Kevinlincs
Permanent resident
Posts: 1605
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« Reply #45 on: 07 February, 2018, 08:14:28 PM » |
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Didn't take much poking around for the bottom to literally fall out!
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #46 on: 07 February, 2018, 08:25:48 PM » |
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The replacement front end had a pretty decent lower member I could use, just the ends needed repairing, the best solution I could find anywhere.
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #47 on: 07 February, 2018, 08:31:25 PM » |
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The inner parts weren't too bad, rotten pieces taken out and the rest cleaned up ready for repair sections to be made up.
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #48 on: 07 February, 2018, 08:34:41 PM » |
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Repair sections were made from thick plate using card then plywood templates before making out of the thick stuff, much easier too make alterations out of card than thick steel!
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #49 on: 07 February, 2018, 08:39:27 PM » |
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The "new" cross member was ready for fitting to the car so now I was sure how much to chop from the car it finally got rid of the rotten section, the dusty section laid on the floor shows how bad it had got!
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #50 on: 07 February, 2018, 08:44:06 PM » |
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The ends of the chassis rails were in a state also once the old metal was cut away which meant more repairs before the new member could be fitted
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #51 on: 07 February, 2018, 08:49:56 PM » |
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The rot from the chassis ends was cut away up to solid metal then readied for the repair sections, I decided the bets course of action was to attach the member which would allow simple repair pieces to be made exactly to suit.
The ends of the member I'd cap off once on the car
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #52 on: 07 February, 2018, 08:53:29 PM » |
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Fitted on the front and the spaces left ready to be filled in..
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #53 on: 07 February, 2018, 08:58:21 PM » |
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Sections being let in, again in thick steel as this is a high strength area.
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #54 on: 07 February, 2018, 09:01:48 PM » |
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This end of the chassis has the bolts for the engine mount so a sturdy repair was needed
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #55 on: 07 February, 2018, 09:07:36 PM » |
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Passenger side was much the same apart from the lack of engine mount bolt holes
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Flavia 815 coupe
Dedra turbo
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1605
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« Reply #56 on: 07 February, 2018, 09:15:43 PM » |
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At last the front of the car can be supported by the cross member again!
A lot of pictures in one go so I'll do another update if there's interest?
All a bit out of sequence though as this was all a couple of years ago now!
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Flavia 815 coupe
Dedra turbo
Delta integrale
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rogerelias
Rebel Poster
Posts: 955
MY 1600HF IN HEARTBEAT GARAGE
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« Reply #57 on: 07 February, 2018, 10:20:32 PM » |
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 you are doing a great job, I would have given up ages ago, in fact I probably wouldn't have started 
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FULVIA 1600HF LUSSO
1958 VELOCETTE MAC
Triumph Bonneville t120v 1972
1968 MGC ROADSTER
1958 Series 2 Appia berlina
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simonandjuliet
Permanent resident
Posts: 2548
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« Reply #58 on: 08 February, 2018, 07:14:18 AM » |
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To be able to weld/fabricate like that ........ great to watch !
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AmilcarCGS, ApriliaCabrio,S2Aprilia, 2xArdea c'cino,S4 Ardea, Appia c'cino, Appia f'cino,B20s4,R4 Sinpar, R4 Rodeo, 65 Moke, 3xR60 Tractor, 2xToselli 78, Moto Guzzi Ercole,LR Defender, Mini ALL4 JCW, Moto Guzzi Cardellino, Fulvia GT, RE Himalayan
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tzf60
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« Reply #59 on: 08 February, 2018, 02:22:36 PM » |
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Kevin,
You clearly have the patience (and perseverance) of Job!
It's an absolutely wonderful transformation.
I can't wait to see the front with it's final coat of red....!!!
Keep her lit!
Tim F
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1939 Series 1 Aprilia undergoing very slow restoration.....
Previous Lancias: 1979 Beta Sedan 2000, 1982 Delta 1500, 1988 Delta 1.3, 1992 Dedra 1.8ie
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