Lancia Motor Club

Model Technical and Interest => Delta and Prisma => Topic started by: Kevinlincs on 31 August, 2015, 10:19:08 PM



Title: my new integrale
Post by: Kevinlincs on 31 August, 2015, 10:19:08 PM
well, my first integrale to be more accurate. a car i've been trying to buy for some time.
needs a fair amount of welding but having done quite a few alfasuds i'm used to rust!

it's an odd car though that needs a little help from you guys to figure out what i've bought. all the trim of a 16V but an 8V engine. i had been told it may be one of the swiss 8V Kat cars but it has nither a kat or ABS, both of which it should have i'm told if a swiss car?

guy i bought it off has had it since virtually new in 1990 so unlikly to have been a parts swap car like you can get with multi owners so he assures me it's as it was when new and i believe him to be genuine.
i've also emailed walkers garage to see if they can shed any light on it, they being the original selling agent.
the car was converted by john whalley to RHD , something i need as i can't get on with LHD cars.

any ideas?

i'll make a start on it next year as too busy at the moment with other stuff.

rot in the usual areas but surprisingly good in others...


Title: Re: my new integrale
Post by: sparehead3 on 01 September, 2015, 11:41:43 AM
Kat ( on an Evo2 ) sits under the passenger footwell so there's a lump there. If you wish to pop the registration on ( or part of it ) then someone may know of it and the history. Just bear in mind this is a public part of the forum if you're sensitive about details like that ( as some are ) - otherwise put something in the members' only section ....


Title: Re: my new integrale
Post by: Kevinlincs on 01 September, 2015, 06:09:43 PM
i've had some news today from walkers which may shed some light onto it, just awaiting more details..


Title: Re: my new integrale
Post by: fay66 on 01 September, 2015, 06:20:11 PM
Paul Baker,
Tipo 038 is your man, Paul is very knowledgable on all integrale/evo and knows what models are what and the 8v Kat cars.He also owned a wicked S4 Stradale ;D ;D
I expect if Paul is about he'll answer you.

Brian
8227 8)


Title: Re: my new integrale
Post by: Kevinlincs on 01 September, 2015, 06:55:51 PM
hi brian.
thanks for the info, i've heard about pauls exploits through the LMC mag over the years so would be keen on hearing from him.
i also met yourself once a few years back at a sharnbrook classic car meet, i was in an alfasud parked next to you, a red ti. loved your fulvia berlina. i'm restoring one for a friend at the moment.

i may have some answers about the cars history from ben at walkers, quite an intersing story if it all turns out to be correct. i'll give more details once it's confirmed.
 


Title: Re: my new integrale
Post by: Kevinlincs on 01 September, 2015, 07:16:24 PM
some rusty pictures, now i've worked out how to post them!


Title: Re: my new integrale
Post by: frankxhv773t on 02 September, 2015, 08:03:04 AM
Yep! That's a fair bit of work but you will know the car inside out by the time you are done. Good luck.

If you were at Sharnbrook are you close enough to join us at the Herts & Beds meet? We would give you lots of encouragement.

Frank


Title: Re: my new integrale
Post by: fay66 on 02 September, 2015, 10:56:15 AM
hi brian.
thanks for the info, i've heard about pauls exploits through the LMC mag over the years so would be keen on hearing from him.
i also met yourself once a few years back at a sharnbrook classic car meet, i was in an alfasud parked next to you, a red ti. loved your fulvia berlina. i'm restoring one for a friend at the moment.

i may have some answers about the cars history from ben at walkers, quite an intersing story if it all turns out to be correct. i'll give more details once it's confirmed.
 
Hi Kevin,
Nice to hear from you.
What year is the Berlina you're restoring please.?
good luck with your own work, that should keep you busy for a while ::)

Brian
8227 8)


Title: Re: my new integrale
Post by: 038tipo on 02 September, 2015, 02:09:33 PM
Hi I think it must have been imported and was originally a Swiss market car then converted by Whalley's after importation, it has an Evo bonnet too just to add confusion.
I am sorry but RHD cars I am not a fan of, the car does not handle the same way as intended and other parts used detract from the feel of the integrale, sorry you do not get on with LHD!
Looks like a complex project, rather you than me!
Good luck!
DVLA must be able to help you with some info on the car when imported Etc?
Paul


Title: Re: my new integrale
Post by: Kevinlincs on 02 September, 2015, 06:34:38 PM
i'm just waiting for confirmation from the original selling agent that may well put to bed what the car is, or was.

i can understand how things get changed around with cars this age if they've been through 10 or more owners but this one is a one owner from new car, and the elderly gent i bought from inisists it is as it was when he got it. if the theory checks out then all will become clear.

i'm up in lincolnshire so sharnbrook was a one off show for me, once i get going though i'd be keen for a meet up.
the welding repairs don't daunt me too much, i've done a few bare shell restorations now so that side i'm happy with. no doubt i'll be asking loads of questions on the technical side of things though so your guys help at that stage would be appreciated.

the berlina is a '72 K plate car brian. in pretty decent shape really.

no probs re the rhd thing paul, i know that the converted cars aren't to everyones taste and have heard about the handling compromises but it's the only one i'd have. i used to work on vw campervans so we had plenty of lhd cars & vans coming in, hated driving them all. just couldn't get used to it.
the bonnet though is a 16V one isn't it? doesn't have the smaller side vents that evo ones have as far as i can tell from pictures of evo's. happy to be told otherwise though so feel free to point me in the right direction.

gave the car a wash tonight just to get rid of some moss from it, amazing how much better they look when wet!


Title: Re: my new integrale
Post by: peteracs on 02 September, 2015, 09:21:25 PM
Hi Kevin

Always interesting to learn of someone in Lincs, given its size, which part of Lincs are you in?

Peter


Title: Re: my new integrale
Post by: Kevinlincs on 02 September, 2015, 10:05:39 PM
Hi Kevin

Always interesting to learn of someone in Lincs, given its size, which part of Lincs are you in?

Peter

Hi Peter.
I'm over towards the coast, between Boston and Skegness.

You're right, it is a big county and Lancia owners are spread out a little!

Kev.


Title: Re: my new integrale
Post by: 038tipo on 03 September, 2015, 09:11:11 AM
 You are right no side vents on bonnet i can see much better now it has been washed
paul


Title: Re: my new integrale
Post by: Kevinlincs on 03 September, 2015, 09:18:20 AM
You are right no side vents on bonnet i can see much better now it has been washed
paul

 ;D there was quite a film of stubborn moss and grime on it, looks better now it's been washed off even if it's now returned to it's natural pink!
no problem though, back to a bare shell once i get started next year so it'll all get fresh paint.

thanks for the advice, looking forward to bugging you guys with questions next year  ;)


Title: Re: my new integrale
Post by: peteracs on 03 September, 2015, 02:43:15 PM

Hi Peter.
I'm over towards the coast, between Boston and Skegness.

You're right, it is a big county and Lancia owners are spread out a little!

Kev.

They are very spread out, hence why I guess it was difficult to keep a regular meeting going. I am near Newark on the Notts border, so not a million miles away, at least in the same part of Lincs.

Peter


Title: Re: my new integrale
Post by: fay66 on 03 September, 2015, 03:06:35 PM

Hi Peter.
I'm over towards the coast, between Boston and Skegness.

You're right, it is a big county and Lancia owners are spread out a little!

Kev.

They are very spread out, hence why I guess it was difficult to keep a regular meeting going. I am near Newark on the Notts border, so not a million miles away, at least in the same part of Lincs.

Peter

Alan Cooper lives in Grimsby but his Volumex has been off the road for sometime now.,although he does have a (lancia)Chrysler, Delta.

Brian
8227 8)


Title: Re: my new integrale
Post by: Kevinlincs on 08 September, 2015, 08:50:44 PM
i've been in touch with walkers, who sold the car when it was new.

they have no records going back that far now unfortunately but an interesting possibilty did surface which surely must be my car.

now, first off the guy i bought the car from (original owner from almost new, purchased the car from walkers) kept banging on about the car being with rally history. not unsurprising with the integrale's history, i may have dismissed his comments too hastily..
the car is now as it was when he bought it, no engine transplants in his ownership and him being the first owner when it was a few months old i presumed it had the original motor

walkers however did throw a thought out there about the car which fits perfectly with what the car is and seems to be.
back in 1989 they were rallying an integrale in group N as i'm sure most of you guys are aware, i saw their car on many occasions including the rac rally of that year.
during '89 the 16V became available in europe but not scheduled here until 1990 so they tell me, which prompted them to purchase a new 16V integrale from germany during late '89 to use the engine to build up for their rally car.
the car from germany they converted to RHD, fitted the blueprinted 8V rally engine and sold the car on at a reduced price....which is no doubt why the gent i bought it off could get his hands on one at last...

it all makes so much sense it has to be true...

in which case my car is  a 16V car from germany originally but now has a blueprinted 8V ex group N rally engine that completed the 1989 mintex rally championship and competed (and finished) that years RAC rally.

so the dilemma is now, put it back to standard or keep with what may well be an interesting car for various reasons.


any thoughts?
the story just sounds about the only option that fits.


it's not like it's a 10+ owners car where the history gets the chinese whipsers treatment.

i'm going to have a chat with the guy i got it from about things now it's becoming clearer, i just wasn't listening correctly before i think!


Title: Re: my new integrale
Post by: DavidLaver on 08 September, 2015, 09:43:45 PM

Well done with the research.

My vote is to keep as is.

David


Title: Re: my new integrale
Post by: DavidLaver on 08 September, 2015, 09:44:16 PM

Another thought is to write into the magazine.


Title: Re: my new integrale
Post by: the.cern on 08 September, 2015, 10:00:33 PM
I agree with David, keep it as it is .... it has been that way for so long ...... for me it is a no-brainer!!!

                              Andy


Title: Re: my new integrale
Post by: Kevinlincs on 08 September, 2015, 10:18:45 PM
i'm gonna chat to the previous owner about it, see if what we presume to be the case is actually the correct set of circumstances.
if it is all correct then i am inclined to keep it as is, such an interesting story of how the car emerged it has to be kept that way, i agree.



Title: Re: my new integrale
Post by: peteracs on 09 September, 2015, 10:27:21 AM
I think it all depends on what your aim for the car is.

