In this webpage we will try to describe the making of a fascinating project.
An old Spanish 1100 cc Alpine A-110 has been transformed into a real 1600-S A-1100 group 4, the ultimate sports version of a model revered by car lovers and highly appreciated by collectors.
Probably because it is my great passion but also because it was a personal challenge, I decided to begin these two and a half years of hard yet very gratifying work to make this project come true.
However, I have to admit that this would not have been possible without the help of great professionals and good friends that have also been seduced by the project.
To all of them, my deepest thanks.
This is the vehicle that will be the starting point of the project. Its current state is not important. The only thing that matters is that it is an A-110. From this vehicle, and based on its essence and history we will build our new Alpine.
In order to be able to properly organize the working plan, the first thing we have to do is to disassemble all the components until the steel backbone chassis can be separated from the fiberglass body.
We are lucky. Rusting has not affected the vehicle. We now have to repair, straighten, align, strengthen and modify its structure so that it can support the new mechanics that will give it a second life.
The most technical and crucial process is probably installing the mechanics of a real 1600 cc group 4 into our car's chassis. New supports and braces, calculation and development of structural elements capable to support bigger efforts, perfect alignment between the front track and the rear track, etc.
A fascinating challenge to get a perfect chassis before assembling it again to its bodywork.
Polyester resin and fiberglass become art. The new front and rear, once the rest of the body has been modified and assembled to the chassis, thus becoming a single body, allow us to have a glimpse to the look of our new Alpine.
Faster steering, gearbox at the right height, redesigned supports, new connecting rods with better graduation, study and construction of a new steering knuckle, restoration of the steering column support, etc.
Support of the upper and lower suspension arms, design and construction of the control arm from lower arm to chassis clamped through a Unibal ball-and-socket joint adaptable to the various positions of the steering alignment.
The ensemble is completed with group 4 springs guided from below to enable assembly and Bilstein shock absorbers.
Pedals are assembled on bronze bushings and grease nipple. A new support for the hydraulic clutch pump is designed and developed. Finally, a new throttle pedal with double cable to carburetors is made.
Front and rear large disks with rear brake adjustment control from the driving seat. Cable handbrake adjustable from the control located in the central tunnel inside the vehicle.
Construction of the support for the hydraulic pump, tied to the clutch cover, to operate the new 215 mm pressure plate. The dented ignition rotor for the electronic ignition signal sensor is lightened and balanced.
The mounted gear assembly, interior drive shaft, primary shaft, crossheads, bearings, etc… are reinforced.
A new support system between rear axle shaft and gearbox using extremely rigid silenblocs is studied and developed in order to improve the guiding of the rear wheel assembly, thus managing to avoid transmitting vibrations to the body.
In the valve cover the pipes are enlarged, bronze guides are installed and the chambers' capacity is equaled for a compression ratio of 10.8 to 1. The rest of the mobile elements are adjusted to get static and dynamic balance. Springs in the rocker arms are eliminated and guided instead with duralumin shells. Oil pump is transformed with a 31 mm pinion. The interior of the oil sump is partitioned. 46-89-81-49 camshaft with gradual distribution pinion. New aluminum pulleys are made for one single rough surfaced belt to alternator and water pump, with automatic strut.
New connecting rod screws are put, steering wheel planimetry is checked, tighten pars are accurately calculated, distributor' stalling, verifying tolerance of the valves' springs and a special assembly greasing.
The ensemble engine-transmission is started, mounted on a support with all cooling elements, temperature control and oil pressure. First break-in and set-up, with a total of two-hour non-stop functioning.
Autobleu originals, modified improving rigidity of the unions and adding a horizontal bar in the lower part that will be used to clamp the harnesses. Support basis are adjusted to the body with polyester resin and reinforced with metallic staples in the fiberglass backfill, better dividing the stress.
Harness clamps are reinforced, the register of the handbrake is adjusted on the central tunnel. A new registry is designed and built in order to improve engine access from the interior. General improvements are made on the finish of the fiberglass surfaces.
Hinges are reconstructed with new bronze shafts and new door locks are installed. Window aluminum frames are adjusted and fiberglass works are made to adjust the fitting and planimetry of the doors.
Several adjustment works are done to install the indicators and headlights, the bonnet locker, the bumper modification, the plate space, the air holes for the brakes, etc. A new air intake grille is made.
The rear part is made detachable. In order to get the new bumper support basis a clay and a few several plaster moulds are made. The pieces are made of fiberglass and united to the body. Other elements such as indicators, rear, brake and reversing lights, letters, air intake grilles, etc are adjusted.
To achieve the best result this process needs to be long. Preparation layers, sandpapering, filling,… Then repeating the process and painting with a blue paint base to look for and correct any flaws. Then again filling, sandpapering… and finally the definitive color: metallic BLUE 331. The dashboard and the doors moldings are painted in black crackle. The rest of the body, engine spaces and the trunk interior are painted in satin black. The inside of the roof is painted satin light beige.
Following a methodic and strict order, we begin the final assembly of all the mechanics on an already finished body. It is time to reap the rewards of the adjustment of the pieces and the assembly made during the coupling phase. Now with the lack of space inside it would be almost impossible to modify certain pieces.
The new electricity system has been completely redesigned and optimized. We highlight the new watertight competition battery on the back axle shaft, the new and more accessible relay/fuse box, Renault original electronic ignition, rev counter turned electronic, two-speed windscreen wiper, new safety elements such as a non functioning gas pump without oil pressure and an external connection to charge the battery.
First contact with the asphalt and first 40 km. These are essential before beginning to work on the upholstery, the doors, the windows and a few final touches.
The car is running smoothly. So it is time we begin to work on the upholstery, using upholstery of the same quality and the Renault diamond shape as the car had in its origin. Special pieces are made to cover the access to the engine, the hand brake and the door hinges. All visible screws and made with rustproof material.
Modplastia seats, harnesses, rear view and outside mirrors are installed.
Finally, to protect the floors, light rubber textured mats are adjusted.
Side and door glasses are made with Makralon Bayer. Mechanisms are restored and adjusted, aluminum moldings, rubbers, seam lines, Plexiglas rear window and more and more ornamental tops are installed. As a friend of mine, a French repairman and owner of an Alpine 1600-S, said: "Such a huge amount of hours devoted to such a small car".
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