815 coupe restoration

[Kevinlincs]

While I planned to mix up the satin black I also did another job I'd wanted to get done since the strip down last year, the metal fuel filler pipe that snakes down from the filler in the car right through the boot and under the car where it joins the tank underneath the boot floor.
It had some rust on it and a fair amount of old underseal which has saved it from rusting out completely.
A good clean off with the knotted wheel which digs the rust out well but if things are too weak it can make holes. Thankfully it was solid under the crud and rust stains.
A treatment with some Kurust then etched and 4 god coats of the satin black should protect the outside enough, it's not like the car will see salty roads again!

[lancianut666]

Looks nice Kevin.
Clarkey

[Kevinlincs]

The flywheel had some scoring in the face where in a previous life it had suffered a worn clutch no doubt being driven on the rivets, so I sent it to my local guy who refaces heads etc.
Got it back this morning and pleased I had it done, there was also 3 high spots on the face as well as the circular scoring so no doubt there would have been clutch drag and judder if I'd just fitted it as is with a new clutch.
With this style of flywheel where the plate sits on a different level to the area where the cover bolts to it is vital to retain the step or you will lose clamping force on the new clutch so he has also removed the 2 clutch alignment pegs and taken the mount area down too by a few thou to regain the step.

Still awaiting the body shell to be finished with the welding, latest update puts it at a while away yet, hopefully it will be completed before the end of the summer so I can get it back before the wet weather returns..


It's much easier this getting someone else to do the bulk of the work, but way more harmful to your pocket and you are at the mercy of their time schedule! But at least it means I haven't run out of enthusiasm for the project yet! Often happens after months of grimy horrible tasks that you get so fed up of it that it becomes a chore, so at least that stage hasn't hit just yet....

[Skidrow]

Good to hear to still have a few gallons left in your tank! Doing a great job and you’ll have a lovely car at the end. 🥳🥳

[Kevinlincs]

Yes, a few gallons left in the tank, and I'll soon be needing them 😀
The floors are all but finished now and given a coat of etch primer.
The outer sills will go on once back on its wheels soon, a bit more work on the inner rear arches then Dan plans to get it back on its axles.
I'll go lend a hand for the outer sills so it shouldn't be that long before it's back with me...

[DavidLaver]

Swanky !!!

Doesn't feel all that long elapsed time. 

[Kevinlincs]

It's coming along now David yes, Dan is doing a great job.
Had a nice chat with him tonight in fact, he's now got it back on its wheels and will be putting the newly made seat mount cross member in soon.
In fact we've come to a plan that will see the outer sills go on around the end of this month or in June then the car is coming back to me for the upper body repairs such as the rear panel reinstallation and the lower front panel bits.
We had planned for him to do pretty much all the welding but as it has taken longer so therefore cost me more than we'd planned and he has jobs stacking up so it makes sense for me to finish off the repairs now Dan has done the awful job of the underbody repairs which were a real mess with the old underseal needing scraping off and of course the front floor pans he made for it.
Although it'll mean more work for me than I'd planned I'm looking forward to getting a strong car back

[DavidLaver]

On a "got to start somewhere" basis towards making stuff like that I've been experimenting.  Rather than clutter this thread I've started another:

https://www.lancia.myzen.co.uk/forum/index.php?topic=14201.0

[Kevinlincs]

Latest update from Dan, he's doing a sterling job 
Other than the red oxide painted rear floor pans the vast majority of this has been made from scratch, front floors all through to the toe boards, the cross member for the seats to bolt down to, inner sills pieces.
Really chuffed with his work.
I'm going to his place in a week or two so we can fit the outer sills then it will be coming back to me, I'll finish off the other bits and pieces like the rear panel refitting and repairs to the front end and windscreen surround.

[Kevinlincs]

Well, the day has arrived at last.
I've been busy enough making a booth inside the workshop so I can work on it without causing dust and dirt over the other cars in the workshop.
I still have a few bits to do like install a fan extraction system and plumb in the compressor but it's almost a useable space.

[Kevinlincs]

Dan has done a fantastic job on the floors, aside from the central strip everything from under the pedals right back to under the rear seats and up behind the rear spring hanger mounts has been remade.
Very pleased with his efforts to put as many original pressings in the new sections, not only to give it strength but it looks less chopped about and more original, a nice effort indeed considering a lot of the tooling for the fly press to create the circles had to be made.

[Kevinlincs]

It's by no means the finished article as far as the welding is concerned, all of which I will complete due in part to me wanting to at least do some of the work but also to rein in the costs, hand fabricated welding work doesn't come cheap due to the time involved.
The eagle eyed will spot the lack of a rear panel, this was cut out so the car could be fixed securely to the rollover frame, plus it was quite rusted and of course heavily dented!
I have a better one that I bought from the consortium, still needs some repairs but far less than the old one.
There are still repairs to the inner rear wheel wells and the window surround, plus the parcel shelf.
Dash panel needs a bit of work, front end around the grille opening has some issues.
All manageable now that I don't have the task of repairing the floors and sills.
The outer sills themselves went on pretty well but will need some fettling at the wing joint as well as the rear quarter attachment. This was agreed that I would sort out rather than Dan, I suspect he was getting ready for a different task by now anyway!

So in a week or so I will get started on the car again.

Order of works are;
Finish the welding work.
Get the car up on stands for the subframe and axle to be blasted and power coated.
Refurbish all the suspension and brakes, new bushes and bearings etc.
Strip out and remake the wiring loom.
Do a full rebuild, dash and all parts to check for fit
Engine and gearbox fit and test.

Once everything is ticked off I will start to think about painting it, in all likelihood it will be me doing it, as long as enthusiasm is still in supply !

Time wise I'm in no rush as this will be, for sure my last big build. At least while I'm still working full time too. Can't guarantee that when I eventually retire in 10 years or so I don't try again, but this will be my final restoration so I plan to enjoy it as much as I can. That was the main reason for getting Dan to do the bulk of the work so at this stage I'm raring to go rather than sick of the car!

[lancianut666]

Great stuff Kev...keep us posted.
Clarkey

[bobhenry999]

Kevin,

Amazing effort, well done you.

Bob

[Kevinlincs]

Thanks guys, I'm trying to make an effort to get the workshop in order before I start on the car myself, progress hould then be steady.
I'll keep a regular update coming.