If you aim to rally it seriously then it would not really matter I guess if you brought back to factory finish or left as is, if however you aim to keep it for normal use etc, then I am with the others, keep it as is, get it documented with previous owner etc and leave well alone. Great story which will be appreciated in years to come. Now all you need to find is the original Walkers rally car and your car's engine to complete the set......

Peter


Title: Re: my new integrale
Post by: Kevinlincs on 09 September, 2015, 08:05:52 PM
the car will be a road car, no intensions of rallying it at all.
done that years back, although i'd love to again i've no intensions of rallying this car.

keeping it as is, or pretty near to, is my intention with it.

may look at a couple of changes, not sure if it has an 8v or 16V gearbox at the moment (or how to tell the difference?) so may change to a 16V one if it hasn't got one, may look at a brake upgrade if possible....do the brembo's fit the 16V hubs?
know i'd have to go for bigger wheels


Title: Re: my new integrale
Post by: frankxhv773t on 10 September, 2015, 12:45:11 PM
I am with the "keep it as it is" camp but do get the documentary proof of it's provenance with statements from Walkers and the previous owner. These may be crucial to it's value in the future to demonstrate it is not just a cobbled together bitsa.


Title: Re: my new integrale
Post by: Evo1 on 10 September, 2015, 02:00:39 PM
If all the past info is correct then keep it as it is, great history which is important with classic motors and also adds value to the car as a bonus ;)


Title: Re: my new integrale
Post by: Kevinlincs on 14 September, 2015, 06:58:24 PM
sorted out the fuel leak yesterday, a broken pipe connector at the pump which luckily we had a complete spare pump to hand so simply swapped the fitting.
with that the car started up once fuel pressue was restored.

good news is it sounds great, no knocking or tapping and not a breath of blue smoke.

leads me to beileve the blueprinted engine theory even more.


so boyed with getting it going we swapped the wheels over for spares as a friend of mine is going to refurbish them for me in exchange for some parts he had, he's a pro wheel refurb guy and has done them for me before, a job i don't mind passing on!

removing the front bumper to see how far the corrosion had spread revealed a bit of rot.....new cross-member needed!!

had a poke around at the rear which also revealed plenty of welding needed but nothing we can't overcome.

let my 17 year old lad drive it the 10 yards back down the drive, he loves it far more than any car we've had here so i shouldn't be short of help!


Title: Re: my new integrale
Post by: frankxhv773t on 15 September, 2015, 08:41:36 PM
Ah, that looks like the special light weight model..and getting lighter!


Title: Re: my new integrale
Post by: Evo1 on 26 September, 2015, 10:10:41 AM
That's a fair bit of tin worm, keep the photos coming always like a good resto thread


Title: Re: my new integrale
Post by: frankxhv773t on 28 September, 2015, 12:11:19 PM
This might be of passing interest. I think I must have copied it off e-bay some years ago. It shows a kit to convert to RHD.



Title: Re: my new integrale
Post by: Kevinlincs on 29 September, 2015, 08:48:10 PM
i've now got hold of some replacement panels, all used of course as finding a new front cross-member was a fruitless task!
also picked up a VGC RHD top scuttle panel from an HF turbo so the wipers will at least be converted to RHD spec too. did originally look for repair panels for the corners but i've got a whole panel now in great condition so will put the lot in.


thanks for the interesting pics, always useful to see them for little details etc.

been swatting up on the manual ready for when the strip down starts, clues on short cuts for getting it down to a bare shell.

on the engine removal the suggestion is to remove the transfer box, then the gearbox and lastly the engine....wouldn't it be simpler to drop the whole lot out in one? noticed there may be some parts that are in-accesible with the transfer box in place but surely leaving the engine and gearbox attached to each other and lowering them out the bottom is the easier way of doing it rather than seperating the 2 in the engine bay?


Title: Re: my new integrale
Post by: frankxhv773t on 12 October, 2015, 06:35:31 PM
I just saw this on e-bay

http://www.ebay.co.uk/itm/LANCIA-DELTA-HF-INTEGRALE-TURBO-8V-4WD-LHD-VERY-CLEAN-ORIGINAL-EXAMPLE-/231718406055?hash=item35f37e47a7

It is advertised as 8v but has a 16v bonnet. It's an import so I wondered if it had any bearing on the question in this case?


Title: Re: my new integrale
Post by: Kevinlincs on 08 November, 2015, 07:43:05 PM
I must say, the engine bay is a tight place on these cars!

had a little bit of time to start stripping out the running gear, it's about ready to drop out now.

I've got it up on axle stands (not as easy as it sounds as there's nothing on the front now capable of supporting the car to jack it!) and removed most bits now including the transfer 'box.
i'll then drop the engine and gearbox down to the ground as one with my crane, spate the two on the ground then crane the engine out over the top. unless I have room to slide the whole lot out the front, but by my measurement I won't have room.

i'll post some pictures of the state of it now it's all getting revealed, pretty rusted the poor old girl


Title: Re: my new integrale
Post by: frankxhv773t on 09 November, 2015, 02:24:13 PM
A friend had his belts changed by a garage that does a lot of Ferraris who cursed the 'grale saying it was a more challenging job than any Ferrari they had done.

Frank T


Title: Re: my new integrale
Post by: RobD on 10 November, 2015, 12:26:29 PM
You're a brave man taking that on Kevin but I'm sure the end result will make it all worth it. Paul's comments about RHD were very interesting, I fancied an Integrale a while back and like you, decided RHD was the way to go. In the end I changed my mind and went for a Fulvia . Being derived from rally cars I would have thought Integrales were set up to have two people in the front anyway and therefore from a balance point of view it would be difficult to get the perfect set up whether the car was driven from the left seat or the right seat. On a road car it probably makes very little difference


Title: Re: my new integrale
Post by: frankxhv773t on 10 November, 2015, 05:38:27 PM
I don't think Paul's comments related to driver position and balance. I have always understood the main problem with RHD conversions is that there is no RHD steering rack available to the quattro specification. Conversions used a RHD Fiat Regatta rack which is too low geared to give the same driving experience. Having said which I always wondered why a Delta HF Turbo rack wasn't the obvious choice for a RHD Integrale.

Frank T


Title: Re: my new integrale
Post by: Kevinlincs on 07 December, 2015, 07:56:54 PM
finally got the car down to my mate's place into the little shed we raised the roof on to use as a workshop that's self contained, means I can make as much dust and mess as I need to without spoiling his other collection.
he has my old dedra turbo in there so wouldn't want to infect that  ;D

still got to try and find time to get stuck in, finishing off the fulvia berlina about now so should be able to get some hours in soon


Title: Re: my new integrale
Post by: Kevinlincs on 19 December, 2015, 08:19:28 PM
made a start on the car now, n/s sill is first on the list.

chopped the sill mount lip off back to the floor and replaced all along with fresh steel.
the rear end where the suspension mount is on the chassis section was too bad to save so I chopped it all out and made a new chassis rail section.

nearly ready for the outer sill to go on to close it all in


Title: Re: my new integrale
Post by: frankxhv773t on 22 December, 2015, 04:30:59 PM
This project looked more than challenging but you seem to be the right man for the job. It would be great to see pictures of the parts you have made up before and after installation.

Frank T


Title: Re: my new integrale
Post by: Kevinlincs on 27 December, 2015, 09:24:48 PM
here you go Frank  ;)
sorry for the poor quality phone camera pictures, must get a proper camera on the job!

the sill to floor panel I made up then repaired the central one.

the rear chassis rail above the suspension was too poor to keep so all got made up again.

today I've replaced the whole rear arch/door section on the n/s with a good used one

the n/s outer sill is just about ready to go in place now that it's all solid down that side


Title: Re: my new integrale
Post by: Kevinlincs on 27 December, 2015, 09:26:14 PM
n/s/r arch repairs


Title: Re: my new integrale
Post by: frankxhv773t on 27 December, 2015, 10:45:44 PM
Thanks Kevin. that's brilliant. I find is very encouraging to see what can be done. One day I may be up there with you.

Frank T


Title: Re: my new integrale
Post by: Kevinlincs on 17 October, 2017, 05:45:36 PM
Is it really coming up to 2 years since I posted on here!

I've not been idle on the car although other projects have seen progress suffer a bit, a Fulvia Berlina has been done and gone, a Hillman Imp for my lad is complete save for a bit of rebuilding, an Alfa Sprint race car plus an Alfa 33 have been painted so although not as much has been done to the integrale as I'd have liked by now the progress had slowed.
This is after all works done as a hobby, in my spare time!

I have posted a few articles in the club mag, I will elaborate a bit more on the pictures and stuff done that's already been in the mag if there's any interest? As I have agreed to send in fairly regular updates now to the magazine I'll hold off on getting this thread up to date..


Title: Re: my new integrale
Post by: simonandjuliet on 17 October, 2017, 07:48:40 PM
You can do both !!



Title: Re: my new integrale
Post by: Rob on 17 October, 2017, 10:25:04 PM
Hi Kevin,

I've really enjoyed reading about your integrale restoration in Viva Lancia! & this thread too. You're obviously not fazed by major structural rust that would make others run a mile. I'm in the process of restoring my Delta HF turbo ie which wasn't quite as bad as yours but not far off! Keep up the excellent work  ;).

Cheers, Rob


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:09:14 PM
I'll attempt to update the integrale progress which has been sporadically continuing amongst all the other jobs I get myself roped into, only being an amateur restoration enthusiast means that these cars are a spare time hobby so not the quickest!I have been putting a few articles together for the magazine but I'll do some more in depth pictures to show the extent of corrosion that I've encountered which may help other guys decide that theirs isn't so bad after all!

One of the previous tasks was the front lower cross member once I'd got the sills done.

There wasn't an awful lot of strength left in it after years of remedial repairs to keep the car on the road by former owners, you do what you have to do to keep the anual MoT guy happy but eventually things go too bad.

I searched far and wide to get a new cross member but alas non were to be found.
A decent used one was located from an HF turbo but that turned out to be different, then I found another on the Welsh border, a nice ride over from the East coast near Skeggy!

The old one was pretty much shot though...





Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:14:28 PM
Didn't take much poking around for the bottom to literally fall out!



Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:25:48 PM
The replacement front end had a pretty decent lower member I could use, just the ends needed repairing, the best solution I could find anywhere.


