Lancia Motor Club

Model Technical and Interest => Fulvia => Topic started by: nthomas1 on 06 September, 2017, 09:10:38 PM



Title: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 06 September, 2017, 09:10:38 PM
Travel and family commitments have kept me from spending much time on my S2 Coupe rebuild this year.  Over the last couple of weeks I've got back to the job of removing paint and old filler from the rear end of the car.  I also revisited the bonnet.  I'd cleaned and de-rusted it last year and finished it with a coat of black Hammerite.  I didn't take it back to bare metal except where there was rust, and I didn't remove all of the thick underseal-like coating on the spars.  Having worked on-and-off for two years now I've learned a lot and I've set my standards higher, so I completely stripped the bonnet back to bare metal last weekend, and have now etch-primed it - see pictures below.  I've bought timber and heavy duty castors so my next job is to build the dolly that will support the front end of the car when I remove the rolling subframe.  My welder (for the back end of the car - valance and rear panel replacement) - has let me down, so I now have to search again for somebody local (Ormskirk, west Lancashire) who doesn't charge Aston/Ferrari prices! 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 06 September, 2017, 09:14:16 PM

Looks lovely just in that primer.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 06 September, 2017, 09:16:17 PM
Lovely ! I know how long these things take to get them looking as good as that

Bon Courage


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: stanley sweet on 07 September, 2017, 10:00:04 AM
Looks very good. I take it that you can bring parts like this back to the house and can use use mains-powered tools to speed things up?


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 07 September, 2017, 10:39:04 AM
Looks very good. I take it that you can bring parts like this back to the house and can use use mains-powered tools to speed things up?

I'm afraid not Stanley.  We live on the first floor of a Victorian villa and it's not practical to take parts up there.  Even if I could, I think it would lead rapidly to divorce proceedings!  So I continue to work in the garage with Ryobi grinders, scraper and drill, and take the five 18v rechargeable batteries up to the apartment every evening for charging.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: peteracs on 08 September, 2017, 01:41:04 PM
Could you use a small generator to save on using battery items if you have no electricity on site?

Peter


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 08 September, 2017, 11:12:46 PM
Could you use a small generator to save on using battery items if you have no electricity on site?

Peter


I did consider that Peter but I'm limited on storage space and was worried about the noise impact on the other people that live in apartments in the building.  I had a generator when I lived in the USA and it was quite noisy and I assumed the same would be true of ones over here.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: andyps on 10 September, 2017, 05:59:17 PM
Some of the Honda generators are very compact and quiet, not cheap to buy however.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 05 January, 2018, 10:27:12 PM
The car is now at the welding shop for rear-end restoration, new rear panel. new rear valance, new driver-side floor pan, new outer sills, and new front subframe mounting boxes.  So far the focus has been on rebuilding the tops of the rear wings - which were full of holes and badly rusted.   As the back end of the car is in much worse condition than the front I think the car must have been parked for a long time with the back end open to the elements.

I'm very impressed with the work that my welder is doing.  He understands the car, and is carefully and rigorously rebuilding, continually checking shut lines for the boot lid, and ensuring left and right sides are symmetrical.  There had been some previous rework to the right side that resulted in an excessive gap on that side which is now being rectified.  The shape of the rear end of the Fulvia presents quite a challenge to the welder.   It was also good today to see the new rear panel and valance held in position with vice grips. I'm looking forward to seeing them welded in place. Below are some before and in-progress pictures.  Onwards and upwards! 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 08 January, 2018, 09:14:05 PM

Inspiring stuff.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 11 January, 2018, 03:05:59 PM
A few more pictures of new metal being welded in.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: Jaydub on 12 January, 2018, 03:29:55 PM
Looking good Norm, your body man knows his stuff. I need to start my restoration this year hopefully.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: SanRemo78 on 12 January, 2018, 06:39:56 PM
He's a magician! He did some very major surgery on my Stratos replica a few years ago replacing a couple of chassis rails in the engine bay that carried the top mounts for the rear suspension after moisture got in through a gap I hadn't spotted. Oops.
He's also build a Stratos replica (that he regrets selling, it's how our paths crossed 30 years ago), had an Evo 2 new back in the day and has another pampered one now. His work on rally cars includes work for RED in Widnes on works cars plus many privateer cars and recently quite a lot of Porsche 911's. They rot something awful but values justify restoration.
If you remember the Peugeot 306 Maxi it was Geoff that made ALL the wings for the entire production run after Peugeot themselves failed to work out how to press them! Also in his portfolio is some pretty radical work grafting Ford Sierra Cosworth running gear into Mk1/2 Escorts and Capris plus Peugeot 405 Mi16 running gear into 205's and 309s.

https://www.pinterest.co.uk/pin/575194183642757391/

And he's got one of those as well, sold it, regretted it and managed to buy it back...

Highly recommended for his skills!

Guy


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 16 January, 2018, 09:11:08 PM
Yes Guy, he certainly knows what he's doing.  He showed me the Stratos door handles that he made. Even my wife (shown holding the handle here) was impressed.  Very impressive!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 16 January, 2018, 09:15:22 PM
Some more progress.  The rear corners of the boot floor have been cut away to allow access to the wing area underneath, where corrosion needs to be sorted out..  The right side floor section is quite ropey so a new section has been fabricated and is ready to be welded in place.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: stanley sweet on 17 January, 2018, 09:37:49 AM
I'm always in awe of this type of craftmanship. I mean how many curves are there just on those rear wing edges alone? I find these kind of people tend to work alone but imagine being young and being taught by someone like this.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancianut666 on 17 January, 2018, 04:28:58 PM
If only we could all weld like your man....


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 24 January, 2018, 04:55:30 PM
Some more progress.  Top edges of the rear wings now complete and primed.  Both lower rear corners reconstructed - with much new metal. A large portion of the rear of the rear wheel arches also rebuilt with new metal.  Just a little more fettling and then the rear panel and valance will be fitted.  Some before and after shots below.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 24 January, 2018, 05:21:20 PM
Looking great !

What is the rear cross member like - they get tatty behind the rear spring mounts and so easy to do when you are at this stage


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 24 January, 2018, 05:45:23 PM
Looking great !

What is the rear cross member like - they get tatty behind the rear spring mounts and so easy to do when you are at this stage

Not sure of the terminology Simon.  Are you referring to the box section that runs across the car under the boot floor, between the fuel tank opening and the rear of the car?  If so, that is in remarkably sound condition.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 26 January, 2018, 04:32:18 PM
I'm pleased with the way the boot floor is looking.  I had de-rusted and then primed/painted the interior except for the corners which were in poor condition. The following three pictures show the right rear corner: 1) as it went to the welder; 2) the template I made to help in fabricating a new section; 3) the new section made by my welder and fitted into place.  Onwards and upwards!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 29 January, 2018, 06:49:38 PM
Big milestone today.  The new rear panel and lower valance have been welded into place - following much corrective surgery to the weld flanges on the wings, and the edges of the wings themselves.  Just some tidying up of the welds left to do before starting on the sills. Very encouraging to have reached this point, and great to have found such a capable welder!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: Jaydub on 29 January, 2018, 08:40:43 PM
Looking good Norm, he certainly knows his craft. I like the temporary clips holding the panels together prior to welding.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: stanley sweet on 30 January, 2018, 10:54:17 AM
This is going to be a very nice Fulvia. Makes a big difference when you find someone you can trust.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 30 January, 2018, 11:29:17 AM

Is that rear panel plug welded or a seam along the edge?


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 30 January, 2018, 02:47:14 PM

Is that rear panel plug welded or a seam along the edge?

They are plug welds David. Done with a mig welder and ground off flush. I figured that would keep me closest to the original spot welds.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 30 January, 2018, 05:52:41 PM
The plug welds look to work well

Slight aside - is the new rear panel "dished" at all , top to bottom and L to R , or is it flat ?


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 30 January, 2018, 06:30:58 PM
The plug welds look to work well

Slight aside - is the new rear panel "dished" at all , top to bottom and L to R , or is it flat ?


