Alfa 33 Rebuild

dickyb

Junior Member
Messages
451
#1
Thought I'd start a new thread for the rebuild as the other one was getting a little elongated.

Car arrived back from the bodyshop on Thursday last week, it looked like a new car on the transporter and I'm very pleased with the end results. Shame it rained and the car got wet and a little dirty but it soon wiped off. I'm still having some fun with legal issues relating to the previous bodyshop who made such a mess of the car but making some progress so hopefully it will be resolved soon.

On the transporter:
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The car shortly after arrival, wheels are temporary and will be replaced with something bigger and better:

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I've made a start on some reassembly but didn't have a lot of time over the weekend. I thought I'd start by installing the wiper motor so that the grilles at the base of the screen could be installed so that the car was a little more waterproof. I then moved onto the wiring loom which was something I was not looking forward to, as some of you may remember from the previous threads the wiring loom when removed looked like this :(:

wires2.jpg

Pretty daunting but once unravelled it went in ok but still looked a mess:

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Doesn't look a lot better here but fusebox has now been mounted and a lot of the wires have been routed to where they need to be so I felt a little happier:
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Unfortunately I only made brief notes on where everything goes as I never imagined it would be 4 years before I reinstalled it all, lots of thinking and looking at stuff closely has helped to resolve a lot of the issues but more to sort out. I had to cut the ignition wiring as the immobiliser terminal blocks wouldn't pass through the ignition barrel but it should be simple enough to solder it all back together. I'm still a little uncertain about some of the earths but more thinking should resolve things.

I won't be able to make much more progress for another week or so as the car is 100 miles away from where I am currently living but next jobs will be to install the fuel system, brake lines and perhaps some items in the engine bay plus some more wiring for the engine and a/c system. I've also noticed the handbrake is only working on one caliper so that's another thing I'll need to look at. Its going to be a mammoth job and I suspect its going to take a long time:(. I don't think it will be back on the road this year which is a pity as it is the car's 20th birthday and its the 30th anniversary of the 33 this year.
 
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Messages
1,956
#4
Is the cat food dish being built into the car? looks daunting right enough, good luck with it. I stripped an old TVR S some years back and it took 2 years to rebuild, so i have been there sir and its scary!! but if you have a look at the finished product, I was well pleased once it was done
Dscn2083.jpg TVR ready for body-small.jpg
 

conaero

Forum Owner
Messages
28,401
#5
Keep going Dicky, I had to rewire from new loom, my 1969 Opel GT. I never stripped the loom so no pics or tags were present.

Whats more, the instructions or the new loom came in German....so it could be worse for you!!!
 

conaero

Forum Owner
Messages
28,401
#7
Being an older car there were less electrical systems but it was a nightmare and several things did not work from the off...no fires though so I should count my blessings.
 

dickyb

Junior Member
Messages
451
#8
Had a week or so working on the 33 and have managed to install a few parts but didn't get as much done as I'd hoped. I found a number of parts that I'd previously refurbished had gone rusty again thanks to a "great" product called POR15. Some people rave about it, I have found it to be a complete failure:(. As a result I have not been able to install a number of things until these parts are refurbished, I'm slowly working my way through them.

I've managed to secure a garage until September so at least I can work in the dry until then, after that the car will be back outside under its cover.

A few pics of the quality of the restoration work that has been carried out, I'm trying to do it justice by ensuring that all the parts that go back on are new or as good as new with all new bolts and fixings fitted wherever possible:

P6160413i.jpg P6160417i.jpg P6160419i.jpg P6180436i.jpg

As anticipated I am encountering a number of problems along the way, mostly due to not remembering how everything goes back together, I never expected it to be 4 years before I reassembled the car :). I've managed to install some fuel lines, a few items in the engine bay and now have most of the main loom wiring sorted and have installed the engine loom and a/c loom (a few problems to sort there), one more wiring loom to go!

P6190445i.jpg P6160421i.jpg P6180441i.jpg

I am hoping to make slow but steady progress over the next few months but unlikely to be back on the road this year
 
Messages
50,649
#9
Is the cat food dish being built into the car? looks daunting right enough, good luck with it. I stripped an old TVR S some years back and it took 2 years to rebuild, so i have been there sir and its scary!! but if you have a look at the finished product, I was well pleased once it was done
View attachment 15441 View attachment 15442
Davy that is just lovely..Have a real sofr spot for the S...Saw it when it first came out on the Stand at the Motorshow in Birmingham....Just adored it after all the wedge shapes that TVR were making......Drove a V8S Version and so wanted one........Reall old fashion big engine long bonnet.....Love them and yours looks stunning.........Must look in the clssifieds now...
 
Messages
50,649
#10
Had a week or so working on the 33 and have managed to install a few parts but didn't get as much done as I'd hoped. I found a number of parts that I'd previously refurbished had gone rusty again thanks to a "great" product called POR15. Some people rave about it, I have found it to be a complete failure:(. As a result I have not been able to install a number of things until these parts are refurbished, I'm slowly working my way through them.

I've managed to secure a garage until September so at least I can work in the dry until then, after that the car will be back outside under its cover.

A few pics of the quality of the restoration work that has been carried out, I'm trying to do it justice by ensuring that all the parts that go back on are new or as good as new with all new bolts and fixings fitted wherever possible:

View attachment 15658 View attachment 15659 View attachment 15660 View attachment 15661

As anticipated I am encountering a number of problems along the way, mostly due to not remembering how everything goes back together, I never expected it to be 4 years before I reassembled the car :). I've managed to install some fuel lines, a few items in the engine bay and now have most of the main loom wiring sorted and have installed the engine loom and a/c loom (a few problems to sort there), one more wiring loom to go!

