Sheet metal work to install the fuel tank

I was trying to repair a part of the trunk floor around the fuel tank using the sheet metal I got from a person of the repair shop. My purpose was just to add some patches for the reinforcement because I had never done the sheet metal repair and didn't have a skill. My only experience for the sheet metal work was to make the dustpan in a class when I was a junior high school student. I liked that class and was good at, but it was 32 years ago. I didn’t know how it would be.

After watching the trunk floor for a while, I started making the pattern paper.

I found some moderate thick papers at my house. And I attached it on the repair part and cut it to fit the shape of the flange to be repaired.

Next, I copied this pattern paper into a sheet metal and cut it.

At first I tried to cut it with sheet metal scissors, but it was difficult because the sheet metal had 1 mm thickness and it was too hard. Therefore, I decided to use the disc grinder. I aimed close to the pattern paper line on the sheet metal as much as possible, and cut it with the disc grinder carefully.

I was a bit nervous because it was just 2nd time for me to use the disc grinder. But it went well.

After this I adjusted the shape with scissors and a file.

The sheet metal became like this. It was not bad!

Next was to bend the sheet metal using a vise and a couple of wood pieces.

Then, I formed the sheet metal adjusting to the shape of the area to be repaired.

Finally, the joint part of the wall and the flange was soldered. I knew welding would be better, but I didn’t have a welder. I thought solder was okay because the base flange was still strong.

The formed sheet metal would be fixed on the flange like this.

This was the work for this day.

Next work would be…

- Remove the rust and old paint at the body side to be repaired,

- Fix the formed sheet metal on the flange with steel rivets and JB Weld,

- Paint the remained POR tank sealer on the repaired parts to prevent the rust.

It was a sheet metal work for the first time in 32 years for me, but it was very interesting.

(My original blog was written on 22nd Sep. 2008)

Comments

Tip to repair rubber parts

I disassembled the rear axle before. There had been no progress on it because I started the repair of the fuel tank during my summer holiday. While painting the fuel tank , I repaired the torn rubber boot of the parking brake wire. I guessed it didn ’ t cost high because it was small rubber part. But I wanted to try the repair method I read on the magazine article before. This was the condition before the repair. The rubber was torn apart and separated almost. I used this self-adhesive type butyl tape. I pasted lots of small pieces of the butyl tape on the back side of the rubber boot. As time goes by , these tapes would melt and stick together. After this I applied plenty of adhesive “ Super X Black ” on the rubber boot. On the magazine of MOTO MAINTENANCE , I read the article that the motorcycle seat was repaired with this method. So , I wanted to try it. After drying 1 day , it became like this....

Pad spring repair

One of the springs to hold the brake pads was broken. At first I thought to buy it, however, I tried to fix it using rivets. It seemed to be strong enough just to hold pads. Later I removed the rust and cleaned them. Note: I have been using this repaired pad soring for 10 years and there is no issue. Pad spring is not an expensive part ptobably (I don't know the exact price), but it is easy to repair if you have ar1750gtv hand rivetter. (My original blog was written on 10th May 2008 )

Body repair around the fuel tank

I found some rust at the flange in body around the fuel tank as I expected. I believed this level of rust in this area was quite usual for old Alfa Romeo. It seemed that this area didn ’ t influence on the body strength , however , I was considering the method what I could do by myself. Anyway in order to prepare the sheet metal for the repair at first , I started to look for the store where I could buy some sheet metal near my house. I tried to research the store on internet , but I couldn ’ t find appropriate stores. Finally I asked the person at repair shop , who did maintenance of my Renault 5 , about the store I could buy some sheet metal. They kindly taught me the store , but at the same time they gave me some sheet metal for free. That was enough volume for what I wanted to do. I didn ’ t expect it. Thanks a lot!!! (My original blog was written on 12th Sep. 2008 )

The day my "onboro ALFA" would revive

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