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:31:25 PM
The inner parts weren't too bad, rotten pieces taken out and the rest cleaned up ready for repair sections to be made up.


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:34:41 PM
Repair sections were made from thick plate using card then plywood templates before making out of the thick stuff, much easier too make alterations out of card than thick steel!


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:39:27 PM
The "new" cross member was ready for fitting to the car so now I was sure how much to chop from the car it finally got rid of the rotten section, the dusty section laid on the floor shows how bad it had got!


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:44:06 PM
The ends of the chassis rails were in a state also once the old metal was cut away which meant more repairs before the new member could be fitted


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:49:56 PM
The rot from the chassis ends was cut away up to solid metal then readied for the repair sections, I decided the bets course of action was to attach the member which would allow simple repair pieces to be made exactly to suit.

The ends of the member I'd cap off once on the car



Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:53:29 PM
Fitted on the front and the spaces left ready to be filled in..


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 08:58:21 PM
Sections being let in, again in thick steel as this is a high strength area.


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 09:01:48 PM
This end of the chassis has the bolts for the engine mount so a sturdy repair was needed


Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 09:07:36 PM
Passenger side was much the same apart from the lack of engine mount bolt holes



Title: Re: my new integrale
Post by: Kevinlincs on 07 February, 2018, 09:15:43 PM
At last the front of the car can be supported by the cross member again!

A lot of pictures in one go so I'll do another update if there's interest?

All a bit out of sequence though as this was all a couple of years ago now!


Title: Re: my new integrale
Post by: rogerelias on 07 February, 2018, 10:20:32 PM
 :o you are doing a great job, I would have given up ages ago, in fact I probably wouldn't have started  ;)


Title: Re: my new integrale
Post by: simonandjuliet on 08 February, 2018, 07:14:18 AM
To be able to weld/fabricate like that ........ great to watch !


Title: Re: my new integrale
Post by: tzf60 on 08 February, 2018, 02:22:36 PM
Kevin,
You clearly have the patience (and perseverance) of Job!
It's an absolutely wonderful transformation.
I can't wait to see the front with it's final coat of red....!!!
 
Keep her lit!
Tim F


Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 07:18:37 PM
Thanks for the votes of praise guys, very much appreciated.
I have indeed questioned my sanity many times over this car but the simple fact is it is a car that I coveted for some time, not just integrales' but this very car with it being a local car to me. Eventually I was lucky (?) enough to be able to buy it from the owner, the only owner of it from new!
Plus of course I just don't have the funds to buy a solid one, and all this work is really only costing me my own time....

If you are all keen on more pictures I'll keep posting..

The inner wing had a couple of holes in it which rather than patch up I chopped a 4" wide strip out, as you do  :o


Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 07:22:08 PM
A new section for the inner wing made up then the lower section of the inner face to link up the two sections.


Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 07:37:06 PM
The strut top area had some fairly well established rot in it. I'd searched for another inner wing or strut repair panel but none available. I ended up getting an HF turbo shell that was in a much worse state generally than my car believe it or not, but actually had good strut tops!


Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 07:47:04 PM
Quite a drastic chop and in a really high strength area but if I was to save the shell then drastic repairs were needed. If the chassis number wasn't stamped on the corner I'd have replaced the whole section but I needed to keep the original corner with the correct number on...




Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 07:52:42 PM
I braced the area and then made up a fairly crude alignment tool that would use the passenger side holes and other key points so once in place I could sit the new section where it should be..


Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 07:56:52 PM
Once happy I could replicate the alignment then a batch of brave pills were downed and the potentially shell running moment came where I chopped a lump out. In reality it's just another piece that needed repairing, everything can be made strong again, just making sure things are in the right place is key!


Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 07:57:44 PM
The old section was just too bad to repair..



Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 08:00:58 PM
The section from the HF was cut to suit the hole size, fitting it onto various planes helps gain some strength of repair, more pieces will get added at a later date.



Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 08:09:04 PM
Starting to get it welded in


Title: Re: my new integrale
Post by: Iggy65 on 08 February, 2018, 08:12:05 PM
Wow, that's some serious restoration of a piece of major structure! True dedication Kevin, well done.


Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 08:12:53 PM
Where it all met the A pillar needed some repairs to make good again, the box section piece being removed to gain better access



Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 08:17:28 PM
The little box bit got fitted back in then to pretty much complete the repairs there, for now.

I'll leave it at that for pictures tonight, don't want to bombard you guys with pages of stuff!

There are worse bits to come I promise you  ;)


Title: Re: my new integrale
Post by: Kevinlincs on 08 February, 2018, 08:18:07 PM
Wow, that's some serious restoration of a piece of major structure! True dedication Kevin, well done.

Thanks, it has been a trial!


Title: Re: my new integrale
Post by: DavidLaver on 08 February, 2018, 10:15:01 PM

Love that wide strip let in.  Epic job on the strut top.


Title: Re: my new integrale
Post by: Rob on 09 February, 2018, 11:49:48 AM
Well done Kevin, with the amount of work that you've done on your integrale I reckon you could have your own TV series! Until then keep posting the pictures & text as it's interesting to see it gradually coming together. You definitely saved this car from the scraper & for that you deserve a big pat on the back. It's easy to buy a nice shiny integrale & keep it up together but buying one like yours & putting your heart & soul into it is certainly 'character building'. Keep up the good work fella  ;).


Title: Re: my new integrale
Post by: DavidLaver on 09 February, 2018, 11:52:53 AM

Any pics / brief story of the alfasuds you did?


Title: Re: my new integrale
Post by: Kevinlincs on 09 February, 2018, 08:16:12 PM

Any pics / brief story of the alfasuds you did?

Thanks again guys, it has been a trial as you all allude to, in fact I haven't reached the end of the welding yet as the car ends up taking a back seat all too often.

I've put some pictures of previous cars in the non Lancia section David  ;)


Title: Re: my new integrale
Post by: the.cern on 10 February, 2018, 12:13:56 PM
Brilliant work Keith and I love the reference to the 'brave pills'. Unfortunately they always seem to be needed, and in large doses, when undertaking a Lancia restoration!!!

                                      Andy


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:10:14 PM
The engine bay and surrounding areas had many little bits and pieces that needed fettling, the bottom edge where the suspension arm bolts to was one such place.

From the outside it looked a bit rusty but nothing serious, I had my doubts though as the top edge hadn't been sealed properly so the potential for moisture to get in was there...


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:12:16 PM
Once the spot welds were drilled out and the outer reinforcing panel peeled back I was glad to have been curious enough...


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:14:44 PM
Luckily the rot was fairly localised so a thick repair panel was made up complete with holes for plug welding.


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:16:30 PM
Penetration coming through nicely behind the pedals


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:24:33 PM
The section above where the RHD conversion mounts for the peddle box is had signs of corrosion too so investigation needed again...


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:27:15 PM
You can see that there has been enough corrosion to allow moisture into the car...


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:29:06 PM
Taking it back to the reinforcing bracket for the peddles


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:31:38 PM
loads of welds then another plate over the top for good luck!


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:39:14 PM
A reinforcing bracket was taken from the white donor HF and welded in place to complete the suspension mount point, the wheel arch bottom across to the sill also got boxed in, sorry for the poor quality of the 'phone pictures!


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:45:07 PM
There was another point at the top on that side near where the chassis rail top meets the bulkhead and inner wing/strut area.
This got cut out with my plasma cutter.


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:47:06 PM
Again, thick steel for these strength repairs, not the easiest to bend and shape


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:49:03 PM
With corner bracket back on


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:54:07 PM
Another piece was on the opposite side chassis rail, where the gearbox mount plate goes.
Some surface rust which got chopped out and repaired..


Title: Re: my new integrale
Post by: Kevinlincs on 13 February, 2018, 09:56:29 PM
Usual process, make a repair section and weld in..


Title: Re: my new integrale
Post by: DavidLaver on 14 February, 2018, 11:21:37 AM

Bits like the "chassis rail top meets the bulkhead and inner wing/strut area" are really satisfying the way they disappear.  Got the radius bang on.  Can see that "it might be ok" is NOT as assumption to make from all the places you've "been curious" and peeled back to have a look see.

Are you putting any extra structure in?  (noticed the extra plate on the RHD conversion) I think it was "Thurbs" race car build thread that listed a few mods.


Title: Re: my new integrale
Post by: DavidLaver on 14 February, 2018, 11:34:40 AM
Looked back and nothing definitive...but maybe it would pop out the pictures to someone more familiar with them:

https://www.facebook.com/pg/LanciaDeltaRacing/photos/?tab=albums

http://www.lancia.myzen.co.uk/forum/index.php?topic=9531.0

http://www.jjperformance.co.uk/


Title: Re: my new integrale
Post by: Kevinlincs on 14 February, 2018, 06:53:22 PM
I'll have a look through that thanks David, always happy to follow advice from other builds.
I am planning on making extra strengthening sections for bits like the strut tops, I'll do that once I can get the car on the tilter soon.

A few more interesting bits to come on here yet though.


Title: Re: my new integrale
Post by: frankxhv773t on 14 February, 2018, 09:06:36 PM
This is a picture of what I think Abarth added to the works cars.


Title: Re: my new integrale
Post by: Kevinlincs on 14 February, 2018, 10:03:11 PM
Think I've seen those kits available somewhere, could have been Walkers?
Think it was about £1500 though!
I'll probably have a good look at them then make my own  ;)


Title: Re: my new integrale
Post by: DavidLaver on 14 February, 2018, 11:40:04 PM

Interesting that its more at the front than the back - any of that holding the engine in or all for suspension loads?   

Looking at it the pillars seem obvious places to double up, but only AFTER looking at it.


Title: Re: my new integrale
Post by: frankxhv773t on 15 February, 2018, 07:50:28 PM
I suspect the amount of strengthening at the front is because that hits first on both take off and landing. If the back hits first your rally is probably over anyway!


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:27:45 PM
I'll post a few more pictures again, seeing as it's been a while since I bombarded you all!

The drivers side rear arch had corrosion mainly inside the car!



Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:28:43 PM
A bit of chopping and solid metal was found...


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:32:13 PM
A few plates needed as there was some degree of curvature in several directions plus a strengthening seam for the underside, as it picks up the seat belt mount strength of repair was important.


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:34:11 PM
The bottom outer corner where it meets the sill had some grot to remove..


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:35:20 PM
Starting to gain shape..


