previous owner was a pilot up there and took the car over. Looks like lots of fun twisty roads to drive on. I googled the lookout and the last photo is a pic looking down and the twisty road leading up to it. Kassam Pass rises 5000 feet over 10 kilometres. I have the original PNG number plate shown in the photos sitting next to me on my shelf at work.   [slideshow...

Assembly Begins #01

I had a bit of an epic day at the body shop working on my doors. I now have winding windows and locking doors! I still need to shimmy the rears a bit further back to get the gaps better and latching nicely, but it was nice putting all the new bits on. Boot and bonnet on, (bonnet sits up as I haven’t screwed the buffers down yet) I tell ya, you really need to get the door reassembly order right. The factory body manual was very useful for this. And thankfully it seems most of my ziplock bags seem to have not disappeared as it was over two years ago that I disassembled them. [slideshow id=10]...

All Painted!

everything is now painted. Due to the nature of my car taking up valuable space on the shop floor I have to get it out of there next week some time so a bit of big Saturday for me to get all the glass and door seals etc on, then it is off to my place. I sorta wish I’d put all the zip lock bags in the one place too as it was over 2 years ago now and its hard work to confirm that I have everything I need. I’ll be reading my Parts Manual for the next few nights as I go to sleep just to figure out where it all goes! [slideshow...

Final Primer

Getting soooo close to paint now. Very exciting   Bit more sanding and the like to go and on goes the paint! I doubt the body was prepped as well as this out of the factory so it is nice to know that this should last me for a while hopefully. All those years of neglect in Nimbin have been reversed. I am still glad that my car has an interesting story to tell though. Still a few holes to drill and cutouts such as the front indicators but Adrian assures me the doors hung well with nice gaps. Its keeping good company next to Daryl’s turbo Alfetta which looks like it might be departing soon. [slideshow...

Shiny Bits

When you have a new paint job it makes everything else look dirty and old so to help remedy the problem I had a bucket of bolts zinc plated. What went in as a filthy pile of screws, bolts and washers , came back in lovely, clean and shiny condition! $60 well spent. They charge by the barrel full, so I was lucky that all the ones I have had plated were spares from a couple of parts cars I have had in the last couple of years. I have the ones I had taken off the Super in labelled ziplock bags so I can match them with the clean ones on reassembly which will make the job much easier. Couldn’t find a local plater that did the black zinc so its all silver for now. Employed the cheap labour again for the sorting. [slideshow...

Test Fitting

We began test fitting some parts this week. Bumpers fit great, and around the front grille is getting there. The tolerances are pretty minimal with these early full width grilles and having a two piece centre heart adds a bit more complexity when it comes to bonnet alignment and adjusting the bump stops. Because the PO had fitted a later grille he had removed many of the fixings for the grille so I have to make up a few tabs and screw fixing points....