Report on (slow) S2 Coupe rebuild progress

[Beckerman67]

 I have my heater box out at the moment and the third cable is held in by a clip that just pulls out with a pair of needle nose pliers.
 See photos:
 Hopefully you can help me. I've taken both side footwell vents off and can't remember which way they go back in. Is the side flap at the front or back?
 Please let me know if the number plate lights arrive OK.
 Robert.

[nthomas1]

Thanks Robert - I would never had guessed they fitted that way!   And yes thanks, the lights arrived yesterday and I've already fitted them.
Are these the flaps that you're referring to?

Guy - if you're reading this - you can pick up the remaining 4 number plate lights whenever you want and take your pick for the Stratos.

[Beckerman67]

 Yes they are the ones. When opened as per your picture, is the plastic deflector at the front or back?

[nthomas1]

Just checked.  Projecting flaps are towards rear of car on mine.

[SanRemo78]

[quote author=nthomas1 link=topic=9873.msg84234#msg84234 date=1593953382
Guy - if you're reading this - you can pick up the remaining 4 number plate lights whenever you want and take your pick for the Stratos.

[/quote]

Cheers Norm, put them to one side withe crimper for me and I'll collect the lot when you've completed the wiring!
Guy

[nthomas1]

Eureka!  With help from the forum I was able to remove the heater control assembly today.

I enlarged an existing small hole in the side of the glove box to gain access to the screw for the clamp that holds the middle cable. 

On disassembly it could be seen that all but one of the 6 large flexible washers had become brittle, and a couple were missing completely, probably broken up over time and the bits dropped into the footwells.  Similarly, the small flexible washer on the fan motor control lever spindle had disintegrated.

The cables for the middle and lower control levers are in good condition and I’ve sprayed some grease into the casings and will reuse them.  The cable from the top lever shows evidence of a previous botched replacement.  You will recall that the lever was jamming half way across its travel.  You can see the cable in the final picture.  It’s the very curved one.  The piano wire had been replaced with wire of a thicker gauge, which did not slide freely, and the end that fits into the control lever had been bent in such a way that it scraped against the top of the metal pressing, and fouled half way through its travel.  The correct way to bend the piano cable at the control arm end can be seen on the other two cables.

I’ve painted the metal housing and cleaned everything up and I’ve ordered a new cable, new flexible washers, and one replacement lever - to replace the one with the broken handle.  They’ll hopefully arrive (from Omicron) by the end of the week.

Onwards and upwards.

[nthomas1]

My front indicators came in a box with my car and looked to be in reasonable condition.  After removing the lenses I could see rust along the edges of the reflectors, and the rubber perimeter seals had become brittle and had broken up (shown at bottom of second picture).  I rust-treated the reflector edges and gave them a couple of coats of silver paint.  I’ve just been painting and weather-sealing some sash windows and had some left over rubber bubble seal, so I cut strips from it and they fitted nicely in the channels around the edges.  I cut strips from the curved part (a bit fiddly) as I didn't want to use the flat part with adhesive on.

Two of the indicator mounting brackets were easily removed from the bumper and cleaned up and painted.  The remaining two are stubborn.  The nuts are rusted in position and won’t budge and the posts rotate inside the rubber cover strips to which they’re bonded.  The other two nuts that hold the end rubber strips in place can be removed so I'm sure I’ll end up removing the strips completely.

Has anybody got experience of repairing a rotating post in the rubber bumper trim?   I think the screws rusting solid is a common problem on Fulvias, certainly the case on my second set of bumpers.  There’s a rubber strip (rear) for sale on Ebay at the moment  and the listing says that new posts have been “chemically bonded in place”.  I’ve written to the seller to ask what product was used - don’t know if I’ll get a reply.