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:37:02 PM
The outer lip was deemed unfit so I made a new one, here ready for fitting after shaping to suit the arch and importantly fitting inside the door shut!


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:38:35 PM
Welded in and the edge rolled under by hand with hammer and dolly.


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:41:21 PM
End of sill finally boxed in, holes will be put in for 25mm grommets so I can inject protective wax in at regular intervals!


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:43:26 PM
Some shots now of the rear arches, plus the lack of any inner arches!



Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:45:51 PM
Passenger rear boot floor



Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:47:34 PM
Through the rear light tyre check  ;D


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:49:10 PM
Drivers rear inner arch...


Title: Re: my new integrale
Post by: Kevinlincs on 28 March, 2018, 06:51:28 PM
View from underneath isn't pretty  :'(


Title: Re: my new integrale
Post by: simonandjuliet on 29 March, 2018, 06:27:55 AM
Scary - keep taking the brave-pills ....


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:35:05 PM
Yes, like so many areas on this car it could so easily be enough to make you think it's not worth the effort!

But still I keep going... ;D

As the rear inner arches look likely to be extremely tricky if not downright uncomfortable to repair with the car sat upright and plans to put it on my rollover jig then the repairs to said area will be left until I can get the car upside-down.
Trouble is the jig mounts through the bumper mounting holes and seeing as the outer arches need repairing I need to be able to mount the bumper to get the alignment right.
As you can see in the picture it has at some point had some repair sections grafted onto the outers, they didn't look too bad but I spied the rivets from underneath and the alignment to the door wasn't quite at the right level.


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:39:19 PM
I don't suppose for a moment that repair sections are available anymore so I set to and made my own.



Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:43:07 PM
Once alignment was sorted out using the door and bumper for reference then the old one could be cut away..


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:45:23 PM
Welded into place, still free floating as such so more work needed to the underside to ensure it kept straight with the bumper.


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:47:21 PM
Before that bit could go in though the boot floor had some rot to get rid of...


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:48:14 PM
The little outrigger and central section needed to go too..


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:50:24 PM
Boot floor section made up and welded in, this was made to overlap the original bumper mount points to create double thickness there, then plug welded on the flats and seamed from below and above.


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:51:57 PM
New outrigger folded up and welded in


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:55:22 PM
Rear panel seam I'd already dug out as it looked rusty, wasn't that bad at all once separated but at least I know it'll be OK, new section made up and let in.


Title: Re: my new integrale
Post by: Kevinlincs on 29 March, 2018, 06:58:35 PM
I made up a section to repair the underside piece but without really knowing exactly what I needed it was difficult to say!

Handily not long after this bit was done I happened across an integrale at Cadwell Park so got to have a better idea of what went where!


Title: Re: my new integrale
Post by: DavidLaver on 30 March, 2018, 10:08:58 AM

That rather sums up this project - a hole so big you needed to look at another car to know what it should look like...


Title: Re: my new integrale
Post by: Rob on 03 April, 2018, 09:24:44 PM
Keep up the good work Kevin, you're doing a cracking job  ;). Really impressed with the repair sections you've been fabricating, some of them look very complex!


Title: Re: my new integrale
Post by: Kevinlincs on 06 April, 2018, 09:47:12 PM
Cheers guys, I'll update a few more pictures over the weekend.

Checking out other cars to see what it should look like in a few places was the only option David, fresh air doesn't give away too many clues  ;D


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:24:05 PM
It seems my promise to update things "over the weekend" didn't quite pan out  ::)

So with inspiration from cars like Robs' and more progress finally being done on my own car rather then my lads Imp I thought I'd inflict a few more pictures on you guys.

The passenger side (RHD converted, remember…..) was no better than the drivers with a few gaping holes to fill in...  ::)


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:25:31 PM
Again, the road car easily be viewed through the rear light opening...


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:27:34 PM
View from under the wheel arch isn't any better  :o


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:31:03 PM
Forward part of the inner arch wasn't up to scratch really either so I cut it out, whilst here it makes no sense to leave stuff


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:32:35 PM
New section shaped to suit keeping close profile with the rest of the arch


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:33:53 PM
Inside the car the repairs continued...


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:35:25 PM
Welded up, inner and outer


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:37:53 PM
With the forward section made solid enough and door alignment kept in check the attention moved to the boot floor area where the fuel pipes etc go through


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:42:30 PM
A new repair section first off made up out of cardboard, then in steel


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:49:38 PM
With the repair patch made and aligmnet checked it was time to chop out the remaining rot that would need removing, not pretty!



Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:51:45 PM
The chassis rail got boxed in then the repair section followed


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:53:25 PM
Starting to gain shape


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:56:09 PM
Lower rear section of inner arch


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 07:59:31 PM
Outrigger and central support braced up


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:01:15 PM
Outer skin being removed after careful measurements and templates being made for its' replacement


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:03:35 PM
Outer panel again hand made, rear door fitted to ensure as best alignment as I could, also the bumper used despite there being no side bracket mounting to hang it on!


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:05:31 PM
And inside view, starting to lose sight of the road!


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:07:24 PM
Panel behind the bumper,


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:09:24 PM
Bumper side mounting bracket..


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:12:08 PM
Side of the suspension turret needed chopping out


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:13:39 PM
Welded up..


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:16:25 PM
The fuel vapour catch tank thingy goes here...


Title: Re: my new integrale
Post by: Kevinlincs on 16 July, 2018, 08:18:56 PM
Last job for this area before I could tackle the upper turret was to box in the front part where the sill ends...

A lot to take in for one night, I promise to try some more if there is an appetite for it?


Title: Re: my new integrale
Post by: Rob on 16 July, 2018, 09:03:52 PM
You're making great progress Kev & I enjoy seeing how you tackle each rusty area with increasing confidence  :). Keep the updates coming on here & Viva Lancia  ;).


Title: Re: my new integrale
Post by: SanRemo78 on 16 July, 2018, 09:16:37 PM
A lot to take in for one night, I promise to try some more if there is an appetite for it?

I'm starving! More please!
Guy


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:29:45 PM
With the work to the rear 1/4 to bumper areas (for which I needed to keep mounting the bumper itself) now done I could at last get the car on the tilter frame.
This means bolting a frame front and rear to the car which then mount onto A frames each end which then allow the car to rotate through 360 degrees, full rotation so you can weld at whatever angle you need.
This frame I've used on a few AlfaSuds so thought it could easy enough be adapted to suit the Delta?

Sorry for the poor quality 'phone pictures...


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:31:25 PM
Rear end awaiting lifting onto frame..


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:36:00 PM
Tiltable to any angle...


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:37:11 PM
Roof just clears the floor by a few inches...



Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:40:39 PM
The reason for turning the car upside down was to gain better access to the rear suspension turrets and make the repairs much easier.

This was what was left of the inner rear arch and strut top to fathom out...not pretty!



Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:43:09 PM
Majority of the strut mount was OK, just the side return section needed cutting out. This is also the piece that's inside the car towards the inner C pillar near the seat belt point, mine was the fully floating type!



Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:44:51 PM
A repair piece was made up from the same thickness 2mm steel as the rest of the tower.


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:46:16 PM
As viewed from inside the car...


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:49:07 PM
Joining section for the inner C pillar, again the access to repair was much easier on the tilter frame.


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:50:46 PM
Reunited!


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:53:27 PM
The inner rear arch was another item that I had little idea of what it should look like as there was nothing much to remove!

Simplest option was to start building it up in manageable sections..


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:57:08 PM
The section for under the arch itself was a bit more tricky, it needed to follow the contours of the outer arch closely to be a tight fit to weld but made from strong enough steel to be usefully strong.


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 09:59:09 PM
All welded in, not the prettiest but solid again.


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 10:00:32 PM
At last, no view of the road through the rear light opening!


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 10:03:13 PM
The side of the tower showed signs that it too craved attention....


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 10:04:59 PM
No prettier from under the arch..the grot had spread quite a way up the hollow parts of the reinforcing section


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 10:06:29 PM
No point being shy, out with the lot!


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 10:09:06 PM
In stead of recreating the double skinned scenario where you actively promote corrosion I made a new repair piece out of single skin but as thick as the 2 pices, the ribs took an age to from in them!


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 10:10:44 PM
Strong again


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 10:12:38 PM
The chassis side under the bottom reinforcer wasn't up to much either..


Title: Re: my new integrale
Post by: Kevinlincs on 22 July, 2018, 10:14:23 PM
All boxed in with more of the thick steel



That's it for now.....I'll carry on again soon with the updates


Title: Re: my new integrale
Post by: lancianut666 on 23 July, 2018, 08:30:40 AM
I love your cutting out of the rust no messing!!!
Clarkey


Title: Re: my new integrale
Post by: frankxhv773t on 23 July, 2018, 06:37:59 PM
I'm wondering what you used to create the reinforcing ribs?


Title: Re: my new integrale
Post by: Kevinlincs on 23 July, 2018, 09:00:37 PM
I love your cutting out of the rust no messing!!!
Clarkey

Only way to me mate!
I always preach to anyone that will listen, welding a plate is the same if it's 4" square or 4' square. May as well get rid of the lot whilst the grinder is at hand.
Will say though that it's not as scary to do now as it was at first, you sometimes feel there's no car left!


Title: Re: my new integrale
Post by: Kevinlincs on 23 July, 2018, 09:04:58 PM
I'm wondering what you used to create the reinforcing ribs?
A tool similar to this, called a bead roller or sometimes a Jenny Wheel
Handy tool for rolling the curved wheel arch sections too.


https://www.ebay.co.uk/itm/19-BENCH-SWAGER-ROTARY-METAL-TOOL-JENNY-BEAD-ROLLER-outil-Werkzeug/253769471478?hash=item3b15d6d5f6%3Ag%3A4gsAAOxygPtS37Mw&_sacat=0&_nkw=bead+roller&_from=R40&rt=nc&_trksid=p2380057.m570.l1311.R1.TR6.TRC2.A0.H0.Xbead+roller.TRS0


Title: Re: my new integrale
Post by: frankxhv773t on 24 July, 2018, 11:04:30 AM
That looks like it might be worth investing in. Did you have to press the swages in stages or was it one continuous slow roll?


