I am glad to see you got to the end... What a major undertaking..

I will be replacing all the front inner panels, shock towers and chassis rails. Managed to find complete sets

i have used inner fenders, chasis rails and shock towers for sedan so i had to fabricate upper portion that's diferent to spider.
just be carefull when putting new rails in, it's critical to measure everything more than once.
use these measures, they are the same, apart from ride height and lenght between axles

I'm a noob when it comes to Fiat's and uni-bodys for that matter. Sorry to interrupt this great thread, I'm also restoring a Fiat 124 Spider I found out mine had been in a crash, yeah the uni-body I think was straightened. But I'm pulling the front fenders off of our car, I figured that part out. I am however having problems with the rear quarter on the drivers side as it will need to be replaced....... The part I'm trying to figure out is how to drill the spot welds out on the top of the quarter between the trunk lid and the area behind the back seat. I have two Fiats one we bought as a running driving rust free California car. Our 69 has rust issues, Probably not really all that bad, but I would rather fix the bent frame rails on the California car than cut out rust on the 69... Also how does the inner fender apron get replaced doesn't that metal get sandwiched in behind the firewall?
Oh and how do you get to the spot welds in the valance area, oh Jeeeeez am I in over my head!!!!! I have so many questions!!!!

Thanks in advance, sorry for the dumb noob questions.

Thanks guys,

I have those and have already passed them on to the panel beater. He ha purposely build the car from jig to ensure measurement are to the millimetre.

Thanks again. Appreciate the support and responses.

Mick

So can anyone answer these questions?

some of the spot welds are not possible to get to. ask me how i know but you have to decide what piece to remove and how it was assembled, take apart in reverse order, i use a air chisel, to break the spot welds i cannot get to to drill, yes it damages something, so i try and damage the panel im removing if i am replacing it with another, if i can cut a section out of the old panel and drill the welds i will do that, but if you are trying to remove and reuse the same panel on the same car, then take your time. and do your best not to damage it much, but you will end up with a repair area somewhere

crazymoose1990 wrote:I'm a noob when it comes to Fiat's and uni-bodys for that matter. Sorry to interrupt this great thread, I'm also restoring a Fiat 124 Spider I found out mine had been in a crash, yeah the uni-body I think was straightened. But I'm pulling the front fenders off of our car, I figured that part out. I am however having problems with the rear quarter on the drivers side as it will need to be replaced....... The part I'm trying to figure out is how to drill the spot welds out on the top of the quarter between the trunk lid and the area behind the back seat. I have two Fiats one we bought as a running driving rust free California car. Our 69 has rust issues, Probably not really all that bad, but I would rather fix the bent frame rails on the California car than cut out rust on the 69... Also how does the inner fender apron get replaced doesn't that metal get sandwiched in behind the firewall?
Oh and how do you get to the spot welds in the valance area, oh Jeeeeez am I in over my head!!!!! I have so many questions!!!!

Thanks in advance, sorry for the dumb noob questions.

hi, i replaced both rear quarters. First i drilled out all the spot welds that are visible, but regards the area in question where the rear wing or fender meets the rear panel i used a grinder and removed sections of the fender to give me access to the lip and to the spot welds.

It's all gone. Now we can get stuck in installing the front end.





A-pillars will need work

you definately got bigger pair than i do.i did it one by one. if you have unmolested crossmember it will be a good reference point for keeping all in it's place.



open up every box section of the bodywork, they were all rotten from inside. even the ones that had no visible holes were thin as paper, 80% eaten away by rust.





increase density of spot welds on chasis rails and shock towers. factory did half assed job on those.




don't get me wrong, i dont doubt your resolve or ability to restore this car properly, i just want to share my painfully gathered experience

Car body is secured on a customised jig. We have all measurements and a new crossmember. I really appreciate your pictures and your comments. Keep them coming. Have you finished car.

not yet. by the way you're going, it's likel you'll overtake me. currently, i'm in the stage of final panel beating before first filler is applyed. i'm trying to straighten out every dent i can find, no matter how small it is. also, the panel gaps are horrific, and what i can see on pictures of other 124 spiders, it's how they came from factory. i'm trying to make them small as possible.
engine is done, full rebuild, gearbox too, new rear axle, rustproofing done, new brake lines, new fuel lines, rebuilt front and rear suspension...

Update

Finally secured a right hand side front new old stock fender. Now we can commence installing the new front end.

New complete inner fenders placed in position with the cross member. We will measure three times before spot welding into position.













New right hand fender with headlight bucket hoops. All new old genuine fiat stock.

Wow! What a project!! Amazing work!! I can tell already that this is going to be a beautiful car!!

Update.. Measuring three times, using lasers... This car will be as straight as it can be...

Panel beater found very few reference points that were accurate. Using beam to ensure all rails are straight and square.