View attachment 15662 View attachment 15664 View attachment 15663

I am hoping to make slow but steady progress over the next few months but unlikely to be back on the road this year
Dicky, she is coming along nicely..........Love reading this thread.
 

mjheathcote

Centenary Club
Messages
6,352
#11
Looking good!
I know what's its like when you start to put things back....it's got to be the best, stainless fasteners, new or reconditioned parts etc.
It took me 5 years to put my Stag back together onto my 'new shell', hope it doesn't take you as long!
 

ZAM400209

Junior Member
Messages
509
#13
oh, I'm massively jealous!

I 'nearly' bought a 146 (which looks better in my eyes now than a 145) some years ago as a third car, but I'd jump at a 33!

Looking at the bulkhead across the engine bay- is it a boxer?


by 'cat food tray' he means the hole in the floorpan for the gearlever! It threw me a bit too, for a moment!
 

dickyb

Junior Member
Messages
451
#15
Thanks for your kind comments everyone, it really helps with motivation to keep going as I'm sure anyone who has done a major rebuild will know.

ZAM: you've opened a can of worms with the 145 vs 146 debate, I run a late 145 Cloverleaf as my daily and I absolutely love it, they are awesome cars and I've kept it all this time as there is nothing that has inspired me to replace it. Now on 146000 miles and still going strong! The 145/146 are mechanically the same so its all down to aesthetics although the 145 is a little lighter (and looks much better in my biased opinion).
Yes the 33 is a boxer, mine has the quad cam 16v with a few tweaks, more details at the beginning of the Alfa 33 restoration thread.
Thanks for clarifying the cat food dish issue, I was totally confused, I don't have a cat. I can see now that the gravel drive visible through the hole for the gearstick kind of looks as though it could be some cat biscuits or something. Some people have vivid imaginations!:)

Not much progress lately, just decided that the fuel tank wasn't good enough as it was brush painted with epoxy and now everything else is so nice it seemed a shame to fit a part where the finish was not quite up to standard. I've got a lot of niggly jobs done now so hopefully some more visible progress in the next few weeks but a few issues to address with the a/c as it was designed for LHD and needs some adjustments to fit onto a RHD car.
 
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Messages
28,216
#16
Thanks for your kind comments everyone, it really helps with motivation to keep going as I'm sure anyone who has done a major rebuild will know.

ZAM: you've opened a can of worms with the 145 vs 146 debate, I run a late 145 Cloverleaf as my daily and I absolutely love it, they are awesome cars and I've kept it all this time as there is nothing that has inspired me to replace it. Now on 146000 miles and still going strong! The 145/146 are mechanically the same so its all down to aesthetics although the 145 is a little lighter (and looks much better in my biased opinion).
Fantastic things. Mrs Catman had one, until someone ran a van into the back of it :(

C
 

mjheathcote

Centenary Club
Messages
6,352
#17
oh, I'm massively jealous!

I 'nearly' bought a 146 (which looks better in my eyes now than a 145) some years ago as a third car, but I'd jump at a 33!

Looking at the bulkhead across the engine bay- is it a boxer?

by 'cat food tray' he means the hole in the floorpan for the gearlever! It threw me a bit too, for a moment!

As well as owning a 33 P4 in the 90's, I also had one of the last 146Ti's in the early 00's.
It was a great hot hatch!
 

StuartW

Centenary Club
Messages
7,877
#18
Looking great! I have fond memories of my 1.7 33 some years ago, that horizontally opposed flat 4 was a delight. I had a switchable 4x4 33 Sportwagon before that too but the less said about that one the better!
Good luck & I look forward to seeing the progress
 

dickyb

Junior Member
Messages
451
#19
Not a huge amount of progress lately but a few more parts have been refitted.

Fuel filler and pipework. The area around the fuel filler cap is notorious for rusting but luckily mine was fine due to being treated with Dinitrol many years ago. The rust tends to come through from the inside, dirt is trapped around the pipework which then holds moisture causing it to rust from the inside out, small signs of rust around the fuel filler cap are normally the tip of the iceberg and much more serious when viewed from inside the wheelarch. I have applied another good coating of Dinitrol for future protection, not very pretty but won't be seen.


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I've managed to fit one doorcard which really helps to make the interior look less of a mess. First I needed to fit inner and outer plastic moisture barrier membranes which was quite a job, then I discovered that all of the captive nuts that hold the door handle bolts were missing. I think they must have been dissolved in the SPL stripping process, luckily I had a few spares to enable me to fit one doorcard but have had to order some more for the other doors. I also found that 2 of my doorcards had got damaged in storage so need to source some more.

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More a/c problems discovered, it seems that Alfa Romeo in their infinite wisdom, decided to change the wiring connectors on the a/c condensers at some point in production. My wiring loom obviously came from a different era to the new condensers and the connectors are different. Not a big issue as I can just change the connectors but another annoying job that will get in the way of making more progress:

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I've also had to modify the evaporator pipework a little as it was fouling on the brake servo bracket, some jiggling around and some new hose clips should sort it. I also need to look at where to mount the filter drier unit, it means drilling a hole somewhere near the brake servo and space will be very tight. I'll leave that job til I'm confident on the routing of all the a/c pipes. Who's bright idea was it to fit an a/c system that wasn't designed for RHD? :(
 
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