Title: Re: my new integrale
Post by: Kevinlincs on 24 July, 2018, 06:18:28 PM
That looks like it might be worth investing in. Did you have to press the swages in stages or was it one continuous slow roll?
On thinner more regular stuff like 1mm or even 1.2mm steel you can do it in one pass.
This steel was about 2.5mm thick so it had to be done in a few runs, nearly more than the tool could handle in reality, hence the wobbly lines!



Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:32:20 PM
The drivers side strut tower and inner wheel arch was much the same process as the other side so I won't go through all that again.

One job that I had been putting off for some time was to clean the underside of the years and years of underseal and mess that had gathered there, not a nice job.

The black underseal was scraped off using a heat gun and a wallpaper scraper, best combination I find for that job. Messy and hot, but best.


Once all that was cleaned off then we were down to the factory rubberised stuff that I use a knotted wheel on an angle grinder to take off, this flings it about a bit but cleans it efficiently and also if there are any rust spots under it then it cleans that too, just be careful not to have exposed skin as the little needles off the knotted wheel easily stick in your cheek! A full face mask is a must, not just goggles.




Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:34:50 PM
After a few hours and a bucket full of rubber crumb you end up with a fairly clean surface...


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:37:46 PM
A few extra areas for repair surfaced under all the covering, the spare wheel well had a smallish rust hole so it was cut out to remove all traces then a new plate made up and welded in..


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:41:03 PM
The captive bolts were rusted around the join with the floor so rather than leave them I cut a section of floor out on each one and welded a new plate with captive stud in place.

The rear corners of the chassis rails had been hiding further corrosion so out it went and thick fresh steel in its' place.


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:42:47 PM
A crack was found near the strengthening plate that holds the seat belt buckles and hand-brake lever...


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:46:26 PM
It was found that the drivers seat mounting was where the crack had formed. Handy that it had been found now rather than later when the car was up and running!

With the car tilted on its' side it was very simple to repair rather then be laid underneath it.



Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:48:07 PM
Time for some seam seal.


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:50:10 PM
Loads of welding seam to seal up, very important incase there are any pin holes in the welds


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:51:39 PM
Etch primed


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:54:07 PM
The a real good layer of the stoneguard material which helps prevent stones chipping down to the metal rather than just using paint. The outer sills also got done as a smooth finish isn't necessary when they are covered by plastic sill covers!


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:56:56 PM
A couple of decent layers of brush able enamel went on after the stoneguard had been allowed a week to go off properly.


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 09:58:27 PM
The rear inner arches got particular attention so make sure for a watertight finish, having the car upside down made this task so much easier.


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 10:00:08 PM
Finally the car could get taken off the tilter and back onto axle stands awaiting suspension.


Title: Re: my new integrale
Post by: Kevinlincs on 10 August, 2018, 10:01:05 PM
Small steps but a hurdle had been reached



Title: Re: my new integrale
Post by: DavidLaver on 11 August, 2018, 04:22:58 PM

That's a milestone.  Looking good.


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 09:51:26 PM
Car continues to tick along, has progressed some way since the last update so I'll do an update or two to catch up with the magazine a little..


One of the first jobs to get done once the car was back the right way up was to change the windscreen surround upper scuttle panel.


This one has the usual rotten corners plus the central wiper mount was gone. I'd managed to pick up a really good used panel which initially I was going to take repair sections from but the decision was changed to changing the whole thing, not only to save chopping out and welding in smaller sections but also to get the wipers parking the right side for this UK car, the replacement panel came off a UK HF Turbo that was already being broken and had little left apart from this great panel!




Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 09:57:25 PM
First job was to make a repeatable template that would sit in the windscreen opening, not just take measurements. As I had plenty of angle and box sections knocking about a simple frame was constructed that fitted snugly which would give a 3D gauge for dimensions not only width and depth but in shape/height of the 'screen aperture.


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:01:59 PM
As the replacement panel had been handily removed with more material than I really needed I could make the decision to join it to the bulkhead inside the car behind the dash rather than the windscreen flange itself.
The A pillars I planned to stagger the joins rather than just jut straight through the whole pillar as that's not a very strong way to join it. The outer panel would be cut about half way up, the door section corner kept all original and the inner pillar would be cut a few inches from the bottom.




Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:03:44 PM
Measure, measure then measure again before cutting a big section of car away at this late stage!


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:05:46 PM
Passenger side not too bad, clean up about all that was required..


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:06:28 PM
Drivers side not so, but nothing too bad


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:07:59 PM
Well worth removing the original panel though, far worse underneath than even appeared on top!


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:09:37 PM
Repairs made to the box section underneath then a new top laid on


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:12:49 PM
As you can see from this the "new" panel was in very good shape but even it had some rust around the little drain tubes from the 'screen corners

Note too how much has been remove from the donor panel, always best to use as little as you need


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:15:17 PM
My own opinion on those drain tubes is they create far more problems than they solve, every car I've now done that has had them has had issues around them, be that the AlfaSuds or anything else.
So I cut the rot out, made up new sections and have welded them over.


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:16:50 PM
Using the alignment frame to check things...


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:18:44 PM
And using the body panels to check for bonnet and wing alignment...


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:20:48 PM
Let the welding begin!


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:22:46 PM
Plug welded to the bulkhead and overlapped on the inner A pillar, careful not to leave sharp edges for the sunroof drain tubes!


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:24:39 PM
Repairs to the drivers side bulkhead..


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:26:49 PM
Grinding off takes an age  :(


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:28:31 PM
Worth the effort though, outer pillar joint came out well both sides.


Title: Re: my new integrale
Post by: Kevinlincs on 30 September, 2018, 10:32:09 PM
Last picture for tonight and one of the reasons the integrale has taken me so long, my lads Hillman Imp that I did a similar amount of welding too and painted..we met up with a good friend of mine Keith in his lovely Sud for a drink, never thought a Sud would look so big!!


Title: Re: my new integrale
Post by: Rob on 02 October, 2018, 10:56:02 AM
Great update Kev  ;D. I think you made the right choice by replacing the whole scuttle panel especially as you could finally have the wipers in the correct position. I liked the windscreen jig too, although not pretty it certainly did a good job of lining the scuttle panel up with the rest of the car  ;). Keep up the great work, I'll be looking forward to the next instalment.
Cheers, Rob


Title: Re: my new integrale
Post by: DavidLaver on 02 October, 2018, 11:20:14 AM

That pillar joint really did come out well.  Once again shows why its necessary to take the brave pills, pull a big bit off, poke all the way down to the foundations and build it back again strong.  Pleased to be rid of those drains?



Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:24:28 PM
Agree with all you say guys, worth the effort to get the wipers parking the right side (incidentally on corresponding with John Whalley that is also a change that he did on all his RHD converted cars, an easy way to see if it is one of his he says, no-one else went to the trouble..) plus you just can't leave any area untouched assuming there isn't rust ready to spread.
I'd rather not be doing this again in 5 years so best carry on whilst at it now!
The water drain tubes I'm glad to see the back of for sure!



I'll do a couple of updates now that continue the rust theme but which I haven't sent in to the magazine as I got the feeling people would be getting the wrong idea about how bad it was!


At this stage the car was moved from my friend Jims' place up to my rented unit so I could get it nearer to the painting stage

Full of optimism that the rust was all but gone I got the pair of wings out that I bought a couple of years back.
The passenger one needed a bit of straightening to the arch lip which went OK but the whole wing itself was quite badly twisted, not something I'd noticed until trial fitted to the car with the side skirt. As it also would need welding repairs in the same place (but admitedly not so far reaching) as the original wign I decided to ditch that one and just repair the original as the fit was so much better.

The rot started at the high point of the arch and stretched all the way down, some repairs would need careful planning..


First job was to tackle the large portion that led into the arch extension..



Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:29:13 PM
Quite a bit was cut away to start with, enough for me to a=manage in one repair section without going too far to start with.
The repair section can be seen on the bonnet awaiting fitting..



Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:31:17 PM
Tacked in place to start with.
Note the wing is still bolted to the car to try and prevent welding a plate on with the wing twisted on a stand or something!


Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:39:22 PM
The curve of the wing actually caused more work to shape being part of a bigger section, shaping one way affects others so you have to give it some thought..




Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:41:17 PM
Eventually though it all gets welded and ground back



Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:44:10 PM
Next job was to do the simpler section that continued down towards the side skirt.


Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:44:50 PM
Much more straightforward but still starting off with a flat piece of steel, folding it to create a straight angled section then shaping it to match the curvature of the wing in both directions comes easier with practice....


Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:46:41 PM
All welded in and smoothed off



Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:50:06 PM
Last job on the wing was to cut off the bottom mount...
A new section made up and let in



Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 07:51:45 PM
A lot of effort for a wing but what do you do?
It needs to last...


Title: Re: my new integrale
Post by: DavidLaver on 02 October, 2018, 09:12:38 PM

That long section - how did you bend and shape it?  "Just" a hammer and edge of the bench or got a shrinker/stretcher or something?


Title: Re: my new integrale
Post by: Kevinlincs on 02 October, 2018, 09:58:21 PM
Yes, a shrinker/stretcher.
It's amazing how easy it is to create curves and control/alter them.
With the practice I've had it's become less of a challenge, that piece maybe took 10 minutes to make.
I did complete wheel arches for the front of the Imp, all the way from the front edge to the bottom near the sill, and that had multiple curves at differing sections.


Title: Re: my new integrale
Post by: DavidLaver on 03 October, 2018, 12:46:27 PM

What I love about this thread is proof you don't HAVE to source new-old-stock this and repair-section that.  Flat steel and time, and sometime surprisingly little time, really is enough.   That bit in ten mins is good going. Obviously that's "in the mode", and "setup to do it", and with a lot of practice. Even if someone got it wrong six times its not going to take longer than "half a morning" to make the bit and the scrap might still get used elsewhere.  Then the welding and grinding and proofing etc etc, but you're showing how far gone a car can be and still be saved on a half sensible budget and graft.

...it also show that even if you do have new-old-stock this and repair-section you do need to peel EVERYTHING back to the bottom layer and patch and proof all the layers back to the top again.

I also looked properly at the Alfasud - looks quite orange next to the Imp.  The Imp at that ride height I assume not too many road humps near you.


