[Avnyc11]

Not to derail the thread, but is the idea here that rebuilds like the are fun to do in someone's spare time, or are they actually meant to save money (because they doesn't save time, and time is money) vs. buying a used car

 

[themecheng87]

Trunk/ deck lid material....

Is it aluminum? Anyone know for sure. I would expect so but cannot be sure. Thanks,

www.giuliaforums.com

Thanks!

 

[themecheng87]

Not to derail the thread, but is the idea here that rebuilds like the are fun to do in someone's spare time, or are they actually meant to save money (because they doesn't save time, and time is money) vs. buying a used car

Great question! For me, personally, this is intended only to be a learning experience. From what I've spent for the G1/G2 cars and misc. parts I think that a conservative estimate (assuming all turns out alright) will cover the costs of the tools that I purchased. Some ways that I've learned to save costs (for the next build) will be transporting my own vehicles (I had to have the G1 shipped) and the other would be to be more patient. Had I waited for the front clip to be purchased, I would have saved costs on the interior parts which I already purchased. Now, instead, I have two sets of red/black interior dash hardware which I need to store and sell - shameless plug to go check out my ebay listings...

As a side note, apparently eBay won't let you sell air bags as an individual seller. So if anyone is looking, I've got both passenger and driver side knee air bags as well as a steering wheel bag and can send pictures if interested.

 

[Avnyc11]

Great question! For me, personally, this is intended only to be a learning experience. From what I've spent for the G1/G2 cars and misc. parts I think that a conservative estimate (assuming all turns out alright) will cover the costs of the tools that I purchased. Some ways that I've learned to save costs (for the next build) will be transporting my own vehicles (I had to have the G1 shipped) and the other would be to be more patient. Had I waited for the front clip to be purchased, I would have saved costs on the interior parts which I already purchased. Now, instead, I have two sets of red/black interior dash hardware which I need to store and sell - shameless plug to go check out my ebay listings...

As a side note, apparently eBay won't let you sell air bags as an individual seller. So if anyone is looking, I've got both passenger and driver side knee air bags as well as a steering wheel bag and can send pictures if interested.

Thanks for explaining

 

[themecheng87]

I’m mocking up the new, G2 pieces on the G1. While the welds appear to align pretty well across the multiple seams, I was wondering if anyone had available some dimensional data that I can cross-reference my setup with. I know that a pretty compressive list is available for OEMs, but I only wanted a handful of point-to-point data that I could use.

 

[Crosshairs]

I’m mocking up the new, G2 pieces on the G1. While the welds appear to align pretty well across the multiple seams, I was wondering if anyone had available some dimensional data that I can cross-reference my setup with. I know that a pretty compressive list is available for OEMs, but I only wanted a handful of point-to-point data that I could use.

I think you know how to read these drawings , but let me know if you have any questions

 

[themecheng87]

I think you know how to read these drawings , but let me know if you have any questions

You’re the man! Exactly what I was looking for - Thank you!

 

[shpuncik]

when in doubt or no measurements you can always watch how sensei does it

 

[themecheng87]

Status update:

Over the past week(s) I’ve been preparing the G2 parts for mounting on the G1 body. This involved spot-weld removal, seam sealer cleanup, metal cleaning, and prep for weld/adhesive. With the help of folks on the forumI was able to locate the oem adhesive requirements and compounds as well as proper oem repair techniques. The forum has been a great resource and I’ve learned a lot - thank you!

Fitting up the G2 parts to the G1 body went relatively well and as I had been expecting. The most difficult part is working by yourself and wishing you had at least one more hand. Nevertheless the overlapping seams, bolt holes, and bracket locations were a great help in getting the new and old structure rough-aligned.

I believe I reassembled the front end three times. First to get a rough alignment. Second time after I had applied weld-thru primer to interfacing weld surfaces. Third time after removing weld-thru primer from spot weld locations. At first a bit counter intuitive but this is done to ensure a good weld - see 3M application guidance.