It is dished Simon, in both directions, just like the original. 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 09 March, 2018, 06:46:14 PM
The first metal was cut away from the driver-side outer sill today.  There's plenty of evidence of poor prior repair work, but it's good to see that the inner sills are quite sound.  The outer sills will be replaced, as will a large section of the driver-side floorpan and the rear subframe mounting box.  The right door has been put back on in order to get the shut lines correct when the new sill and quarter panels are fitted. It's good to be working on the sills, having spent so much time on the rear end of the car!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancialulu on 09 March, 2018, 09:55:54 PM
Perceived wisdom is to insert a central steel membrane twixt inner and outer sills. Adds a bit of weight but adds a lot of strength.....


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 11 March, 2018, 10:51:42 AM
Here are the new sills, quarter panels and mounting boxes ready to be fitted.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 11 March, 2018, 07:13:09 PM
Nice .... looking forward to seeing them go in


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 12 March, 2018, 11:42:11 PM

Any thoughts on jacking points? 

My car has only one out of four in place and it is in poor condition. The others are missing as a result of some rather botched work on the weld flanges by a former owner.  Are they better omitted, with jacking taking place elsewhere, or should they be fitted?  As I'm having new outer sills fitted I'm wondering whether to have 4 new jacking points fabricated.  If that makes sense can anybody provide decent photographs and dimensions of them?  They are just visible on one picture in TAV but there's no illustration of them.   Here's a picture of one on an HF taken at last year's AGM.   


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancialulu on 13 March, 2018, 08:05:19 AM
Norman I would make/remake the jacking points and the sill detail so that the car is "correct". I think I have the template for the jacking points and can email you a scan. BTW are you going to add the central membrane between the inner and outer sill? Tim


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: chriswgawne on 13 March, 2018, 09:17:31 AM
Norman,
Your are doing a fine job properly on the rest of the car so please renew the jacking points (even if you don't use them).
These days I start from the premise that Lancia's engineers ( as opposed maybe to their accountants) always knew what they were doing so why try to change what was almost certainly pretty good in the first place.
And when the old car market re-adjusts downwards ( its the next thing to happen in the cycle) the cars that will hold their value best will be those which exhibit originality whether it be engine, interior or body.
I say this having gone down many expensive blind alleys in my motoring life doing exactly the opposite of what I preach these days.
Chris   


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 13 March, 2018, 09:48:54 AM
Do you still have the square bits with holes underneath as well ? They are on the HF but not, I think on S1 cars. They are useful when there is a car lift available for tyre fitting etc


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: the.cern on 13 March, 2018, 07:11:47 PM
Hello Norman, I absolutely agree with Chris and Tim .... 'do it as it was' is a great maxim.
I have never worked on a Fulvia, but, from what Tim has said, assume there is an inner sill, an outer sill and a central diaphragm. If that is the case and the central diaphragm has suffered which is invariably the case, in my opinion you MUST repair it. This is a hugely important part of the vehicle's structural integrity. If you the whole assembly is not sound then using the new jacking point may well cause, at the least, local buckling of the sill. Ship and ha'porth o tar comes to mind!!

I have been enjoying your restoration saga, don't spoil it now!! Good luck!

                                                                              Andy


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 13 March, 2018, 09:56:38 PM

Tim, Chris, Simon, Andy - thanks for the advice on the jacking points.  I will ensure that they are fitted and that originality is maintained.

Tim - thanks for the offer of the template.  Iíve sent you a pm.

Simon - yes, all four of the square locator brackets with holes in are still in place.  The first picture below shows left front, which is where the one decent jacking point is located.  The second picture shows right front, which is on a section of floor pan which is being replaced, so Iíll be careful to keep the bracket for reuse.

Andy - the S2 was factory fitted with a central membrane between inner and outer sill only at either end. It was not continued for the full length of the outer sill - so was not present for the central portion of the car below the doors.  Some people, during rebuilds, have fitted a full length membrane as Tim suggests.  I can see the value of that for strengthening cars for rallying or racing but am not sure of the added value for a road car.  I plan to talk to my welder about it when Iím next back in Lancashire.

Thanks again to you all for the advice and interest.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 22 March, 2018, 07:33:09 PM

Metal is being cut away to allow the new outer sills to be fitted.  There's evidence of a poor repair to the inner sill on the right rear corner of the car, so that is being rectified.  Work is proceeding slowly as my welder gets asked to do a lot of "urgent" work for motor sport teams.  That suits me as I'm not in that much of a hurry to finish, especially as I'm away in Spain such a lot, and it gives me time to work on the refurbishment of the twelve boxes of parts that have been removed from the car! Tomorrow I'm off to the Classic Car Restoration show at the NEC so have gathered a stack of hardware samples to look for while there.  There were quite a few hardware suppliers at the show last year with a lot on sale.

Last week I noticed that the flare on the right rear wheel arch was not as pronounced as that on the other three arches.  Further examination revealed a prior repair, using a lot of lead filler.  I decide to replace the wheel arch on that corner in order to get all the flares to match up.  I ordered a new one from David Ashworth ten days ago and picked it up today and dropped it with the welder who was impressed with the quality of the part - see picture below. 

I'm hoping to see a lot of progress on the sills over the next week.  On Monday I'll be helping to lift the body off the front subframe to provide access to the subframe mounting boxes. Will keep you posted. 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 27 March, 2018, 03:12:59 PM
This morning the first new subframe mounting box was installed - on the left side of the car.  The second picture shows the jig that was welded up to ensure correct positioning of the new box. We kept the subframe under the car with the body hoisted up about 3 inches while the old box was being cut out.  That enabled us to lower the body back onto the subframe and connect the mount for final alignment prior to welding. A new inner sill section was then welded in place.  Next we're going to install the right hand mounting box before then fitting the outer sills on both sides and do some floor patching.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 29 March, 2018, 04:22:20 PM
Almost ready to fit the left-side outer sill.  It was something of a horror story when we removed the old outer sill and wing sections.  The rusty bottom edges of the wings and sill had been beaten in and new metal welded over the top, with loads of lead filler all over the place.  Some sections were half an inch thick - so I'm looking forward to my new lightweight car! 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancialulu on 29 March, 2018, 04:48:40 PM
cant recommend strongly enough of putting in a central membrane while all is open. huge increase in rigidity....


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 01 April, 2018, 08:51:04 PM
If squeamish please look away now.  Here's some of the metal and filler cut away from my Fulvia's sills and wings last week.  The rusty lower portions of the wing sections between the door and wheel arches had been bashed in and overlaid with new metal and lead filler.  Same with the sills, with a combination of lead and polyester filler. You can see the double layers of metal in the sill picture.  That bottom piece in the first picture measures about 20 by 30 centimetres but weighs a couple of kilos!  My car will be a lot lighter when I'm finished..... superleggera Fulvia.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 02 April, 2018, 01:01:52 PM
First sill strengthener fitted this morning.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 02 April, 2018, 03:54:25 PM
Did you make your own inner sill/strengthener or buy it in ?

Tempted to do the same when I get to doing the HF


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 02 April, 2018, 07:01:59 PM
Did you make your own inner sill/strengthener or buy it in ?

Tempted to do the same when I get to doing the HF

Simon - my welder fabricated it to his own design.  He does a lot of motorsport work so the lightening/strengthening holes were a reflex action for him!  Most of the applications I've seen in the blogsphere have been just flat plates.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancialulu on 03 April, 2018, 08:03:40 AM
First sill strengthener fitted this morning.
Nice!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 03 April, 2018, 07:11:02 PM
Three more pictures of the sill strengtheners: (1) the holes being cut with a plasma cutter, (2) forming the flares around the holes, (c) the final insert ready for fitment.   


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 03 April, 2018, 08:07:13 PM
I like that !

Dog has a plasma cutter and I have a press, so should be possible here in rural France as well .....


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 03 April, 2018, 10:14:39 PM

A couple of times I've come across people with plasma cutters they don't use, a 1mm disk or an air saw being weapons of choice.  Cutting holes that neat is a great example of what a plasma does well... 

Was wondering how big a starrett hole saw went - five inches is the answer...  I expect "if it was me" I'd be trying to get a jigsaw to turn tight enough.

