Metal Fabrication

In addition to providing custom wiring looms, reproduction parts and restoration services we are also assisting restorers with a number of metal products such as floor pan, sill kits, and special parts. For more details please contact us.

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Our parts catalogue just keep growing. (3/23/2015) - As indicated earlier, we continue to bring a number of parts only available from Italy in the past. All of our product offering are hand built and tested for accuracy and fit made here in the U.S. Here are a … Continue reading
Full steam ahead Skipper!!!! (2/15/2015) - It will be hard to explain where we are with this car before I give a proper introduction of what was needed to bring this car to where it is today. I purchased the remnants of this shell for $100 … Continue reading
Giulietta Spider 08578: Saved from the crusher? (8/2/2014) - Last Summer I purchased this Giulietta Spider that was destined to find its way to the crusher. The purchase price was a nominal fee of $100 and for me, it makes perfect sense given that I have all the needed … Continue reading
A day for celebration (6/8/2014) - Trying to get caught up has become an insurmountable task since returning home from  a well deserved “vacation” in Spain. Note that I included quotations to the word vacation because I did manage to do some work on a couple … Continue reading
Update: 1959 Fiat 1100cc 4 doors (3/14/2014) - Here is some good progress on the 1959 Fiat 1100cc project. Since work started late last Wednesday, all the rust on the car has been removed, new patches and fabrication have been completed and welded in place. Final work, which … Continue reading
Arrival of 1959 Fiat 1100 4 door Sedan (3/8/2014) - Since our first publication the giulietta shop continues to receive a number of inquiries about our metal fabrication, metal restoration, and other related restoration services. Earlier this week we welcomed the arrival of this 1959 Fiat 1100cc four door sedan … Continue reading
Building a new Giulietta Sprint Veloce Air Scoop (2/12/2014) - In addition to working on our restoration projects we continue to make inroads with new products that are hard to source. Our goal is to continue expanding our product line and offer restorers a consistent venue for parts that are … Continue reading
Update: AR*171268 (Hand planishing) (1/30/2014) - We are now going through the hand planishing process of the entire car in order to ensure that all the panels are straight before we move to the final lead work and bodywork stage at which point the car is … Continue reading
Update: AR*171268 ( The fabrication details) (1/23/2014) - It is 5:00 am and before I get out of bed and with laptop on hand I am going to post a few more photos and comments before I get my day started with wiring harnesses deliveries. I am happy … Continue reading
Update: AR*171268 (Oxy-acetylene vs Mig welding) (1/21/2014) - For me, one of the biggest conundrums involving the welding process is understanding the differences between Oxy-acetylene vs Mig welding. First and foremost, I have to admit that Mig welding is very easy to learn and just as easy to … Continue reading
Update: AR381173 – The fabrication details (1/20/2014) - While mapping the work to be completed on any project we tend to overlook the specific details and the SS we just completed was no exception. Some of the important details were either missing or consumed with corrosion. I was … Continue reading
Update: AR*171268 New sills (1/5/2014) - With the new year in full swing, we continue to make speedy progress on our 1961 Giulietta Spider.  Last week, both the outer sills (rockers) as well as the front cross members were completed. Although, the cross members had been … Continue reading
Update: AR*171268 – Nearing Final Metal Repair (12/12/2013) - The 1961 Giulietta Spider 171268 is moving with amazing rhythm and speed.  As of today, the cabin floors, trunk floor and all structural components are nearly completed. Of course, not including some of the outer sheetmetal work already done.  With luck, … Continue reading
Update: AR*171268 – Extensive Metal Repair & Replacement (11/25/2013) - Here are a few photos of the extensive cosmetic surgery required once all paint and filler was removed. Upon removal of the old paint and fiber glass we discovered that the damage was a lot more extensive than anticipated and … Continue reading
Restoration: 1961 Giulietta Spider – AR*171268 (11/20/2013) - Now that we got four cars out of the way and awaiting paint work we are beginning to work on a 1961 Giulietta Spider. After close inspection, we concluded that there will be a lot more work than anticipated. My … Continue reading
Update: AR*381173 – Body Work Completed (3/18/2013) - Many, and I mean many, hours of work and Giulia Sprint Speciale 381173 is, I am happy to say is… on its way to redemption.  All the rust has been replaced, all the floors are done, and we are finishing our way around the outside metal. … Continue reading
Update: AR*381173 – Final Stages of Body Work (3/14/2013) - Work on the SS continues at an incredible pace and now that the undercarriage is completely cleaned of rust, tart, fiber glass as well as paint.  All the rusted body parts have been removed and new parts have been fabricated. … Continue reading
Update: AR*381173 – Restoration & Bodywork Progress (2/10/2013) - Restoration on Sprint Speciale 381173 started on December 28th, 2012 and as of today we have logged 280 hrs. So, what has been done in 280 hrs? Removing everything from the car except suspension.  Paint stripping, bondo, fiber glass, undercoating, and sand blasting.  … Continue reading
Update: AR*381173 – Fabricating door frame replacments (2/8/2013) - The SS doors where in a complete state of disrepair and new frames had to be made along with 3 quarters of the door skin on one door and about 1 quarter of the other door.
Update: AR*381173 – Floor Pans & inner sill replacement (2/6/2013) - Below are photos of the most recent progress on the front and rear floor pan. We opted to preserve as much as the original seat rail support as possible. When we replaced the inner sills support section we punched and … Continue reading
Update: AR*381173 – Metal Repairs (2/1/2013) - The extensive metal repair process has begun.    
Update: AR1495*F04695 – Sheet Metal Repairs (5/24/2012) - Additional progress on F04695 sheet metal repairs. I was fortunate enough that this particular car was very good with the exception of some badly done body work as it was revealed as the car was stripped to metal. Lots of … Continue reading
Update: AR1495*F04695 – Sheet Metal Repairs (7/21/2011) - As stated on the 06611 post, I am starting to move on into the spider veloce and work continuity is seamless.  As suspected, the few small pinholes on the rockers were a clear indication of some rust treatment required inside … Continue reading
Update: AR1493E*06611 – Metal Work is Done (7/21/2011) - Work on 06611 continues, all metal work is done (Thank God)!!!! and the final cleaning is happening.  Now ready for the Metal prep and epoxy primer. Once epoxy primer is applied I will be moving on to the 58 Spider … Continue reading
Update: AR1493E*06611 – Trunk Floor (2/13/2011) - All of the wiring harness work, the unusual Texas cold winter and other family and business affairs  have been keeping me from maintaining steady progress on Sprint 06611 sheet metal work. Removing, making a trunk floor from a flat sheet of metal, and … Continue reading
Update: AR1493E*06611 – Trunk Lid Lower Frame Support (1/20/2011) - Here are some photos for the trunk lid lower frame support as we repair the old one and make a template for the ones in the future. Next will be the trunk  floor to be made.
Update: AR1493E*06611 – Rear Metal Work (1/19/2011) - We continue to make headway on E06611 and as of last weekend most of all the vehicle’s rear metal work has been completed.  We had to cut the lower section of the trunk lid and replace it with a new … Continue reading