After reassembling the final time, I loosely clamped all interfaces. Using the oem dimensional data that was shared to me I was able to fine tune the position of parts to meet oem spec (+\- 2mm). This was achieved using ratchet straps and the original brackets to pull parts into position according to the spec. With the structure aligned, my brother and I did plug welds at all of the cut spot-weld locations to secure the body and injected 3M structural adhesive at the prescribed locations.

 

[themecheng87]

The welding at some locations was very tricky due to the minor thickness of some of the overlapping panels, but we quickly came to a rhythm that worked well.

Today then has been the cleanup and finishing of the structural part of this project. I’m fast forwarding a bit here, but I applied 3M seam sealer to the oem locations and have applied a PG1 paint with clear coat to the frame to cover the G2 white. I know that the frame color of the Giulia is a bit more “primer” than a metallic finish coat, but I decided to go with the metallic coat to get some experience with it in a less critical/visible area. I’m pretty pleased with it and am looking forward to reassembling things once the paint had a few days to cure.

 

[themecheng87]

Over the past week I’ve been slowly putting together the hoses and wiring bundles throughout the engine bay. Going well in most cases as I get to select the best part from two cars to reassemble to the body. However there are two things that I could use some help with.

1) What is the part number and where can I find the small plastic clip that secures the brake pedal to the brake booster (master cylinder) push rod?

2) The last wire cable I needed to repair was the passenger headlight. All other connectors and wire colors have aligned between the G1 and G2 wire bundles. However, the G2 (being a 2019) uses one additional pin and a few different wire colors when compared to the original G1 (2017) cable. Can someone provide any guidance and a wire diagram of this section for both model years?

Thanks folks!

 

[Crosshairs]

Let me see what I can dig up

 

[themecheng87]

I did a little comparison between the (good) G2 wiring bundle versus the damaged G1 bundle. I found that for the headlights I had and the G1 bundle the car is plumbed for, that I could interpolate the wires needed. There must have been some wiring color changes on a few of the signal lines or there is some difference between passenger and driver sides, but without a wiring diagram it’s hard to be sure. Nevertheless, the differences I saw were:

Pin / G1 Driver Side / G2 Driver Side / G2 Passenger Side
1 / Grey-Green / Grey-Green / Grey-Black
12 / Grey-Black / Purple-Black /
13 / Unused / Black-Purple / Changed to Unused

The rest of the wiring harness has been repaired and routed through the chassis as well as any hoses/tubes that would go in prior to engine installation. I’m getting close!

 

[themecheng87]

Time for another status update!

I believe where I left off last was with the inspection and repair of wiring bundle issues. A lot of work has been done since this last post and here are a few images to accompany the latest state of the rebuild.( I've used a lot of blue painters tape to help me identify connections and make notes to myself regarding routing of cables/hoses )

• Completed wire routing and repair using G2 engine bay wiring bundle adapted to G1 car.
• Reinstalled brake booster and brake lines
• Reinstalled the engine / transmission and torqued/spec'd all interfaces
• Reinstalled steering gear and suspension/wheel hardware
• Installed G2 radiators/condenser/intercooler
• Installed G2 coolant system and related hardware
• Installed G2 airbox cleaner and related ducting
• Test fit fenders/hood/lights prior to painting
• Repaired/repainted 2x wheels
• Reinstalled driver airbags, seat, and trim

 

[themecheng87]

Once complete with the mechanics of the assembly, I've done the following maintenance - partially because its consistent with a 50k mile service and partially because I didn't have any history on the vehicle and wanted to establish a clean "dataset".