Looking at that press I wonder if it would punch those holes. Found tools at sensible prices for two inches.  That's got to be close?  For a 2in saw £10, £40 for the press tool.  The really big saw is £30.  I wonder how many jig saw blades I'd get through...

Turns out a tool NOT to use is a zip saw:

https://www.amazon.co.uk/RotoZip-XB-MC1-Metal-Cutting-XBIT/dp/B000CEQEZ4/ref=sr_1_9?s=industrial&ie=UTF8&qid=1522793157&sr=1-9&keywords=rotozip+saw


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: SanRemo78 on 04 April, 2018, 08:00:01 AM
Before Geoff got his plasma cutter he used to punch holes with this sort of kit - inexpensive if you're using them all the time and only doing one size, easy to use.
https://www.ebay.co.uk/itm/BGS-Screw-Hole-Punch-32-mm-For-Stainless-Steel-Sinks-Taps-Etc-3902/272251063721?epid=2255403975&hash=item3f636d8da9:g:7toAAOSwbPxXQdzG
I've never seen him using the press to form the edges though it is the easiest way. Whenever I've wanted to countersink a hole in steel or ally I've used a socket on one size, a suitably sized ball bearing. And a hammer. It works but isn't as precise as what Geoff achieves.
Guy


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 04 April, 2018, 10:33:43 AM
Ah...so THAT'S the tool for the job...

You got me looking - and I found larger.

https://www.ebay.co.uk/itm/Exact-30515-63-5mm-M63-Screw-Hole-Punch/152940124581?epid=574846079&hash=item239bf119a5:g:JPMAAOSwOhVZtbe8

"Facom" is the other brand I saw, but quite a bit more expensive and still with 63mm as the maximum.  For "money no object" they do a hydraulic driver.

"Q Max" go to 75mm.

At the budget end Frosts have a set, and also sell the flair tools:

https://www.frost.co.uk/set-of-4-knockout-punch-set-circular-punches.html

https://www.frost.co.uk/hole-flares.html

RS have a wide range. 

"Punch/flare" yeilds three part sets like this:

https://www.ebay.co.uk/itm/Allstar-Performance-11076-Punch-Flare-Tool-2-5-8-Diameter-Hole-Steel-in-Black/232685120558?epid=1437060428&hash=item362d1d2c2e:g:4g4AAOSwYRhamhF2


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 04 April, 2018, 08:58:01 PM
Just saw this on Ebay.  My wife thinks it is very appropriate!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: D5177_55A on 05 April, 2018, 05:09:10 PM
Blimey, with all the Fulviaís off the road, that guy must be a millionaire!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 07 April, 2018, 08:49:22 PM

Having browsed a few days ago the internet now throws similar back at me.  From their web page I like this supplier.  The "about" reads well and the opening times has "If you are looking to spend an obscene amount of money we may even open up on a Saturday morning or evening for a private viewing!"

https://www.stakesys.co.uk/hole-punches-hole-saws

Then there's the look-a-likey for a whole set and hydraulic puttler for the price of one punch...how do they do it...?

https://www.ebay.co.uk/itm/Hydraulic-Round-Hole-Punch-Kits-Metalworking-Hand-Tool-W-6-Dies-22-to-60mm/182710936112?epid=2209810059&hash=item2a8a6ba230:g:5wYAAOSwQwBZi~Z2

I still think the "if it was me" would be a hole saw, a hammer, and a bit of pipe, but interesting to see what's out there and how its done properly.  The stakesys write up on the flares was interesting - if you like that sort of thing :)   "Aircraft flares and automotive flares Ė whatís the difference?"

https://www.stakesys.co.uk/stakesy-s-sheet-metal-hole-flares


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 07 April, 2018, 09:08:12 PM
Left side almost finished.  Just some fettling to the rear wheel arch.  So that's a new subframe mounting box, half inner sill, two floor patches, sill strengthener, outer sill, and quarter wing sections all fitted, as well as patching to the inner wheel arches. Take a look at the thickness of the lead filler in the first picture....... that necessitated removing more of the wing than was originally thought necessary.

Now to the right side!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: SanRemo78 on 07 April, 2018, 09:27:04 PM
Then there's the look-a-likey for a whole set and hydraulic puttler for the price of one punch...how do they do it...?

https://www.ebay.co.uk/itm/Hydraulic-Round-Hole-Punch-Kits-Metalworking-Hand-Tool-W-6-Dies-22-to-60mm/182710936112?epid=2209810059&hash=item2a8a6ba230:g:5wYAAOSwQwBZi~Z2


Cheap tools from China. I'm not saying the quality is bad but you may have to wait a while for them to arrive and will have problems with warranty claims... As with anything on eBay, check out the sellers feedback rating, use a credit card through PayPal so you're covered for non delivery and don't order if you're at all suspicious or need the goods quick. Also check out the item using the same description, there are sellers out there using multiple names that you can spot by their standard feedback comments, especially on negative feedbacks.
Guy


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: frankxhv773t on 08 April, 2018, 06:22:31 PM
There might be enough lead to weigh in at the local scrappy and pay for the restoration. ;D


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 13 April, 2018, 05:02:11 PM
My welding guy also builds and sells high-end racing simulators, so I got to drive the Col de Turini in a Fulvia while I was there today.  My car looked on enviously (or perhaps dreading the day when I get behind the wheel of it!)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancialulu on 13 April, 2018, 07:04:40 PM
My welding guy also builds and sells high-end racing simulators, so I got to drive the Col de Turini in a Fulvia while I was there today.  My car looked on enviously (or perhaps dreading the day when I get behind the wheel of it!)
I have driven CdT in my white HF with Fulvia friends on the 50th Anniversario rally its worth a go as we went up in semi darkness due to various problems. Stayed the night at the top then went down the other side in the morning sounding glorious on the multiple Fulvia overruns!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 13 April, 2018, 11:03:56 PM
My welding guy also builds and sells high-end racing simulators, so I got to drive the Col de Turini in a Fulvia while I was there today.  My car looked on enviously (or perhaps dreading the day when I get behind the wheel of it!)
I have driven CdT in my white HF with Fulvia friends on the 50th Anniversario rally its worth a go as we went up in semi darkness due to various problems. Stayed the night at the top then went down the other side in the morning sounding glorious on the multiple Fulvia overruns!
It was glorious and never to be forgotten, not sure which was more exciting going up in the total darkness in my case, or batting down the other side popping and banging on the overrun in the daylight😆
Brian
8227 8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: SanRemo78 on 14 April, 2018, 01:22:26 PM
My welding guy also builds and sells high-end racing simulators, so I got to drive the Col de Turini in a Fulvia while I was there today.  My car looked on enviously (or perhaps dreading the day when I get behind the wheel of it!)

Did you try it with the Virtual Reality goggles Norm? I see Geoff in the background fixing another alloy wheel - probably another German cheese one..


I spotted this on eBay

https://www.ebay.co.uk/itm/LANCIA-FULVIA-COUPE-BREAKING-SERIES-2-LISTING-FOR-A-SET-OF-WHEEL-NUTS/152949496138?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D2%26asc%3D49131%26meid%3Dc61f2a318c3e47aeb6b0ff4494e6c279%26pid%3D100005%26rk%3D3%26rkt%3D6%26sd%3D232732693756%26itm%3D152949496138&_trksid=p2047675.c100005.m1851

Might be worth asking what state the seat hinge chrome is in?

Guy


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 15 April, 2018, 09:16:34 PM
No Guy - I didn't try it with the VR goggles, maybe next time.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 15 April, 2018, 09:24:54 PM

I am struggling to determine the shape of the trailing edges of the doors.  Mine are badly corroded, with metal missing.  The first picture below shows the right hand door.  Alongside I've put a sketch where I've filled in with shading what I think the correct outline should be. The second picture shows the left door.  Does anybody have any pictures by any chance of door tops without trim that I could use a guide?   I'm particularly concerned to get the top edge of the door jamb (if that is the right terminology) correct.  The front and back surfaces seem more obvious.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: frankxhv773t on 16 April, 2018, 07:52:54 PM
I don't know if these help at all. They are alloy doors but may be similar.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 16 April, 2018, 08:54:03 PM
Thanks Frank.  I would assume that the top edge profile is the same on alloy and steel doors as the trim is interchangeable.  If these are doors in your possession, rather than reference photos from your files, would it be possible for you to take a couple of close-up pictures of the trailing edges - similar views to those I included in my post?