6 Responses to Metal Fabrication

  1. Diego Grados says:

    Hi Lionel
    I’m from Peru, and I have a 1961 Alfa Romeo Giulietta Sprint Veloce (101 Series). There is one part missing in my car, and that is the Air intake Box that connects to the Heater, located behind the front right light. Is that a piece you can fabricate??

    • aisllc says:

      Hello Diego,

      I provably can do better! Let me check but, I believe that I might have a spare heater unit available. If not, I can make one. Also, note that I have a number of reproductions parts for sale listed under the AIS Store front. Regards, Lionel

  2. Chris says:

    Hi Lionel and greetings from Australia.
    Further to our email correspondence, please let me know sometime whether it is possible to have the rear cross-member/chassis rail sections and the rear valance fabricated.
    Kind regards,
    Chris
    PS: I am also interested in your reproduction toolkits and leather straps for the toolkit/folding top.

    • aisllc says:

      Hello Chris,

      We are about to finish Giulietta Spider 171268 and will take some time of from cars so that we can complete a number of requests for metal fabrications like yours and others. I do have a couple of tool kits left and will set aside one for you. Remember, that earlier Giuliettas are the black anodized sets and the 101 the cadmium plated sets.

      Regards,
      Lionel

  3. Chris says:

    Thanks again Lionel. I appreciate your help.
    I’ve been following your latest rebuild – as usual, fantastic work.
    Regards,
    Chris

  4. Chris says:

    PS: My car is a 1957 model, so is an early 750 (1495 01440)

    Chris

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