Title: Re: my new integrale
Post by: lancianut666 on 03 October, 2018, 04:32:42 PM
We want more Imp pictures! I've had 2.. great cars...shame about the heaters though.
Clarkey


Title: Re: my new integrale
Post by: Kevinlincs on 03 October, 2018, 09:30:45 PM
The lack of repair panels shouldn't hinder any job, most stuff can be made up. OK the curved bigger sections will take more time and effort plus most likely be made from more than one piece but practice gains you confidence which makes it easier to tackle the complicated stuff. I'm no expert, still only do these jobs as a hobby but I've studied from the people that do know and picked up tips which I try out, but thanks for all the comments.


This next section didn't make it to the magazine either, I'm sure everyone's seen rusty rear roofs on the Delta before!

It actually didn't look too bad to start with...


Title: Re: my new integrale
Post by: Kevinlincs on 03 October, 2018, 09:34:20 PM
Saying about the panels being tricky sometimes to make is very true, the rear edge curves not only down side to side on the horizontal level but also curves in across the vertical, not straight all the way across, this made making a full width repair section a pain. It did take a few goes to get right, eventually I accepted it was as near as I could get it..this was mid attempt


Title: Re: my new integrale
Post by: Kevinlincs on 03 October, 2018, 09:36:54 PM
A lot of careful welding, you can't rush it or you'll end up with a scene from the North Sea!
The repair section was welded here to the back edge of the roof at the fold rather than further along the roof skin.


Title: Re: my new integrale
Post by: Kevinlincs on 03 October, 2018, 09:39:13 PM
The passenger side section though had rot stretching along the roof skin which had to be removed, came out pretty good considering how easy it is to distort these sections.


Title: Re: my new integrale
Post by: Kevinlincs on 03 October, 2018, 09:42:03 PM
The underside needed some repairs which got spot welded, this section will be getting some protection once the wiring is back in, hopefully to prevent further rust coming back...


Title: Re: my new integrale
Post by: Kevinlincs on 03 October, 2018, 09:43:54 PM
The front roof edge needed slightly less work but still new metal needed to go in...



Title: Re: my new integrale
Post by: DavidLaver on 03 October, 2018, 10:10:24 PM

That's such a labour of love...

Tips to keep the distortion out?   Tacks every 6ins then cool with a bucket and cloth before going again?  Air line?

Simple things: how do you hold it all in line before you start welding? (magnets?)  Did that one go on straight enough or did the repair section move with the heat?


(...and anyone tried this stuff? https://www.ebay.co.uk/p/Heat-Block-Cold-Front-Heat-Stop-Paste/562469449?iid=231543952294&chn=ps)



Title: Re: my new integrale
Post by: Kevinlincs on 03 October, 2018, 10:40:48 PM
Keeping distortion out is an impossible task David, it's just trying to minimise it. If you notice on the pictures where I repaired the front wing it's built up slowly from a series of tacks. I have loads of different clamps, regular mole grips and clamps with flat faces, some can again be seen in the front wing pictures. Tacks are spaced out then gradually filled in, taking your time is key. I do sometimes use an airline if it's a bigger patch, I've seen that heat soak paste used before and it does seem to work. An example of how patient you need to be is when I welded the repair arches to Robs' Imp the welding itself took over an hour...that's just the welding, not the grinding or prep...


When I asked a tutor about the best way to avoid distortion when say repairing a door bottom his reply was he wouldn't ever repair a door bottom! Said he'd rather make a new door skin...This was at a course I paid for myself where they restore Jag XK150's to a ridiculously high standard...makes my work look like the local Blacksmith has been at it!

This wing was a huge amount of work to repair, but then replacement ones could be bought....at £500 a side! My lad reckoned there wasn't the budget. The arch lip I made from a length, folded shaped then the top return side bead rolled in. This arch took over an hour to weld in...


Title: Re: my new integrale
Post by: simonandjuliet on 04 October, 2018, 07:49:01 AM
I take a deep breath every time I look at this post .....


Title: Re: my new integrale
Post by: DavidLaver on 04 October, 2018, 11:24:02 AM

That son of yours better be VERY pleased :)

With the roof was there access on the inside for clamps?   I suppose could always make some spacer blocks or something.  I guess its case by case matching the problem against a lifetime's collection of clamps.

Enjoy / recommend the course?  Sorry if there's already been an answer on one of the previous pages...

Found two I'd heard of and a third new to me:

http://www.contouracademy.com
http://www.mphmotorpanels.com
http://www.storik.co.uk/




Title: Re: my new integrale
Post by: Kevinlincs on 04 October, 2018, 06:11:42 PM
I used to have to take a deep breath every time before starting but I've done a few different cars now so you get used to what you can and can't do, it really all is just a variation of the same...

This though, to continue the Imp posts if I may for a moment, was one of the trickier parts to make despite being one of the smallest!

I've seen Imps' before that have had this part smoothed over, either from new metal or just filled over, we wanted to keep the original look.

It's at the C pillar where it joins to the rear quarter panel, there should be 3 grooves in it, that proved to be the tricky bit!


Title: Re: my new integrale
Post by: Kevinlincs on 04 October, 2018, 06:15:12 PM
I tried to make the 3 grooves using my bead roller but they were too close to each other.

The solution was a bit more agricultural!

I got a block of hardwood, cut a groove in it then laid the new panel over it using a 4" bolster chisel to make the grooves


Title: Re: my new integrale
Post by: Kevinlincs on 04 October, 2018, 06:16:30 PM
Then the panel got shaped to replicate the pillar...


Title: Re: my new integrale
Post by: Kevinlincs on 04 October, 2018, 06:18:21 PM
The pillar cut off to suit...note some previous repairs made to the inside, now that was a mess!


Title: Re: my new integrale
Post by: Kevinlincs on 04 October, 2018, 06:19:25 PM
The panel finished...


Title: Re: my new integrale
Post by: Kevinlincs on 04 October, 2018, 06:22:33 PM
And fitted.



Title: Re: my new integrale
Post by: Kevinlincs on 04 October, 2018, 06:29:43 PM
Same area just after being painted..



Title: Re: my new integrale
Post by: Kevinlincs on 04 October, 2018, 06:33:04 PM

That son of yours better be VERY pleased :)

With the roof was there access on the inside for clamps?   I suppose could always make some spacer blocks or something.  I guess its case by case matching the problem against a lifetime's collection of clamps.

Enjoy / recommend the course?  Sorry if there's already been an answer on one of the previous pages...

Found two I'd heard of and a third new to me:

http://www.contouracademy.com
http://www.mphmotorpanels.com
http://www.storik.co.uk/



He is pleased, which helps!

Must admit it's nice to see him enjoying something positive in these days...


The course I went on David was the top one on that list, contour academy. Couldn't recommend then highly enough.


Enough on the Imp for now...until I post some more integrale pics. 




Title: Re: my new integrale
Post by: Kevinlincs on 22 October, 2018, 05:52:25 PM
A little update to get things back on the Lancia track...

The passenger front door I'd sort of dismissed as being OK, a bit scabby but basically sound.

Should have known better really!

Once the seal had been removed from the underside it was clear the welder would be needed some more. Most of the seal retaining strip came away with the seal  ;D


Title: Re: my new integrale
Post by: Kevinlincs on 22 October, 2018, 05:56:19 PM
The door bottom itself was in no condition worthy of staying so it got cut out and a new section made up.


Title: Re: my new integrale
Post by: Kevinlincs on 22 October, 2018, 05:59:24 PM
This section was welded into place which would then allow the outer skin to be attached plus somewhere to weld the seal retaining strip to.


Title: Re: my new integrale
Post by: Kevinlincs on 22 October, 2018, 06:01:28 PM
Seal retaining strip made up and plug welded in



Title: Re: my new integrale
Post by: Kevinlincs on 22 October, 2018, 06:05:12 PM
Door skin repaired with folded and sealed underside lip


Title: Re: my new integrale
Post by: Kevinlincs on 22 October, 2018, 06:09:17 PM
Outer side  sorted


Title: Re: my new integrale
Post by: Kevinlincs on 22 October, 2018, 06:12:10 PM
Thankfully the rear door was much more but did have a collection of small dents from all the times it's been moved from here to there and stored not too safely. Knocked out as much as possible but some couldn't be got to.
Both doors ready to be primed


Title: Re: my new integrale
Post by: Kevinlincs on 22 October, 2018, 06:14:40 PM
Shell getting closer to being straight.


Title: Re: my new integrale
Post by: Kevinlincs on 27 October, 2018, 08:38:12 PM
Found this picture of when the integrale arrived home, at the time I'd got this nice series 1 AlfaSud Ti that I'd done a reasonable amount of work on.
It unfortunately had to make way for the Delta..


Title: Re: my new integrale
Post by: frankxhv773t on 27 October, 2018, 10:59:44 PM
AS my wife says of me, you seem to have an unquenchable thirst for new and more exotic ways to experience rust!


Title: Re: my new integrale
Post by: Kevinlincs on 28 October, 2018, 05:05:34 PM
AS my wife says of me, you seem to have an unquenchable thirst for new and more exotic ways to experience rust!



 :D Very true Frank  ;D


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 09:41:13 PM
The car did eventually get primed, etch primer first then a few coats of this thick 2K filler primer I like to use as it goes off fairly quickly and gives plenty of depth to be flatted off to level any minor deviations or scratches.


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 09:42:25 PM
Under bonnet got the same treatment, more awkward areas to rub down!



Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 09:44:25 PM
Important once all the primer is flatted off to spend time taking the old masking paper off and doing it again, the dust that is on this paper would blow off when you paint and make a right mess!


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 09:47:21 PM
As painted, is more red than the 'phone camera shows...


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 09:48:14 PM
Engine bay looking much smarter


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 09:49:35 PM
The repairs to the rear roof have come out well.


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 09:50:52 PM
Likewise the front windscreen scuttle top change has blended in very nicely.



Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 09:53:54 PM
The arch extensions and repairs to door openings look better than they did.


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:01:37 PM
The car then got moved out so the remaining panels could be looked at.
Hatchback had the familiar rust in the corners, no big surprise!


Outer corner repaired with a new lip


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:04:33 PM
Inside needed a few repairs too...


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:07:40 PM
Drivers door bottom had the usual issue under the seal retaining strip...


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:09:07 PM
Hole cut out, new patch made up ready to go in


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:12:03 PM
Strong again.


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:13:59 PM
New seal retaining strip made up and welded in.


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:15:14 PM
The bonnet was in great shape, or so I thought....


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:16:42 PM
With the hinge off and the scab attacked with a knotted wheel a nice hole soon formed...