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 17 April, 2018, 07:01:45 AM
If not, I can send some pictures later in the week when we get back from Spain


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: frankxhv773t on 17 April, 2018, 05:43:11 PM
Sorry Norman, they are just part of my hoard of pictures culled from the internet on the basis that they may be of use to someone some day.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 17 April, 2018, 10:00:51 PM
OK Frank - i suspected the pictures might be from your files.  I too keep a large number of reference images!

Simon - that would be great if you could provide some images.  There's no hurry as I'm off to Spain tomorrow for 6 weeks so work on my rebuild is suspended.  I've spent the last few days refurbishing parts from the 12 boxes that contain most of my Fulvia - less body, subframe  and engine.  I'm finding the work quite enjoyable - not tedious as I'd expected.  Thanks for your tip about using phosphoric acid as rust remover.  It's extremely effective.  I have a row of 6 jars and a couple of trays with parts soaking in readiness for wire brushing and final fettling before painting.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 25 April, 2018, 09:00:47 PM
The last job I was doing before heading for Spain was tidying up the engine bay and rear side of the front valance.  A lot of wire brushing and sanding/grinding, then residual rust treatment, priming and painting.  Here's some shots of progress on the inside of the front valance that I'm quite pleased with.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: stanley sweet on 26 April, 2018, 08:52:31 AM
That's good work with the engine in situ. Looks like knuckle grazing work. Suffrage looks good too. That should have read subframe. I'm beginning to think my phone is an Enigma machine.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 02 May, 2018, 07:13:24 PM
As promised, pictures of the door edge - let me know if you want more or better quality .....

Great job with the valance - especially with the engine in place, difficult to do !


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 03 May, 2018, 08:50:01 PM
Great - thanks Simon. Thatís exactly what I was looking for!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: SanRemo78 on 10 May, 2018, 12:51:24 PM
Seat hinges - still looking for any decent ones Norman?

https://www.ebay.co.uk/itm/Pair-seat-guide-USED-Lancia-Fulvia-Coupe/173311052911?hash=item285a24cc6f:g:ngQAAOSwwbdWINFe

One day I'll find some cheap ones!

Guy


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancialulu on 10 May, 2018, 01:06:01 PM
single seat fulvia!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 10 May, 2018, 06:10:13 PM
Seat hinges - still looking for any decent ones Norman?

https://www.ebay.co.uk/itm/Pair-seat-guide-USED-Lancia-Fulvia-Coupe/173311052911?hash=item285a24cc6f:g:ngQAAOSwwbdWINFe

One day I'll find some cheap ones!

Guy


Tricky decisions at every point Guy!
I'm reluctant to splash out this sort of money for a pair when it's actually only half of one pair that is badly pitted.  Will continue to ponder this as I continue work on the body.  Dismantling and getting the one arm chromed may still be best option.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 10 May, 2018, 06:15:08 PM
Like Simon with his HF, Iíve been tidying up the engine bay on my car.  I've been fortunate that my welder has been happy for me to work on my car while in his workshop.  I imagine that's rare but we are both Lancia and motor racing enthusiasts so spend a lot of time sharing stories.  When I get back from Spain in a monthís time Iíll continue with this engine bay tidying.  Iíve been getting rid of all rust then painting with smooth white Hammerite Direct-to-Rust paint to catch any residual rust that Iíve missed.  The colour is not that far off Bianco Saratoga but my intention is to later prime and paint over the Hammerite with body colour.

The first picture below shows an area that Iíve worked on - rear horizontal surface plus part of the rear of the dashboard/bulkhead.  To make it easier to work on the rest of the horizontal surfaces I will remove the chassis plates - assuming that it will be easy to re-rivet them back on. I bought a riveter but (like most of the tools I've bought) have never used one before so will practice first!

Iíd also like to remove the windscreen wipers and motor to improve access.   Are there any hints/tips for doing this?  I read somewhere that when the rubber-insulated mounts in the engine bay are removed (bolted through to footwell) the wiper mechanism can be withdrawn without dismantling the linkages.  That is of course having first unfastened the bases to which the wiper arms are attached.  Should these bases simply pull free from above after the nuts are removed - shown in second picture?

As always, any hints and tips will be gratefully received.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: davidwheeler on 10 May, 2018, 08:18:33 PM
They do indeed but then it can be a fearful struggle to extract them.  You may well find it easier to undo the connecting link - it should be quite easy to unclip.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 10 May, 2018, 09:08:08 PM
I have recently removed the wiper mechanism and taken it to pieces, so will take some photos over the weekend. It was a pain to remove and I am wondering how best to put it back now that I have painted under the bonnet.

I may try and rebuild it in situ ....... or maybe not !



Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 11 May, 2018, 07:25:32 AM

Simon - need "an apprentice" with small hands and slim arms...? 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 16 May, 2018, 05:07:39 PM
Iím just looking ahead to when I re-fit the interior trim to my car later this year year.  I have a question regarding the chrome-finish strips near the bottom of each door card.  They are part reference number 49 in TAV.  Firstly, does anybody know how to remove them?  I donít want to risk damaging them but there are no fittings shown in TAV, and there are no fastenings visible on the rear of the door card so it looks like they may be attached to the vinyl rather than to the card behind it.  Secondly, has anybody ever had them re-chromed?  The strip on one side of my car is peeling badly - see picture below - exposing the pinkish coloured (plastic?) sub structure.  On the other door the chrome finish is missing completely.  The re-trimmed door cards that I have bought do not have this chromed strip, and looking at reference pictures in my library it seems like many people omit them when re-trimming.  Just wondering whatís the best approach.    


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 17 May, 2018, 07:32:33 PM
David - just spotted this one !

Too late on this occasion but there is always something to do .... so keep checking Ryanair !

Re wiper mechanism, I have refitted mine and will update the thread with pictures, but I did put it back bit at a time without damaging the new paint.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 27 May, 2018, 11:41:45 AM
My welder has made more progress on the car.  He is now (in my absence) working on the right side.  A section of the front floorpan which was badly corroded has been cut away and a new panel, sourced from David Ashworth, has been welded in place.  A new subframe mount has been fitted - shown in the last picture with a reference plate still tagged in place to ensure correct positioning.  That will now be removed and the inner sill built up before fitting the sill strengthening plate and outer sill.

Simon - thanks for the information on windscreen wiper removal and fitment.

All - any thoughts on door card trim? See my question and photographs above.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: Scott on 28 May, 2018, 06:45:32 AM
Re. door cards:
Those chrome strips do indeed seem to have been glued in situ.
If it is a small area that needs patching then you could consider some chrome foil. Search for something like 'chrome detailing foil tape' online. Using a scalpel to cut out either side of the offending area to create a rectangle and then by putting in a replacement rectangle you should be able to affect a good, and near invisible, repair (assuming the tape has the same shininess of course!).

Re. windscreen wipers:
Are everyone's wipers as slow as mine?! I can't believe this is by design but it's how it's always been! I would be interested to hear if the lethargy is general or if I need to exchange/uprate my motor etc. I usually use rain-x if venturing out and the weather is looking iffy but I don't really like this stuff as it leaves a slightly opaque film on the glass so would rather do something about the wipers if I can!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 28 May, 2018, 08:25:37 AM
Just a thought but when I worked for Vauxhall many years ago starting in the early 1960, I seem to remember the chrome strips having clenching teeth that attached them only to the back of the material, there was then a layer of padding between this and the board, the material was then electrically welded to the board, turned over and the edges of the material stapled to the back of the board.
Brian 8)
8227


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: eog on 28 May, 2018, 02:58:59 PM
Re your lower door card chrome trim, just looking at a Lotus Elan (1960/70) front bumper.
The insert bumper to body may do the trick.
Not certain if I can post link but here goes
 https://paulmattysportscars.co.uk/product/elan-front-bumper-trim/


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 29 May, 2018, 07:22:12 AM
Thanks for the responses regarding the door card trim:

Scott - Iíve bought some chrome wrap and will have a go at covering them.  I wonít try patching but rather will cover the entire strip, then judge whether they look good enough to be used or whether I should just omit the strips altogether.

