Review by Pete Vack
While Paul Wilson is showing VeloceToday readers how he handcrafted a unique body for his 6C2500 chassis, this book in the 105 Series, Alfa Romeo Arese, shows us modern production methods, circa 1963, to make an Alfa Giulia, and provides an interesting contrast of traditional and modern Alfa Romeo construction techniques. (Scroll down to see photos.)
It is gratifying to know that someone like Paul (and a few other brave and talented souls) can create a beautiful body on an Alfa chassis using simple hand tools and an English wheel. But it is also exciting to see how, using mass production technology,* given a pressed steel panel and a lot of complex jigs, an Alfa Romeo is welded together to make a complete whole, coming together at various stages until it is ready for paint and wiring and interiors and engines. Granted, the entire process is very similar with an AMC Pacer as the end result, but I’m sorry, Alfas are so much more interesting, even circa 1963. We have to admit that the thrill of the new is personified in these images, and the fact that no restoration effort can ever really recreate that very first time makes viewing the process very special. For those of use who have owned and worked on the 105 series, it is a case of deja vu, oh yes, been there and done that and (like installing the engine) glad to know the factory did it the same way!
Thanks to Patrick Dasse’s efforts to publish these rare factory documents, we see photos from two facilities; the foundry, still at Portello, and the spanking new factory at Arese, about 10 miles north of the Portello location, needed in order to produce Alfa Romeos on a scale unheard of in the past. According to the author, with the introduction of the mass produced 1900, production rose to 4411 cars per year by 1953. By 1960, total Giulietta production was 33606 cars annually. And, with the introduction of the 105 series and the new plant at Arese, annual production rose to 123,309 by 1971.
Years ago, in August 2006, we ran similar production line photos of Alfas, in this case, earlier 101 series cars on the production line at Portello, taken from an issue of Quattroruote and of course Alfa PR photos. But there were only 75 photos, and as they were printed on pulp they did not reproduce well. https://velocetoday.com/birth-of-a-giulietta-part-1/ Alfa Arese, on the other hand, offers over 380 photos, all superbly reproduced on quality gloss paper. A world of difference.
Patrick Dasse has compiled these photos, all from the same period, and includes the foundry and mechanical assembly still done at Portello, as well as hundreds of photos taken at Arese. And he doesn’t miss a beat…from casting a block and head to the complete assembly of the engine, rear end and transmission. Then onto Arese where there are photos of the steel sheets awaiting cutting and then pressing, the presses themselves, cutting, fitting, welding on a variety of jigs, and so on throughout the entire production process. There are some phases that are missing, but very few. We don’t see the arrival and installation of the Borgo pistons and liners, bearing shells, detail suspension members, etc. Only one or two photos show us the fabrication and installation of the interiors.
In addition to the production and assembly photos, Dasse has included images from the design lab, testing and training, which add to the understanding of the many aspects of the Arese facility. We needn’t mention that this book is another treasure for Alfa owners and enthusiasts and we highly recommend it.
Read Review of Book 1: Berlina
Read Review of Book 2: RHD Alfas
Read Review of Book 3: Junior Zagato Alfas
*In Italy, pressed steel panels were in play since at least 1934 at Fiat’s Lingotto plant and nothing much has changed aside from more computers and robotics.
Below, a small selection of the photos from the book.
Pouring the molten aluminum into a mold for the Alfa block at Portello.
The heads were cast using sand cores, and here are show with the flashings.
Machining the crank.
Assembling the head with a single Solex carb.
Engine assembly made easy.
Brake drums before final machining.
Assembling a rear axle, almost a work of art in itself.
Ten miles down the road at the new Arese Plant
After the flat sheets are cut, they are sent to the presses, and then to the door assembly station, and welded.
GTA rear body sections are not welded but riveted to the subframe structure. But is this a GTA?
A Giulia sedan unit frame ready for outer panels.
Welding the front end of a GT coupe.
Painting is the next step with several different phases.
Installing the wiring harness.
Completed bodies are inline to get have the mechanicals installed.
Alfa’s way of sliding the engine and transmission into the car.
The interior was the last to be installed.
All in a day’s work.
Alfa Romeo Arese
By Patrick Dasse
384 pages, 364 black and white photographs.
Size: 25,7 x 22,9 cm
Weight: 1,9 kg
Language: English – German
Author: Patrick Dasse
ISBN 978-3-87166-163-1
89 Euro plus shipping
Free shipping within Germany.
Order here: https://dingwort-verlag.de/alfa-romeo/12/alfa-romeo-junior-z?c=5
We were in Italy a few years ago and our bus drove right by the Alfa Arese plant,with the Brembo brake factory right next door
Unfortunately I could not persuade the bus driver to stop because he had an agenda to take the passengers to Switzerland
Anther missed automotive opportunity!
Wow, these have to be the most beautiful Alfa production pictures I’ve ever seen.
No Alfa Romeo enthusiast should be without this series of books.These are the holy grail of my motoring library.
I just decided I am buying a copy for my wife to give me for Father’s Day!