You have made me miss my 83 Alfa Romeo GTV 6. I loved that car but as my first wife it didn't work out as a daily driver!

Please don’t hate the fact that I’m glad you are having to tackle the a pillar. My ‘68 junior has split seams all along the sills, and I imagine this is one of the jobs that lies ahead for me. To see it done right is a real boon, and 105 owners who watch this will be cheering you on, where ever they are. All the best Jethro, and thanks for the content, it’s always well done, considered and nicely shot.

Jethro wear a friggin' filter mask while grinding/cutting! You've got a lot of cars to fix and you need to be around to film it for us! Enjoyed your efforts on this episode, keep at it dude.

Your car is full of surprises! It may take longer to restore, but I am glad you are doing it the right way. Your positive outlook is inspiring.

Must give you much satisfaction with that grinder.....replacing with nice fresh metal, Good job .Keeps me watching

JB-again-thanks-a really informative and important series. I'm very glad you are documenting this-I will be on a similar path soon I believe. Super important series for the entire Alfa community A request for you: when you start the series on fabrication, please tell us about the tools used, the materials (gauge of metal etc) and the plans for long term preservation. ie; after the cutting, forming an welding, what steps and materials were used to prevent rust--oxide primers, POR 15 etc. The thing that confuses me is how to deal with any preventative metal prep measures being burned off during welding. So, after the welds, how do we preserve the metal in a closed area that is subject to future water ingress- waxoyl or POR 15 sprayed from a wand etc.

wow the last time with blasting it seemed rust free ... very useful to know that of course there can be rust that is hidden. I'm sure that many alfas that look great from outside they have hidden rust. Now it requires a lot of work in rebuilding the pieces. Very thanks Jethro for sharing this video.

Afternoon Jethro 😁 Love the cool way you talk about what your doing on the Alfa’s and your handy work . Loved everything I’ve watch so far. Cheers Stevie 😎🇬🇧

No worries there, then..Jethro...One thing with old cars, no matter how well they have been looked after or 'repaired' they will always give you a surprise when you dig a little deeper. Luckily enough you are digging that bit deeper...many would just rehash the old and move something like that along...great progress, even though you may feel that you have taken a few steps backwards..

Nice workshop, beautiful handiwork! Your patience and attention to detail are a real inspiration to all of who spend our time and money repairing old classics. Thanks for the videos!

Fascinating tour of those innards, Jethro - thanks! I'll second the safety nerd stuff. So not worth damaging your lungs, ears, or eyes doing this!

Always like your clean and calm approach in the repairs being done bro...keep it up!!

Ha. Rust in a classic? Where have we heard that before?! What surprises me is that even in a mild climate these cars still rust. I don't want to think what would happen in a country with snow and salt. Well, good on you for giving it a crack and may the force be with you. I am too old for this kind of shit.

I'm sure you probably know this but if not, remember to take the spare wheel bracket off your rusty well as it doesn't come with the replacement panel. So much for all the Alfas sold in the UK as coming from rust free South Africa! Really enjoying the video, keep it coming.

Hey Jethro, thanks for your hard work (including filming and editing of course). Thanks to your videos I found the courage to takle on my own Bertone's body work. What can I say, I now know the feeling of discovering poor repair jobs from previous owners :-) Keep it up and best regards from a Swiss Alfista

About 8 years ago, I missed an opportunity to buy my a 1750 Junior from Mombasa Island in Kenya for about 30000 ZAR. It was pretty rusty and had not moved in probably 20 years, seeing this...I think I should thank my lucky stars!...though often think of it....

Hey Jethro. This is very interesting to me. In my own barn I have a 1975 GT 1600 Jr. which unfortunately has suffered under the elements for too long, so it has lots of rust issues. Seeing you dive into the metal like you do gives me confidence that I can fix mine. After all - it's just sheet metal...

Really inspiring stuff, your so thorough and clearly dedicated with your approach.

Many thanks for another great episode. Given what you found considering the cleanness that it seemed to be, I shudder to think of the work needed before me so I'll watch and save this and upcoming episodes A suggestion would be to include some shots from the parts catalogue to help illustrate the layers you will be dealing with. My project GTV has in addition to the ills yours has rusty cowl areas. More fun. Keep up the great work

Seems like restoring an old car is always full of unwanted surprises. Hopefully it will be easy to fix. Nice video as always ;)

Great work ! If you plan on cutting more away from the a pillar section try to brace the body with some steel hollow section lenghts, it might sag if your remove the innermost 'kick' panel. The left and right 'kick' panels are asymetrical, so don't do what I did and try to make a mirror image of them!! I bought them eventually as they are difficult to make perfect without the right tools

Great stuff. Will be watching.

Thanks for sharing! I have quite a bit of metal work ahead of me with my '72 GTV 2000 project. I need to buy an angle grinder, etc myself. Cheers.

another great disassembly vid of you cutting stuff up! :) can't wait to see you fabricating hahahaha

You have to love 'rust free' cars. The more you dig into this, the more scared of mine I become ;)

Good one Jethro! I really appreciate the detail as always. Makes me wonder how many 105 rust-buckets with nice paint, and artfully sculpted Bondi are winning blue ribbons in car shows these days, lol!

Have you ever considered providing a drain in these rebuilt sills so they don’t hold moisture? Sometimes the factory wasn’t building for the long run. My body-man did so in a Plymouth i had restored

Is there a plan to treat the replacement steel and the surface rust on the otherwise good stuff that's covered up again?

Hello Jethro. First, Thank you for your videos. I have only one notice. Try to hold unmoving your camera. And, try to display small parts from your work to your car, separetely, with plenty of time, to be clearly understood. Thank you Again !!!!

Question: when you send a body for blastin, do they spray a primer protection coat on the bare metal afterwards?

Thanks Jethro looks familiar LOL?

What separates the pro from the amateur - they do stuff in a way you can bare for years. Its a little bit confusing seeing this guy grinding with minimal safety gear like face shield, shield of grinder, dust mask or hearing protection. Also I wouldn't were my automatic watch or götti glasses in the shop.

I enjoy watching this vids, but when I do I am always left with these questions; how did you learn all this stuff, and how do you have time to do this stuff? That car rotisserie alone looked so time consuming.

You can't even see the hidden rust (inner sills) on these cars until you cut them open.

Great Stuff! Get yourself some POR to kill that rust.

Iv done that repair 3 times not fun but keep going..their all the same..

What can you do to prevent rust from appearing again?

Not to be health and safety bore, but an exploding cutoff wheel can really ruin your day, as can progressive hearing loss. From the amp and speaker in your workshop I'm guessing you're a musician. Deafness can be a real drawback when you're playing. Ear defenders and a guard on your grinder might be a good idea.

God im so scared to strip my paint.

Yeah yeah yeah, we get it Alfas are prone to rust... get on with fixing it.

All the cars of that era rusted.

Jethro! Wear goggles and hearing protection for heaven's sake! Seriously! You are a very meticulous and methodical worker, but please, this could seriously injure your eyes and you are damage your hearing.

When you start off saying "whats up guys" you have lost me immediately-leave off the hype of all the others -PLEASE !! be original-dont need it .