Brian - I was thinking along the same lines about the fastening method.  I might try removing the vinyl cover from one of my old door cards to see whatís visible at the back.

Maurice - thanks for the suggestion. Iíll take a look.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: frankxhv773t on 29 May, 2018, 05:55:12 PM
The Elan part looks like an aluminium extrusion to me so would not be what is needed. Covering in chrome foil sounds the best approach but I would be tempted to strip all the old foil off before recovering. It is rather unforgiving of blemishes in the base material.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 01 June, 2018, 06:21:40 PM
Thanks for the advice Frank - will take that on board.

Work has continued on the right side of my car.  The old sill has been cut away exposing the considerable rust underneath.  The new driver floor-pan is now in place as is the subframe mounting box, and a new section of metal has been welded in place to replace the section of the floor under the rear portion of the inner sill.  A strengthening plate, same as that installed on the left side of the car, has been welded in place and the new outer sill has been fitted.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: frankxhv773t on 01 June, 2018, 06:24:59 PM
On a small and very pedantic note, your car is being worked on by your "weldor" while you are away. He is using a "welder". Even spell check doesn't recognise "weldor" though.



Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 01 June, 2018, 06:31:27 PM
I mentioned in a previous post that I was concerned that the right rear driver-side wheel arch flare looked incorrect, and that I had bought a new wheel arch (from David Ashworth) to replace it.  Cutting away the old wheel arch revealed about 12mm of lead filler topped by about 7mm of plastic filler - see pictures below. That has all been cut away and the new wheel arch fitted.  The other 3 arches all seem ok.  I'm getting close to final paint prep now.  The only remaining welding tasks are sorting out the rear edges of the doors, and replacing the jacking points.  I'm pleased with progress!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 01 June, 2018, 06:42:05 PM
On a small and very pedantic note, your car is being worked on by your "weldor" while you are away. He is using a "welder". Even spell check doesn't recognise "weldor" though.

Interesting Frank.  I've never seen the word "weldor".  Wikipedia says: "A welder or lit operator is a tradesperson who specializes in fusing materials together. The term welder refers to the operator, the machine is referred to as the welding power supply".




Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: frankxhv773t on 01 June, 2018, 06:55:02 PM
"Weldor" seems to have fallen out of use but I always remember an admonishment in an old technical book, weldor as in operator. I'll get back in my little box now.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 02 June, 2018, 01:04:10 AM
Norman,
She should be about 5mph faster with that lot removed!
 Brian
8227  8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 03 June, 2018, 06:49:45 PM
Norman,
She should be about 5mph faster with that lot removed!
 Brian
8227  8)

And more economical Brian.  As somebody said earlier: Fulvia Superleggera!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: eog on 13 June, 2018, 09:47:37 PM
Sorry to go backwards to door card trim but have just found this
https://www.carbuildersolutions.com/uk/self-adhesive-trims
as I was looking for new trim for lower gear lever centre console trim
 https://www.carbuildersolutions.com/uk/brushed-stainless-effect-plastic-u-edge-trim-12mm-x-5mm-per-metre.
Will let you get on with your work now!
Maurice


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 14 June, 2018, 06:47:01 AM
Sorry to go backwards to door card trim but have just found this
https://www.carbuildersolutions.com/uk/self-adhesive-trims
as I was looking for new trim for lower gear lever centre console trim
 https://www.carbuildersolutions.com/uk/brushed-stainless-effect-plastic-u-edge-trim-12mm-x-5mm-per-metre.
Will let you get on with your work now!
Maurice
Thanks Maurice,
Very interesting.
Brian
8227  8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 14 June, 2018, 06:21:46 PM
Thanks for your response on the door cards Maurice - there are some nice looking trims on that website but none that would match the factory fit item. I have pretty much decided to move forward without the chrome trims.  I tried removing the vinyl cover from the backing board on one of my old door cards to see how the trims were attached but everything seemed to be well glued inside and I don't really want to sacrifice a decent door card in what might prove a hopeless quest!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 14 June, 2018, 06:34:06 PM
Welding work is now almost complete - just a couple of jobs to finish off tomorrow and I'll hopefully then be heading for paint.  A painter on the same industrial development has looked over the car and I'm waiting for a quote from him.  He comes strongly recommended by my Integrale-owning welder who has used his services a number of times.  Jobs completed this week included some small patching to corroded spots on the doors, windscreen surround and lower edge of front valance.  The corroded rear ends of the door tops have been made good - see pictures below.  Finally, four new jacking points have been fabricated from heavy gauge metal strip and have been welded in place behind the new sill flanges.  The fourth picture below shows the outline shape after plasma-cutting and ready for cut-off.   While the welder has been weaving his magic I've continued with the refurbishment of the engine bay.  The driver-side is shown below, with chassis plates temporarily removed.  I should be able to bring the passenger side up to the same level tomorrow.    


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 16 June, 2018, 06:01:22 PM
Final welding completed this morning: flange under front valance straightened and patched, rear weld flange trimmed, and some other fettling.  Now ready for paint preparation and paint.  Waiting (with baited breath) for quote from paint shop!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 16 June, 2018, 06:27:27 PM
Exciting !

Hope the paint quote doesn't spoil your weekend .....


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: jmspear on 17 June, 2018, 08:56:55 PM
Off topic for Lancia, my HF 1600 doesn't need painting, but I will be getting my alfasud sprint painted when I have finished all my welding (a lot of welding as its an alfasud) so am really interested in what your quote looks like (for budgeting purposes) I would really appreciate it if you let me know how much as albeit a different car, the level of work will be very similar. You can pm if you prefer. Many thanks John


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 17 June, 2018, 09:54:52 PM
I've pm'd you John.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: SanRemo78 on 19 June, 2018, 09:22:20 PM
Another seat option for those hinges Norm?
https://www.ebay.co.uk/itm/LANCIA-FULVIA-COUPE-SEATS/273309028611?hash=item3fa27cd103:g:TCoAAOSwWw1a8bke
Guy


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 19 June, 2018, 09:39:45 PM
Thanks Guy - I'll take a look.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 19 June, 2018, 09:42:37 PM
I started cleaning up the window runners and quarter lights today.  Iíve removed the old quarter light seals as I have new ones on order.  I damaged the original ones while drilling out the three bolts that secured the bottom edge of the quarter light frames to the top of the doors.  The bolts had rusted solid both sides and I had to drill down through the small openings in the lower edge of the seals - quite a tricky thing to do and with inevitable damage.  The seals are a bit ropey in other areas so it will be good to fit new ones.   Iíve also ordered replacements for all of the u-channel  seals and scraper seals.

The two rear window glass runners are in poor condition at their bottom ends.  Rust is so bad that the bracket of one has come adrift, and it is not possible on either runner to discern what the actual profile of the end of the runner should be (square, or angled like the other end), and I canít tell how long the runners should be overall. I will make up a couple of short matching u-shaped sections and have them welded in place once I know the dimensions.  If anybody can help with a photograph that shows the profile, and can provide the overall length (see my picture below) Iíd be very grateful.

The other problem I encountered is that one of the long forward runners has been welded at some stage, and shows very poor workmanship with globs of weld.  The build-up is such that the correct channel seal will not fit.  A previous owner had replaced the top half of the length of seal with a non-original much shallower seal that was a very poor fit.  Iíll see how much of the build-up I can grind off while still retaining enough strength.  Iím guessing a replacement part would be hard to find.

Itís good to be working on the refurbishment of my boxes of parts now that welding on the body and closures is complete!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 20 June, 2018, 10:18:55 AM

Am enjoying the archaeology.