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:18:02 PM
Skin cut off, reinforcer cleaned, new patch waiting to go in.


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:19:29 PM
Bolts fitted into the hinge mount points to make sure it doesn't move, don't want to be covering up the bolt holes!


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:20:22 PM
And smoothed off



Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:24:45 PM
So I could paint the front wings without laying them down which I didn't want to do so I could paint around the edges etc I made up these simple stands, just some spare angle attached to a brake drum for a base then the little arms at the top are adjustable to suit differing mounting holes so I can use them again in the future.


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:26:35 PM
Wing mounts like this...


Title: Re: my new integrale
Post by: Kevinlincs on 13 November, 2018, 10:27:19 PM
Which allows lovely access for painting


Title: Re: my new integrale
Post by: DavidLaver on 14 November, 2018, 11:48:57 AM


My favourite is the roof photo.  It really has come out well...   I expect you were as nervous as you were excited to see it in colour and reflected and to see how well you'd done.  Judgement day!!!


Title: Re: my new integrale
Post by: frankxhv773t on 14 November, 2018, 12:10:53 PM
The wing stand looks as though it would be unstable but I can't imagine you making anything like that. How far can it tilt before it overbalances?


Title: Re: my new integrale
Post by: Kevinlincs on 14 November, 2018, 10:35:00 PM


My favourite is the roof photo.  It really has come out well...   I expect you were as nervous as you were excited to see it in colour and reflected and to see how well you'd done.  Judgement day!!!

Only a small step in reality David but a huge psychological hurdle overcome, it really does feel like you're on the home straight when the paint goes on....relity is though there's stilla  huge amount to do!

Repairs have come out well yes, roof amongst them  ;)


Title: Re: my new integrale
Post by: Kevinlincs on 14 November, 2018, 10:37:03 PM
The wing stand looks as though it would be unstable but I can't imagine you making anything like that. How far can it tilt before it overbalances?

It is a lot more stable then it looks Frank, amazingly so really. The brake disc sits flat to the floor and is quite a large diameter one with a lot of heavy mass, takes quite a bit to try and knock it over.
Only issue I found though is my use of angle steel for the stem, when you spray the wing the frame tends to oscillate!  ;D


Title: Re: my new integrale
Post by: Rob on 15 November, 2018, 11:40:43 PM
I have to hand it to you Kev the shell was looking spot on after you'd finished all the repairs & now that you've laid down a few coats of Monza Rosso it looks factory fresh! You must be chuffed  ;D.


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:10:56 PM
Yep, chuffed Rob that's for sure! Sorry for the delay in replying but I have now almost caught up with where I'm at with the car, but I'll elaborate a bit more on here from the magazine articles, make a break from the Christmas talk!

The remaining panels got painted red, a while back now it seems but was really only in October I'd guess..

Hatchback I needed to paint the inside as well as outside so hanging it form the roof seemed the best solution.


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:12:01 PM
So the inside could get painted without any masking lines, along the top inside and out too.


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:15:55 PM
Bonnet got painted but as I only had to do so much of the underside it got perched on a workmate so I could do it all at the same time.


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:17:19 PM
The vents that were in them I'd assumed to be plastic but are actually an alloy, so they were rubbed down and painted after much cleaning of moss and debris!



Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:19:15 PM
This passenger wing was the one I had to do a bit of welding to, came out pretty well I think  8)


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:21:09 PM
Frames I'd made up allowed the underside to be painted too.


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:23:42 PM
The door painting frames also allow the door shuts and underside to be painted too, again it means no masking lines.



Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:26:05 PM
A few remaining metal parts and the end was in sight.
I managed to stumble across a new old stock rear hatch hinge which was great, a shame I couldn't find two though. But that did give me two semi worn out hinges to make one good one from, which was succesful using pins and bushes to make good so all the play from the old hinges is gone.


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:27:53 PM
Rear hatch corners repairs came out well...


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:29:52 PM
The door frames then needed to be satin black so that was next job whilst the weather was still OK



Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:30:51 PM
Along with the outer weather strips



Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:42:27 PM
I then remembered that the 1/4 light/window runners would need painting to match so the search started to find them!
Found the rears fairly easily but spent a good hour or more searching for the fronts. Checking my pictures seemed the solution to see when they were last on the car....which was when I spotted the fronts don't have any!! FOOL!!!!  ::) ;D

I did however have 3 good drivers ones but only one passenger, which had a rotten bottom few inches plus the lower mounting missing.
Solution was to use the good section from a drivers side and weld it onto the passenger one, as luck would have it I managed to make the repairs under the window line so they are inside the door but really it went well. Smoothed out and mounting points affixed and checked in a door for alignment.


Gutter trims also got the satin black treatment so that everything will match along the side.




Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:43:56 PM
Long sections gripped from underneath then clamped in a workmate so nothing touching to get a clean paint finish.


Title: Re: my new integrale
Post by: Kevinlincs on 24 December, 2018, 04:45:13 PM
The little mesh grilles that fit in the front bumper completed the list of black bits...


Title: Re: my new integrale
Post by: DavidLaver on 26 December, 2018, 09:08:22 PM

How long were you looking before you realised they didn't exist...

That wing did look GOOD.  Really well done.  Getting close now!


Title: Re: my new integrale
Post by: Kevinlincs on 26 December, 2018, 11:00:15 PM

How long were you looking before you realised they didn't exist...

That wing did look GOOD.  Really well done.  Getting close now!

The front door window guides? Far too long David  ;D

I actually searched through my loft where some parts remain, plus in all areas of my unit before resorting to pictures to see if they were on the car still when it went to Jims for me to start the welding….was only then that I noticed the windows were in place and were full windows!! Numpty! Too many cars taken apart since then, that's my excuse!


Title: Re: my new integrale
Post by: Rob on 14 January, 2019, 08:35:42 PM
Only the wheels left to do! What condition is the interior in? I hope it doesn't need a retrim as the material in the centre of the seats is VERY expensive  ::).


Title: Re: my new integrale
Post by: Kevinlincs on 14 January, 2019, 08:44:02 PM
Only the wheels left to do! What condition is the interior in? I hope it doesn't need a retrim as the material in the centre of the seats is VERY expensive  ::).

 ;D bit more than that mate but progress at last

Interior is in great condition given its age. The old fella I got it off always used though seat covers you used to see, changed them every few years, original seat material has hardly seen daylight so is in great condition.

Only thing interior wise I'm still to sort out is getting a better steering wheel or getting mine retrimmed plus the rooflining needs sorting.
May have a go at the roof myself...
Looks like a decent sized piece of material stretched out and glued should do the job, same for the sunroof...then again I am crap at it!


Title: Re: my new integrale
Post by: frankxhv773t on 15 January, 2019, 11:55:26 AM
It might be worth posting some pictures of the roof lining when you get to that stage to show what the problems are and see what ideas people have. I would suggest "stretching" the material indicates the wrong mind set as it may tend to shrink and pull away.


Title: Re: my new integrale
Post by: Kevinlincs on 15 January, 2019, 07:07:48 PM
Good idea Frank, I'm up at the car tomorrow so I'll dig it out and take some snaps.


Title: Re: my new integrale
Post by: Rob on 16 January, 2019, 07:33:59 PM
I had the roof lining on my Delta done by a local trimmers who made a nice job of it. You could do it yourself fairly easily - as long as you're careful but lining the sunroof panel is a bit more involved & looks like you'd have to be quite handy with a sewing machine.


Title: Re: my new integrale
Post by: Kevinlincs on 16 January, 2019, 11:06:35 PM
Yes the main section looks fairly straightforward Rob doesn't it, but agree the sunroof panel will be the tricky bit, not least because I can't remember how it all came apart! Good job of took some pictures...


This is the roof panel, hardboard with screwed and stapled side panels.





Title: Re: my new integrale
Post by: Kevinlincs on 16 January, 2019, 11:07:52 PM
Underside, should be fairly simple to fit new material?

 


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:28:51 PM
With the car painted late on late year it got a ride across the yard in the sunshine


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:40:00 PM
With the car pushed into the bigger workshop and the freshly painted panels laid on trestles it didn't take long for me to worry about knocking them off so the decision was made, the safest place for them was on the car!


For fitting them to the car by myself without damaging the paint I had to think about the best way, so came up with a method that worked very well.

First off fit the door latch mechanism to the door and door shut.

Then an extra long stud was screwed into the top hinge mnount.

This allowed the door to be lifted onto it's latch whilst sliding the top hinge over the stud. Once the door was latched it was simple to put the 3 correct hinge bolts in before removing the long stud and tightening up all 4 bolts.




Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:41:54 PM
With the lock mechanism then removed the door could be aligned on the hinges then the latch refitted and adjusted for a good shut.



Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:43:23 PM
Pleased enough with the shut lines from my arch repairs I made


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:47:14 PM
Windows too were deemed safer fitted to the doors!
Freshly painted (and repaired, this side) window runner with weather strip. Most of the bits were faded so all got painted with the same satin black


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:51:33 PM
Front doors went on using the same method, gutter trims were faded to grey so satin black went on those too, B pillar plastic trims looked out of place too so they got painted with plenty of plasticisor to stop them cracking and peeling.


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:54:24 PM
Front windscreen went in without issue


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:55:33 PM
Sits nice with the A pillar repairs where it got joined half way up...


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:57:10 PM
With the dash all sorted I decided best to fit in before putting the passenger front door on so access was a bit easier..


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 09:59:27 PM
Vents fitted into bonnet, again mainly so they have somewhere safe to be stored!

Some of these pictures make the car look pink, I promise it hasn't faded already! The camera on my mobile doesn't seem to like red...


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 10:02:13 PM
Hatch got fitted back to the car, then the refurbished number plate surround and rear window went on.


Title: Re: my new integrale
Post by: Kevinlincs on 24 February, 2019, 10:03:54 PM
Car was finally starting to look like a car again!



Title: Re: my new integrale
Post by: Kevinlincs on 28 February, 2019, 09:22:24 PM
The bumpers looked too bad to fit now, and the front one had been lacquered which was now peeling so best solution was just to paint them.


Once rubbed down it was clear that both the red and black bits would need doing, no point in half measures.







Title: Re: my new integrale
Post by: Kevinlincs on 28 February, 2019, 09:25:39 PM
Satin black bits to be done first, masked off both bumpers together for ease of painting. You can see where the black had faded through, fine line masking tape for a crisp edge.