• Oil Change / Filter
• Transmission Fluid / Filter
• Engine / Turbo coolant fill and bleed
• Brake fluid fill / bleed
• Engine air filter
• Cabin air filter***

*** Man, generally I have enjoyed working on this car. I've been pleased with the mechanical fit in the assembly and the overall design of the car. HOWEVER, when it came to the cabin air filter I have to say that this was one of the most frustrating items to service - IMO an afterthought in the design process. The old filter was quite deteriorated and the removal of it resulted in a torn filter which needed to be extracted with long needle-nose pliers and a good deal of cursing. Installing the new filter was about the same... The acordian style filter crumbles when being slide from an odd-angle into a channel hidden behind a mess of cables/ductwork/dash panel frame/etc. A total PITA... rant over.

With a clean set of filters/fluids, I started her up! All in all, a little anti-climatic. It powered on and started humming. I heard a bit of rattle in the engine-bay that appeared to be located at the wastegate solenoid control arm. After running the MultiECUScan I found that I had a wastegate position sensor failure that I traced back to a broken wire between the wastegate solenoid and the PCM - once fixed the solenoid position registered and the rattle went away.

The normal fault clearing needed to occur including the ABS System / Power Steering / Parking Brake / dynamic struts / etc. and proxy scan, but once cleared, they remain off. The only two that I've got currently since driving the car on the backroads for a little test-ride are some low-pressure lights on the tires and the parking sense system (front bumper not installed yet). The car tracks well down the road at 50~60mph though I haven't gunned it with the front-end still not yet fully assembled - just a slight shake at 45-50mph which I believe is due to the wheel balance. Neverthless, I'm pretty pleased!

Next steps for this build:
1 - Line up paint of bumper / fenders / hood
2 - Repair and touch-up left/right rockers
3 - Reinstall splash guards and engine-bay trim
4 - May need a new battery (TBD)
5 - Will need an alignment
5 - DONE

Potential upgrades:

• I've got a 2019 Radio unit and display so I'm considering undertaking the CarPlay update for this 2017
• Custom paint overlay to the base Vesuvio paint on repair parts
• Suggestions?

 

[Avnyc11]

Great progress in just 6 months. Albeit I don't know much but I thought it would take longer.

 

[Vangiulia]

Impressive!! The way u keep ur garage floor so clean. For ur next project u dont have to test fit the hood and fenders, just get a tram gauge and it could measure the dimensions. From there u can chdck with the specs so no need to test fit.

 

[themecheng87]

Impressive!! The way u keep ur garage floor so clean. For ur next project u dont have to test fit the hood and fenders, just get a tram gauge and it could measure the dimensions. From there u can chdck with the specs so no need to test fit.

Thank you! Yes, I've found cleaning the area after each "milestone" is my method for ensuring I've not missed a leak, all fasteners are accounted for, makes it more "pleasant" to work on a cold floor, and generally just to stay sane

I haven't yet decided if rebuilding cars is a new hobby of mine - my wife would plead not, but I've gotten a real kick out of this one. I'll definitely be considering a tram gauge for future builds if that's the path I go down. Thanks for the recommendation.

 

[themecheng87]

Status update:

The G2 parts are at the paint shop getting worked-up this week. Sanding down / primer / paint / clear coat done to match the G1 body.

We had some trouble at first getting an exact match after taking the VIN's "PG1" (Vesuvio Gray) or when using a paint scanner - the PG1 ordered from two different suppliers was more "pink-ish" than desired whereas the paint scan resulted in a more "black-ish" paint. Eventually we came to a mix of both the PG1 and paint scan colors which really looks great. Hoping to get the parts back late this week so that I can reassemble (for the last time!?) the front end of this car.

For those interested - I've started a second thread listing the left-over parts I have from this build. Have a look and if you see something that you need, send me a note!

Side question - has anyone come across a good set of mud flaps for the Giulia (front/back)? I have a bit of gravel on my daily commute and would hate to start sending rocks up over the rockers if possible. I know that there are many options for a clear protective film, but intially am not a fan of that approach. I'm curious what options you guys have come across.

 

[Vangiulia]

The mudguard will make the car look like a corolla. So no, i dont use mud guard...