Grinding the blobby weld - to my mind that's not something to fret over.  Either you'll be able to grind enough away for a seal to fit, or it falls apart and needs welding again.  Perhaps that job includes cutting a bit out and letting some new metal in.   Perhaps even if able to grind enough away I'd give it a good wiggle to be sure its still strong.

Are you a "keep everything possible" person or looking to "source better bits"?

As an aside here's a recent example of conservation.  Not sure if they bottled the air out the tyres to re-use but I bet they thought about it.

http://www.julianparkerltd.uk/the-1928-fabric-bodied-austin-7/

http://www.julianparkerltd.uk

https://www.facebook.com/JulianParkerLimited/


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 01 July, 2018, 09:11:24 PM
Some impressive work there in that rebuild David. 

In answer to your question I'm trying to make the right decision at each stage.  I'm keeping parts where I can, but buying new if the existing part is too poor for refurbishment.  My budget was blown long ago!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 01 July, 2018, 09:17:20 PM
Iíve been continuing with the clean-up of the engine bay. Almost complete now - just the top right surface left to do. See first two pictures.

Refurbishment of my boxes of parts is proceeding quite well. Iíve taken a bunch of stuff back to bare metal and then etch primed: heater box, front bumper brackets, rear window runners, door jamb plates, and bonnet hinge strengtheners. I still have some patching to do to the window runners and one of the door jamb plates then all of this can be painted.

Iím somewhat worried about the painting of the car. I now have a quote and will be discussing it with the paintshop early this week. But reading Simonís comments on his HF thread about colour matching have made me very nervous!  I want to keep the car in its original colour Bianco Saratoga, and Iíve found the following paint codes:
- Max Meyer 1.306.1435
- Lechler 1329
- Glasurit 170 ( which I think is Lanciaís code)

Are there any hints and tips for my discussion with the paint shop?  I know next to nothing about car paint and have heard or read terms such as cellulose, water-based and twin-pack bandied around but I donít know how these relate to current paint technology. With regard to colour matching I was hoping to just be able to quote the colour codes as mentioned above. I donít want the colour to be spectro-matched to the existing colour as the car has been resprayed by a previous owner and I donít know how accurate it is. Sometimes the colour seems to me to have a slight greenish caste to it. I donít know how ďpureĒ a white Bianco Saratoga should be. I didnít get that same impression with other white Fulvias like Timís, or Brianís at last yearís AGM, but then again I donít known if they stayed with original colour.

From that stream of consciousness I guess my key question to other forum members is how do I get closest to original 1973 S2 Coupe Bianco Saratoga color!  Itís a substantial outlay so Iíd like to get it right!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 02 July, 2018, 12:08:36 AM
Norman,
Amazed at the quality you're achieving.
Don't wish to cause my confusion but my Fulvia Tavoli which appears to have been updated to1/1976, shows Bianco Saratoga synthetique codes as
lancia 6980031
Max Meyer 1.346.1435.
With no reference of a application by Glasurit.
Lechler are not even shown as a supplier.
Brian
8227  8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 02 July, 2018, 05:01:56 PM

Thanks Brian - that's interesting!  I have three independent references to Max Meyer 1.306.1435.  Spoke to the paint shop today and they are planning to use two-pack paint, and will get it from Lechler or Glasurit so I guess the discussion around the Max Meyer option is now moot.

I'm still interested in any feedback on paint types.  Can anybody confirm that two-pack is the right type to use?

Also, any comments on Bianco Saratoga?  As I mentioned above, a number of white Fulvias that I've seen appear to be in a "bright" white, rather than the somewhat cream-ish colour that my car is currently finished in.  I bought a small touch-up bottle of Bianco Saratoga a while ago and that appears similar to my cars cream-ish colour.  Does anybody out there have a Series 2 Coupe in original Bianco Saratoga?

Has anybody used a white from a non-Lancia make?

The car was wheeled to the prep-area of the paint shop this morning.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancialulu on 02 July, 2018, 05:46:28 PM
Norman

My HF was painted Bianco Saratoga 2 pack. I have the left over.... There is no green tinge to it, but it is not pure white. It has a lot of black in it! search on line and you might find a Lechler car paint colour database. that goes back to the 1940's.

If you can get it in one pack which I think Lechler have a recipe for that is closer to the original finish of cellulose, but having said that I am happy with my 2 pack (dont have the code to hand) which has lasted well for last 12 years.

Make sure the body shop takes time to "shape" the car for optimum results...


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 04 July, 2018, 06:33:56 PM
Very exciting stage !

I love the Bianca Saratoga/black combination.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 04 July, 2018, 09:01:33 PM
Thanks for that information Tim.  I've talked a lot with the painter about the process of blending in the new metal and I'm optimistic that he will do a good job.  He's happy for me to stop by the workshop every day so I'll be able to keep a close eye on it.

Yes, Simon, an exciting stage!  My first S2 coupe which I owned in the late 1970s was also Bianco Saratoga - but with blue cloth. That was an amazing combination, but I'm looking forward to doing this one in black.  I have a complete new interior (recovered seats, parcel shelf, door cards, footwell panels and rear trim panels, carpet and off-white headliner.  I've already refurbished the dashboard which I explained in detail in a previous post.  I still have to refurbish the steering wheel and re-line the glove box.

I refitted the bonnet strengthening brackets this morning after de-rusting and painting them.  It's funny how much satisfaction you can get from small details!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 13 July, 2018, 07:59:34 AM
While the car is in the paint shop I thought I'd take another look at the seat tilt mechanisms.  Only one of the four is in really poor condition so I thought I'd try to disassemble it so that I could take the parts to a metal finisher to see what re-chroming would cost. At the same time I'm continuing the search for a replacement in better condition.

I managed to remove the spring quite easily but the two main portions do not easily come apart.  A chap from Slovenia sent me some pictures of his re-chromed components but he can't recall how (10 years ago) he took the two components apart - other than that he had to do some grinding on the arrowed part B in the attached picture. I can see how metal could be ground off but I don't know how I would refit them.  Has anybody out there done this?

While scratching my head about this I took a few minutes off to fit a Fulvia vinyl banner to the garage wall.  Bought it quite cheaply on Ebay.  The company that provided it now also sells a version with a cutaway Fulvia picture.   Also thought you might like to see my "Aurelia" inspirational nitrile gloves!

   


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: stanley sweet on 13 July, 2018, 10:15:17 AM
I've seen those signs on ebay. Looks to be good quality - might be tempted. Depending on how wide your garage is you might want to stick some kind of pads on the wall to protect your doors when you open them. Be a shame to scrape the edge by accident after all this work. My garage is quite narrow and very easy to hit the door edges but I've always had a big piece of polystyrene taped to the wall which has prevented any damage. I recently installed my highly sophisticated 'tennis ball on a string' parking aid. As long as the ball slides along the passenger windows I'm at the perfect distance. With the big tumblehome on a Fulvia, no passenger mirror plus the extra width of the wheelarch extensions I have I always found it a bit nervewracking. Your Fulvia looks like it will be a little gem when it's all back together.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 28 July, 2018, 10:58:44 AM
That's good advice Stanley.  I have some thick black foam floor tiles that I'll cut into strips and mount on the wall.

I've been refurbishing the engine bay components (air box, heater air intake, radiator) and having a look to see how sound the welded brackets are on the back of my bumpers.  I've got two front bumpers but neither has the bolt-on side brackets - see 31 and 32 on the Tav diagram below.  Does anybody know the dimensions for these by any chance?




Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: D5177_55A on 28 July, 2018, 03:09:32 PM
Hope this helps. I think its part 32 (nearside). The larger, almost square hole would need more space (in the hole) for bumper levelling purposes.



Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 28 July, 2018, 05:34:51 PM
Brilliant.  Thank you so much for those dimensions!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 30 July, 2018, 06:13:00 PM
Some progress in the paint shop.  Very thin layers of filler are being used to smooth the transition from new metal to old, and "shape" the car where necessary. Getting closer to paint!