Title: Re: my new integrale
Post by: Kevinlincs on 28 February, 2019, 09:29:21 PM
Left for a whiule to cure as I don't have an oven for it..


Title: Re: my new integrale
Post by: Kevinlincs on 28 February, 2019, 09:31:39 PM
A few days later I could mask out the central black section to do the red. This all good some plasticisor added so it remains flexible enough. Adhesion promotors went onto the bare plastic first to prevent any flaking...


Title: Re: my new integrale
Post by: Kevinlincs on 28 February, 2019, 09:33:53 PM
The bumpers all done, complete with pink looking paint from the phone camera! Honest, it's the correct red shade it should be...


Title: Re: my new integrale
Post by: Iggy65 on 28 February, 2019, 09:43:16 PM
Fabulous work, Kev. What a achievement!


Title: Re: my new integrale
Post by: stanley sweet on 01 March, 2019, 12:24:23 AM
The amount of work you've put in and the quality is fantastic. When you say you've rubbed down things like the bumpers there must be a lot of dust floating around the place. How did you get the bumper absolutely clean and dust free again for painting?


Title: Re: my new integrale
Post by: Kevinlincs on 01 March, 2019, 07:47:24 PM
Cheers guys! Yes, it's been a big effort but I'm getting there....it'll be out and about this year sometime..

For the painting and dust scenario the trick is to prepare well. If you can do the sanding outside that saves some cleaning for floors etc. I'm lucky that I have a half decent extractor in the little unit that takes away a lot of the airborne dust.

Once the piece is ready for priming then an airline gets the majority of the dust off, after that it's a case of wiping down with panel wipe which is amazing how much more dust that pulls out even when you think the piece is fairly clean. After that then tack rags are used which again pulls yet more from the surface, these are little cloths with a tacky surface (surprisingly!) so all the fine bits left over plus the marks left by the panel wipe get lifted off.
It's VITAL on these stages that gloves are worn for these processes, latex or vinyl not cotton, as the oils and dirt from your hands will contaminate the piece to be painted and possibly cause some reaction when the primer goes on.


All takes time but saves having to do it again!


Title: Re: my new integrale
Post by: Rob on 01 March, 2019, 08:59:34 PM
Fairplay Kev it's really coming together now  ;D. You must be putting some serious hours in to be moving it along this quickly & to such an excellent standard!  ;)


Title: Re: my new integrale
Post by: Kevinlincs on 01 March, 2019, 09:46:08 PM
Fairplay Kev it's really coming together now  ;D. You must be putting some serious hours in to be moving it along this quickly & to such an excellent standard!  ;)

You know how much effort it takes Rob, but equally it takes a huge amount of commitment if not stubbornness to see the project through. You've had just as much to do, in fact on looking back through your car it's amazing how similar the needed repairs look!


The car is a fair bit on from this though at the moment, at this point I'm hoping it'll be on the road around May this year...


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:19:14 PM
When I got the car painted it was time to now fit the rear suspension that I was going to use, rather than the spare bits it was sat on whilst being painted.

Happily the rear jacking points are now strong enough to hold the car!

With it up on axle stands the old suspension got dropped off and the new, powder coated items await fitment.


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:23:20 PM
The original rear subframe I'd had blasted with a view of repairing it a year or two ago but it was pretty badly holed, could have been repaired but would have been a lot of work. I'd since then found a much better one on eBay fairly local to me so I bought that and had it blasted and powder coated.
The rear diff was fitted to it and readied for fitting to the car.


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:24:31 PM
The long studs you may have spotted poking out of the boot floor I'd made from a couple of spare bolts then welded some threaded bar to them to make the extra long studs...


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:27:24 PM
The reason for making them was that again, working on my own I have to try and plan things so jacking up the rear subframe with diff attached and trying to stop it falling off whilst trying to line up the mounting bolts, that didn't fill me with hope of a happy outcome!

Solution was to fit the studs into the mounting holes in the car then the assembly could be very simply, and safely jacked up to the car floor.


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:29:58 PM
With it jacked up against the underside of the car it was easy to remove a stud and fit the correct bolt with no fear of it falling or being out of line, worked a treat!

I'd actually done this before with these studs but on an Alfa 155 rear axle after I'd done some welding to it, homemade tools used twice!


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:33:20 PM
Rear hubs I'd already cleaned and painted after fitting new bearings, driveshafts got new rubber boots.


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:36:21 PM
Suspension arms also readily painted with new bushes where needed, new rear load compensator was sourced as old one was totally seized, I have also added the diff guard which is also said to stiffen the inner suspension mount points on the diff subframe, also powder coated. 


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:39:21 PM
The brackets for the rear anti-roll bar on, new powerflex bushes not out of vanity but because they were available...


Title: Re: my new integrale
Post by: Kevinlincs on 03 March, 2019, 08:46:58 PM
The brake compensator mechanism I may actually have fitted wrongly, seems different way up now I've looked at old pictures so may have to alter that..

The front tracking adjuster arms I have welded a large nut onto so I can adjust it much easier, you can see it here..

The pivot bushes for the compensator arm I struggled to find, at the time...since then of course I've found some..didn't fancy using the Brass bushes on offer
So I measured the holes for what I needed then found a company selling nylon bushes in the size to suit. 
All fitted well so hopefully will do another 30 years




Title: Re: my new integrale
Post by: DavidLaver on 04 March, 2019, 11:39:16 PM

Some cars get displayed on a turntable.  Yours I'd have at a show on a powered rotisserie.


Title: Re: my new integrale
Post by: CasualSaint on 05 March, 2019, 12:14:26 AM
Fantastic work and having done it myself i know the shear amount of it you will have had to put in!

Bushes are becoming increasingly difficult to locate, i think Beilstein in Germany have some sets, but they're expensive along with a few other European suppliers.
Go careful though your not on the rear jacking points, you've got the axle stands under the production line locators ( there should be 2 more on the front floorpans ), they are only there to stop the vehicles bumping into each other on the conveyor belt as you load the weight back into the shell you could damage them! I always have to tell MOT inspectors not to jack on them.


Title: Re: my new integrale
Post by: Kevinlincs on 05 March, 2019, 07:32:37 PM
Cheers guys, it's been a load of work that's for sure!

The parts where the axle stands are under on the rear were rotten so I built them up with strong steel to use as jacking points, the original ones half way down the sills I didn't redo. So I've now got 4 good strong jacking/axle stand points at each corner near the sill end. You're right about the original location points being flimsy so I did away with them.



Don't know about it being on a rotisserie in the future, this car will get used as intended so it won't stay this clean and tidy for long  ;D


Title: Re: my new integrale
Post by: simonandjuliet on 05 March, 2019, 08:08:49 PM
Really enjoying this thread!!


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:16:11 PM
A good while ago the engine got fitted to my engine stand in my shed at home awaiting the time to be taken apart, I didn't want to have it done then sat waiting for the car.
It ran OK but as was now around 30 years old it was due a refresh at least!


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:27:38 PM
The water rail along the back of the engine had rotted out so a good used one went on the list to be found, managed to get a rust free one which I got powder coated so hopefully it'll last another 30 years!


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:29:48 PM
Generally everything looked tired and ready for new seals etc


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:35:57 PM
Head came off without too many dramas, I took it off to have a quick look in the bores to see what the wear was like (very minimal thankfully) but also so I could slide it under my workbench where it would sit until nearer the time when I needed it, which would mean 18 months or so later!


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:48:25 PM
Skip forward to the end of last year and with the car being near done the engine became priority.
The sump is kind of odd, has a large aluminium main section with a steel bottom plate, looks like it's been a bit leaky..


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:50:33 PM
Crank all looked good


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:51:55 PM
Bores were in great shape, hardly a mark on them and no lip you could feel


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:55:27 PM
The water jacket at the rear had quite a build up of sediment behind the blanking plate, not ideal!


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 10:59:49 PM
The crank was checked out and declared fit so once cleaned down and any potentially dubious core plugs removed it was time to hone the bores


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 11:02:12 PM
The bores were checked using new piston rings for end gap which were within tolerance so with the pistons cleaned they all went back in


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 11:04:12 PM
I decided against painting the block as I like the original look with it's stencilling plus it's effort that is pretty much hidden anyway, and as I've said before it's not a show car merely going to be a good one I don't mind using.


Title: Re: my new integrale
Post by: Kevinlincs on 31 March, 2019, 11:08:51 PM
Crankshaft went back in with new big end shells, main bearing shells and thrust washers.
Plastigauge was used to check for bearing clearance so everything was checked to be within spec.

 


Title: Re: my new integrale
Post by: Kevinlincs on 07 April, 2019, 09:24:51 PM
The cylinder head got stripped down and skimmed, valves lapped in and all built back up.


Title: Re: my new integrale
Post by: Kevinlincs on 07 April, 2019, 09:27:11 PM
With the engine block moved up to the unit as I wouldn't be able to move the engine complete from my shed at home, it went on the engine stand for the head to be refitted..


Title: Re: my new integrale
Post by: Kevinlincs on 07 April, 2019, 09:28:49 PM
New water pump, both timing belt and balance belt with new bearings and tensioners.


Title: Re: my new integrale
Post by: Kevinlincs on 07 April, 2019, 09:33:23 PM
Refurbished alternator, power steering pump, sump etc back on


Title: Re: my new integrale
Post by: Kevinlincs on 07 April, 2019, 09:37:21 PM
After a lot of thought I decided to go for a refurbishment of the standard turbo rather than a hybrid upgrade, mainly as it will be a useable car rather than looking for big power. Plus I don't plan on modifying a load of stuff to make use of extra boost!
The turbo and manifold I left off until the engine goes back in


Title: Re: my new integrale
Post by: Kevinlincs on 07 April, 2019, 09:41:12 PM
Back down off the engine stand so the flywheel and new clutch could go on


Title: Re: my new integrale
Post by: Kevinlincs on 07 April, 2019, 09:42:08 PM
Gearbox back on


Title: Re: my new integrale
Post by: Kevinlincs on 07 April, 2019, 09:43:27 PM
...and transfer 'box


Title: Re: my new integrale
Post by: lancianut666 on 08 April, 2019, 10:22:41 AM
Excellent blog this one... can't wait for it to start up  ;D