1600 Alfa GT Step Nose Metalwork
In our metal workshop, we have recently been working on a GT 1600 Alfa Romeo 105/115 Series “Step Nose” Coupé. Produced between 1963 and 1977, this Alfa gets its name from the subtle, elevated “step” in the front bodywork where the bonnet meets the nose, giving the earlier models a unique, angular face. This Alfa Romeo has come in for a wide variety of metalwork repairs, which our panel beater, Rob, has recently been working on. We are repairing any areas containing rust and restoring the structural integrity of this classic Italian car.
To begin the restoration process, the step nose was mounted on the Car-O-Liner jig. This precision alignment system enables the body shell to be accurately aligned and securely held in position during repairs. Using certain original reference points on the Alfa’s body ensured that the measurements matched factory specifications, giving a true baseline before any metalwork began. This step is crucial for this Alfa Romeo GT because a small misalignment can affect the panel fit and handling geometry.
Once the Alfa Romeo was mounted on the Car-O-Liner jig, we began to fit the new front chassis leg. The leg was fabricated by our senior panel beater, Darren, before its installation. This structural section runs from the front of the car back into the engine bay, supporting the suspension and engine loads. We ensured that the front chassis leg was correctly aligned and positioned before welding it in place; this step was crucial to ensure the car remains strong, safe, and able to support the precise fit of the surrounding panels. After the new chassis leg was installed, the new front crossmember was then fitted. This component ties the left and right chassis legs together, adding rigidity to the front end and helping with accurate panel alignment later.
After these key structural areas were installed, our attention moved to the A-pillar area at the front of the GT 1600 Alfa Romeo, a common rust spot on the 1960 Alfa Romeos’. This vertical support pillar at the front edge of the door opening runs from the sill to the roof, forming the side of the windscreen frame. This particular area is prone to rust because of water ingress around the windscreen and poor drainage inside the sills. Repairing the A-pillar is another key area for restoring structural integrity. It’s critically important that the pillar is aligned correctly to ensure the body shell has strong rigidity. Additionally, it ensures that the door hinge mounting points are correctly aligned and that the windscreen aperture stays square.
The A-pillar repair also provided a strong and clean metal foundation to install new sills. In addition, our panel beater, Rob, replaced the lower sections of the A-post and B-post panels and new floor crossmembers were also installed. This stage of the restoration puts a lot of strength back into the body and provides secure mounting points for the seats and other interior fittings. The next phase of the restoration process will focus on repairing the rear chassis rail and rear floor area. We will continue to keep you up to date and informed about this restoration through our social media and blog updates.
If you are interested in getting any metalwork restored or repaired on your classic Italian car, please don’t hesitate to get in contact. Our world-renowned Auto body restoration technicians can repair or restore bodywork and fabricate bespoke panels. No job is too big and no task too small to be given our full attention. If you are interested in our metalwork services, please contact us on 0115 926 2266 or email us at info@alficina.com.