In the meantime I'm working my way through the boxes of components in the garage and refurbishing them.  The heater air inlet and the carburettor inbox and filter holder have been cleaned and de-rusted and will be painted satin black.  I've just got the radiator and fuel tank out of the garage loft to start work on them next. 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 30 July, 2018, 11:19:46 PM
Hi Norman,
Looking good.
Why satin for the air cleaner?
My air cleaner was nearer gloss.
Brian
8227  8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 31 July, 2018, 06:25:03 AM
Hi Norman,
Looking good.
Why satin for the air cleaner?
My air cleaner was nearer gloss.
Brian
8227  8)
Thatís interesting Brian. I looked at lots of engine bay pictures on google and saw satin/matt finishes and gloss. I tried to figure out whether the gloss finishes were the result of people refurbishing with gloss paint. Or were the satin/matt examples just the result of gloss fading over the years. I assumed (maybe wrongly)  the former. The question applies to the radiator top, carb inlet assembly and heater air inlet box. Itís on my long list of research questions for the AGM car park this weekend when I hope to be able to look closely at a number of Fulvias. Other ďoriginalityĒ questions on my list relate to engine bay decals and plates, carpets/mats, screw/bolt types and boot interior fittings.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: chriswgawne on 31 July, 2018, 09:13:20 AM
I believe the under bonnet black Fulvia components were gloss originally. Certainly my new1973 Fulvia 3  Coupe was as was Jackys very original Fulvia 2C we ran in the mid 70's whereas Aurelia B20s for example were largely satin black including the engine bay itself.
Chris


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 08 August, 2018, 06:30:59 PM

Some more progress on engine bay components today.  All of the black painted parts have now been cleaned and de-rusted.  I tried a couple of blacks to get close to the factory finish and found that Hammerite smooth black gives a finish somewhere between satin and gloss - perhaps a bit closer to gloss - which appears to be close to the correct finish.  The carburettor air inlet box and heater box are shown in my Heath-Robinson spray booth (plastic sheet suspended from ladders). Iím quite pleased with the way they are looking.

While the paint was drying I made a start on the radiator, which had a lot of surface rust and had been badly painted with thick black paint showing lots of brush marks.  Once I finish stripping the old paint off Iíll look for a radiator specialist to give it a pressure test before I paint it to match.

It was hugely valuable to be able to crawl over some of the S2s and S3s at the AGM at the weekend.   Thanks especially to Neil Simms, David Townsend and Geoff Johnson and their partners who allowed me to inspect their cars very closely and take a lot of reference photographs.  The other wonderful cars attending the event gave me inspiration in bucket loads!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: frankxhv773t on 08 August, 2018, 09:45:16 PM
I use a lot of black smooth hammarite for such things and it seems to last very well.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 09 August, 2018, 11:30:11 AM
Certainly looks good Norman.
Great chatting to you Sunday.
Brian
8227 8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 09 August, 2018, 06:54:19 PM

I enjoyed talking to you too Brian, and it's always good to see how Fay is doing!

I made good progress in the garage today.  Finished cleaning up and de-rusting the radiator and will be taking it to a specialist tomorrow to see if I can get it pressure tested.

I cleaned and de-rusted one of the window regulators - see picture below showing it beside the other one which I'll do tomorrow. One of my window winders is missing the black disc.  I might try to make something to fit - unless someone has one lying around that they'd like to sell.

I have an update on the front window glass runner that I mentioned earlier in the thread.  It had been badly welded and the brightwork on the quarter light surround was badly marked.  I managed to buy a used driver-side door (with most components still attached) fairly cheaply on Ebay and picked it up in London after the AGM event finished on Sunday, en-route to collecting my wife from my daughter's place in Bow Quarter.  The rear runner was in even worse condition than my own, but thankfully the front runner with quarter-light attached was in a good state.

I drove home on Monday via Omicron where I collected some parts for the car including repro door caps and a new pair of rubber seals for the quarter lights.  Now that I have the latter I'll start on cleaning and de-rusting the front runner assemblies next.     


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 09 August, 2018, 10:39:17 PM
Norman,
if you don't have any luck finding a black disc I can probably sort you one out, although it probably would have been off a Vauxhall!
Brian
8227 8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 10 August, 2018, 06:58:51 PM
Norman,
if you don't have any luck finding a black disc I can probably sort you one out, although it probably would have been off a Vauxhall!
Brian
8227 8)

Thanks Brian - I may well take you up on that offer.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 10 August, 2018, 07:02:28 PM

I took my cleaned-up radiator to a specialist today for pressure test and possibly a new core, and I stopped by the paint shop to see progress on the shaping of the transition between new metal and old prior to painting. Very pleased with progress so far.  A few pictures below.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: davidwheeler on 11 August, 2018, 06:03:51 PM
I suspect you wil come back with a new core and for the £100 or so it costs it is well worth it.   The old one is almost certainly clogged after nearly 50 years.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 12 August, 2018, 11:54:19 AM
I've been working on the front window runners, that have the quarter light frame attached. The left one is original from my car and the right one is from a door I bought on Ebay.  They've cleaned up well, but the curvatures are quite different.  The right one is the more curved so I compared it with the one I removed from my car (the one with the large blobs of welds that I talked about in an earlier post) and it has similar curvature. So the problem is not because I'm using a part from a different car.

I don't know how much I should be worried about the difference! I've attached some pictures showing the extent of the difference as measured at the bottom end and in the middle.  Does anybody have any examples they could measure in order to tell me which is correct?  

I also made a start on cleaning up the door top external trim strip in readiness to fit new scraper seal. I naively thought that would be an easy job. However the old scraper is stapled on and quite fiddly to remove.  As soon as I started to pull a section away on the first door it pretty well disintegrated.  The final picture shows the one from the other door at the bottom of the picture - ostensibly looking to be in reasonable condition!  The first one looked like that before I started the removal process.  Interesting what you find.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 16 August, 2018, 08:06:08 PM

Getting there!  Hopefully will be in primer next week.
I'm still puzzled by the curvature differences on the window glass front runners - see previous comments.  Would be glad of any pointers.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 16 August, 2018, 09:41:05 PM
Any chance series 1& 2 are different?
Brian
8227 8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: davidwheeler on 18 August, 2018, 09:10:46 AM
I suspect past brutality rather than any intrinsic difference.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 18 August, 2018, 02:16:55 PM

Is there a facility to adjust the quarter light top in and out by moving the bottom? 

THE lesson here is to get it to fit first, then work on the finish...  I wonder how many have spent a fortune on chrome for bits that then don't fit?


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 18 August, 2018, 04:50:00 PM

Is there a facility to adjust the quarter light top in and out by moving the bottom? 

THE lesson here is to get it to fit first, then work on the finish...  I wonder how many have spent a fortune on chrome for bits that then don't fit?

There are two fixings, both to the inner skin of the door.  The top one is very close to the top edge of the door where the quarterlight base is attached with three machine screws, so little or no opportunity for adjustment there.  The bottom fixing could be shimmed with washers, but only in a direction that would pull the top of the quarterlight in (which might make sense on the passenger side if that's where the problem is).  The only way to pivot the top outwards (to address the driver side where greater curvature exists, assuming that is where the problem is) would be to modify the lower fixing bracket that is welded onto the runner channel. I wouldn't want to mess with the bracket.  I guess I'll have to trial fit the runners when I get the car back from the paint shop and see how they it close.  It's just very frustrating to have no idea how great the curvatures should be!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: Neil on 20 August, 2018, 08:02:46 PM
Norman, I have found a spare window winder knob, with the black disk still fitted, it has parted company from the handle, a small split on side, you are welcome to have it.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 20 August, 2018, 08:53:31 PM
Norman, I have found a spare window winder knob, with the black disk still fitted, it has parted company from the handle, a small split on side, you are welcome to have it.
Thanks Neill  I've pm'd you.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 23 August, 2018, 07:42:57 PM
That door that I bought on Ebay has proved to be quite a bonanza.  If you've been following this thread you'll know that I only bought the door to get the front window runner and quarter light assembly.  That component proved to be in very good condition and alone was worth what I paid for the door.  I've stripped all of the other parts off the door yielding a stainless steel front cap, an internal door handle and door lock, and window regulator mechanism, all in good condition.  There was  also a door stay and plate that will plug another gap in my part inventory as my car came with only one fitted.  In addition, the rear window runner has come in very handy.  The top and bottom ends were badly corroded but I've been able to use the centre portion to provide a couple of repair sections that can now be welded onto my own two rear runners - both of which were badly corroded at their lower ends - see first picture below.  Other parts from my doors are cleaning up nicely thanks to a lot of elbow grease.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 15 October, 2018, 09:08:10 PM
Back home after six weeks away so working on the car again.  The paint shop has waited for me to return so that I could inspect the final shaping before the car gets primed.  It is up on a ramp at the moment so I can work on the underfloor for the next few days.  The radiator is back from the specialist and the examination and pressure test revealed that it is in very good shape and not in need of a recore.  I think it may have been replaced by a previous owner.  The specialist painted it for me so it now looks like a new one!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 21 October, 2018, 09:50:06 PM
The paint shop has completed all shaping and smoothing of the new metal and dressed all imperfections. The joins between old and new metal have all been Tiger-sealed.  While the car has been up on the hoist I have removed all surface rust from the underside and have treated the few areas of discolouration that remained with Jennolite rust converter.  I've been very fortunate that the paint shop has allowed me to work on the car while in their workshop. They've undersealed the underside of the car and the wheel arches with U-Pol under seal, and the car is now ready for its first coat of primer.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 23 October, 2018, 06:51:35 PM

