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Author Topic: Report on (slow) S2 Coupe rebuild progress  (Read 6494 times)
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stanley sweet
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« Reply #15 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.
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1971 Fulvia 1.3S 'Leggera'  1999 Lancia Lybra 1.9JTD LX SW
lancianut666
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Slow but rough


« Reply #16 on: 17 January, 2018, 04:28:58 PM »

If only we could all weld like your man....
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Fulvia Coupe S2 Flavia Coupe 1967 1.8 Kugelfischer Prisma 1.6 carb Y10 Fila Y10 Touring Dedra 1.8 Dedra 2.0 Turbo Appia S1
nthomas1
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« Reply #17 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.


* a IMG_1916 copy.JPG (351.73 KB, 1559x1169 - viewed 40 times.)

* b IMG_1939 copy.JPG (243.97 KB, 1200x1600 - viewed 27 times.)

* c IMG_1894 copy.JPG (410.04 KB, 1559x1169 - viewed 32 times.)

* d IMG_1924 copy.JPG (266.97 KB, 1200x1600 - viewed 26 times.)

* e IMG_1903 copy.JPG (462.11 KB, 1843x1382 - viewed 44 times.)
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
2015 Alfa Romeo Mito
2011 Peugeot 207 (in Spain)
2017 Ford Kuga
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
simonandjuliet
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« Reply #18 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
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S1 Aprilia Cabrio, S2 Aprilia, S1 Appia Promiscuo, S2 Appia furgoncino, S3 Appia, R4 Sinpar, R4 Rodeo, Velosolex, R60 Tractor, Moto Guzzi Ercole, Disco 3, Mini ALL4 JCW, Moto Guzzi Cardellino 73,Honda XLV750R,Fulvia 1600 HF,1 & 1/2 Rallye S's
nthomas1
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« Reply #19 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.
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
2015 Alfa Romeo Mito
2011 Peugeot 207 (in Spain)
2017 Ford Kuga
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
nthomas1
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« Reply #20 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!


* aaa IMG_6618 copy.JPG (862.94 KB, 1276x1701 - viewed 34 times.)

* bbb IMG_0962 copy.JPG (583.75 KB, 1276x1701 - viewed 37 times.)

* ccc IMG_1931 copy.JPG (235.46 KB, 1200x1600 - viewed 42 times.)
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
2015 Alfa Romeo Mito
2011 Peugeot 207 (in Spain)
2017 Ford Kuga
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
nthomas1
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« Reply #21 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!


* 045 IMG_2063 copy.PNG (515.88 KB, 638x480 - viewed 282 times.)

* 070 IMG_2055 copy.PNG (774.03 KB, 638x745 - viewed 306 times.)
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
2015 Alfa Romeo Mito
2011 Peugeot 207 (in Spain)
2017 Ford Kuga
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
Jaydub
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« Reply #22 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.
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1600 HF. S2.
stanley sweet
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« Reply #23 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.
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1971 Fulvia 1.3S 'Leggera'  1999 Lancia Lybra 1.9JTD LX SW
DavidLaver
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« Reply #24 on: 30 January, 2018, 11:29:17 AM »


Is that rear panel plug welded or a seam along the edge?
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David Laver, Lewisham.
nthomas1
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« Reply #25 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.
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
2015 Alfa Romeo Mito
2011 Peugeot 207 (in Spain)
2017 Ford Kuga
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
simonandjuliet
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« Reply #26 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 ?
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S1 Aprilia Cabrio, S2 Aprilia, S1 Appia Promiscuo, S2 Appia furgoncino, S3 Appia, R4 Sinpar, R4 Rodeo, Velosolex, R60 Tractor, Moto Guzzi Ercole, Disco 3, Mini ALL4 JCW, Moto Guzzi Cardellino 73,Honda XLV750R,Fulvia 1600 HF,1 & 1/2 Rallye S's
nthomas1
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« Reply #27 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. 
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
2015 Alfa Romeo Mito
2011 Peugeot 207 (in Spain)
2017 Ford Kuga
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
nthomas1
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« Reply #28 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!


* IMG_2476 copy.JPG (1462.06 KB, 3264x2448 - viewed 36 times.)
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
2015 Alfa Romeo Mito
2011 Peugeot 207 (in Spain)
2017 Ford Kuga
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
lancialulu
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« Reply #29 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.....
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Its not the winning but taking part! or is it taking apart?
1955 Aurelia B12
1967 Flavia Vignale iniezione
1967 Fulvia HFR
1972 1600 HF
1972 1600 Fulvia Sport
1978 Transformer HF3000 Strato's replica
1979 2500 Gamma Coupe
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