First primer was applied to the car today - just to the areas that have been worked on in the welding shop. Residual white paint areas have been flatted.  Imperfections will be sorted out next and the car will then go into the spray booth for a full primer coat. 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: SanRemo78 on 23 October, 2018, 07:26:17 PM
Looking good Norm!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: Jaydub on 23 October, 2018, 07:54:48 PM
Great progress Norm, won`t be long, keep at it.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: D5177_55A on 24 October, 2018, 03:52:50 PM
Nice job; especially that underside.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 24 October, 2018, 04:45:59 PM
Nearly there !!

It easy to forget how long the journey is - remind yourself what it was like when you first started ....


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 28 October, 2018, 08:39:15 PM
In anticipation of getting the car back and starting the assembly process Iím now looking at the electrical parts.  Iím starting from a zero knowledge base on auto electrics - so will be looking for advice!   The rear lights are in quite good condition - see first picture.  

In order to get them ready for re-fitting I assume that the appropriate steps are:
- Clean (fine emory paper) all bulb holders
- Replace all bulbs Ö. where do I find the bulb specifications?
- Examine wires for breaks in insulation
- Clean all spade terminals (again, fine emory paper)
Does this make sense and is there anything else I should be doing?

Iím also interested in any hints/tips on the beige bases (TAV 5) where I have two problems:

1) Some of the threaded bosses that receive the machine screws (three out of eight) that hold the outer lens are missing.
These are moulded into the plastic. The second picture, left side, shows an example of where one is missing.
Any suggestions as to how to repair?  I can think of three possible solutions:
    A - Find a source of the bosses and glue/Araldite them in position.  I suspect they are not available!
    B - Pass the existing machine screw through the hole and fasten with a nut
    C - Fill the hole with a hard setting putty (see third picture) and drill to receive a regular screw rather than a machine screw
I'm going to have to use option C for the hole where the plastic has broken away around it!

2) Some of the posts (three out of six)  that are used to fasten the beige bases (TAV 5) to the rear panel of the car are missing.
These are moulded into the plastic with the threaded post projecting from the rear. The second picture, right side, shows an example of where one is missing.
Again, any suggestions as to how repair would be appreciated.  In this case I can think of two possible solutions:
    A - Find a source of the posts and glue/Araldite them in position.  Again, I suspect they are not available!
    B - Fill the hole with a hard setting putty into which a machine screw head has been inserted.

I assume these are quite common problems!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: fay66 on 28 October, 2018, 09:20:03 PM
Hi Norman,
For bulb specs see the handbook.
Don't forget to use petroleum jelly on all clean earth points.
Brian
8227
 8)


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: lancialulu on 29 October, 2018, 07:17:00 AM
With all the hard work on the bodywork I would suggest the rear lights some how have to have the correct solution of correct screws and therefore correct mounting threads. You can make a good set out of several broken sets...


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: frankxhv773t on 29 October, 2018, 06:23:32 PM
To be honest I would seek out a better pair of the beige base units. There must be ones about that aren't bust up. Failing that I would go for chemical metal because you can drill and tap it to take the machine screws.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 29 October, 2018, 09:06:37 PM
To be honest I would seek out a better pair of the beige base units. There must be ones about that aren't bust up. Failing that I would go for chemical metal because you can drill and tap it to take the machine screws.

I know what you mean Frank but I've been looking for alternatives for a while.  Really good condition ones are around £300 per pair, which I'm reluctant to shell out as my lenses are so good.  I've seen cheaper ones but the beige base units have been really no better than mine!   People often sell the lenses alone, but I've not seen the beige units for sale on their own.  I suspect that's because they tend to be damaged much like my own. I'll keep looking but in the meantime I think I'll repair mine using the metal epoxy putty. 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: DavidLaver on 29 October, 2018, 10:40:51 PM
I can think of three possible solutions:
    A - Find a source of the bosses and glue/Araldite them in position.  I suspect they are not available!
    B - Pass the existing machine screw through the hole and fasten with a nut
    C - Fill the hole with a hard setting putty (see third picture) and drill to receive a regular screw rather than a machine screw

---------------

I've no idea what the "boss" looks like...but could you use a nut glued in instead of a boss?  Could you cut the correct thread into a short length of tube and set that? 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 08 November, 2018, 07:05:27 PM

Well, a big milestone reached today as the body shell was painted in original Bianco Saratoga. The doors, boot lid, bonnet, fuel flap and door jamb shut plates will be painted tomorrow.  Here's a few pictures, plus a couple of montages as a reminder of some of the earlier work to get this far!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 14 November, 2018, 05:10:52 PM

"I've no idea what the "boss" looks like...but could you use a nut glued in instead of a boss?  Could you cut the correct thread into a short length of tube and set that?"

Thanks David, boss was my term for a threaded metal collar.   Yes. I plan to do something along the lines you describe. I'll post the outcome.   


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: Jaydub on 19 November, 2018, 08:50:59 PM
Hi Norm, I would use Riv Nuts of the correct thread size ( M4 or M5 maybe?) and glue those in place. They are available on Amazon for example. You might need to modify the backing plate but I think that would work.

John


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: SanRemo78 on 20 November, 2018, 12:46:32 PM
Rivnuts - excellent idea! If you're not sure Norm just drop round to my place in Bootle, I've got a large variety of these and the setting tool although I'd recommend gluing them in the plastic bodies rather than crushing them as that's damage the plastic more!
Guy


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 20 November, 2018, 03:39:57 PM
Brilliant. Thanks for the suggestion John. Iíd never heard of rivnuts so just looked them up on Google. The cylindrical steel ones look just like what is set into the backing plates.

Guy, thanks for the offer. Iíll call you when back in UK early December to see when would be a good time to pop round.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 06 December, 2018, 04:50:29 PM
I've just arrived back in the UK and saw my freshly painted Fulvia for the first time today (in the metal, as opposed to in the photographs sent by the paint shop).  I'm absolutely delighted with the quality of the finish. Next step will be to get the car transported home, so hoping for a few days without rain! 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: IanC on 06 December, 2018, 04:58:34 PM
Thatís lovely!


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: stanley sweet on 06 December, 2018, 05:48:47 PM
Looks great. That's a very nice shade of white, like Tim Heath's. Not a fridge white.


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: nthomas1 on 06 December, 2018, 06:11:38 PM
Looks great. That's a very nice shade of white, like Tim Heath's. Not a fridge white.

It's Bianco Saratoga Stanley, same colour as Tim's, and was the original factory colour for my car. Much nicer than some of the washing machine whites you see.... or fridge white as you call it!
 


Title: Re: Report on (slow) S2 Coupe rebuild progress
Post by: simonandjuliet on 06 December, 2018, 06:59:26 PM
Probably my favourite Fulvia colour