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Author Topic: Series 2 Coupe Restoration  (Read 384 times)
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nthomas1
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Posts: 749



« on: 03 May, 2021, 12:59:32 PM »


As many of you know, I documented the restoration of my Series 2 Coupe on the Forum over the last 5 years.  This was in order to get assistance from others more skilled and experienced than me, and in order to leave a record that would help others following a similar path - especially those starting out with a similar lack of skill and experience to my own!

The thread focuses on bodywork, glass, exterior and interior trim and electrical work.  It does not feature much in the way of mechanical information as my car came to me in quite good mechanical condition.   Fortunately, mechanical information is available extensively on other Forum threads.  My thread can be found by scrolling down the Form Fulvia list of threads, or by searching within the Forum or via Google for “slow S2 coupe rebuild”.

The restoration has very much been a non-linear process, as I would start jobs and then be held up through lack of knowledge or while waiting for parts.  I would sometimes start a task and not return to finish it until weeks or months later.  That can make finding specific information in the thread quite difficult and frustrating.  I’ve therefore put together this index, which I hope will prove useful.  The index has also been posted to the thread, and is shown on page 51.

Once again I would like to say a massive thank you to all those who have offered advice and encouragement to my endeavours!
 
**************************************************

INDEX - format is topic followed by page number(s) in the thread.

Body
- rear wing tops repair and welding - 1, 2
- rear wings, lower portions refurb - 2
- rear panel fitting - 2
- rear lower valance fitting - 2
- sill refurbishment - 2, 3, 4, 6
- sill strengtheners - 2, 3, 4
- subframe mounting boxes - 2, 6
- jacking points - 2, 7
- quarter repair sections - 4
- rear wheel arch replacement - 2, 7
- front valance de-rust and paint - 5
- floor panel replacement  - 6
- interior paint - 14
- cavity waxing - 28

Paint & Under-seal
- paint selection - 8
- prep for paint - 7, 8, 9
- primer applied - 10
- top coat applied - 10
- under-seal applied - 10

Glass
- rear screen install - 28
- rear quarter light install - 28, 36
- windscreen install - 32, 36

Engine bay
- paintwork refurb - 6, 7, 8, 14
- black paint selection - 9
- decals - 14

Bonnet
- de-rust and prime - 1
- hinges - 8
- edge rubber u-trim - 11, 12
- fitting the 1.3S badge 11, 12, 38
- bonnet lock striker - 37
- bonnet safety catch - 37
- bonnet release cable - 37
- sound deadening - 38
- cavity waxing - 38
- front seal install - 38, 39

Boot
- floor refurbishment, new metal - 1, 2
- floor tiger seal - 13
- interior Hammerited - 13
- boot lid stay refurbishment - 13
- catch refurbishment - 18
- catch fitment  - 50
- boot lid rubber edge strips - 39
- boot lid stainless steel trim strip - 39

Doors
- door top metal repair - 5, 7
- door assembly jigs - 16
- door mirror  - 16
- quarter-light refurbishment - 8, 9, 10, 16
- quarter-light installation - 16
- rear window channel refurbishment - 10, 13
- door glass refitting - 16, 17
- window regulator refurbishment - 9
- window regulator refitting - 16, 17
- inner window scrapers - 20, 21
- outer window scrapers - 9, 37
- outer door top stainless trim - 37
- window winder handles - 9, 40
- door lock mechanism refurb - 10, 17
- door fitting - 30, 31, 39, 45
- door adjustment - 47
- door card fitment - 40
- interior door handles - 40
- door inner waterproofing - 45

Exterior Trim
- exterior metalwork protection - 13, 32
- roof gutter stainless trim strips - 20, 21, 31
- door aperture trim install - 20, 21, 30, 31
- outer door seals - 31
- front end stainless steel trim fitting - 35
- rear panel badges - 38
- rear reflectors - 39
- rear end stainless steel trim strip - 39
- rear bumper repairs - 33, 34, 35
- front bumper brackets - 8
- front bumper refurb - 35
- front bumper install - 37
- number plate fitting - 38
- windscreen wipers - 6

Interior trim
- headliner install - 14, 15, 19, 20
- sun visor install - 36
- rear view mirror install - 36
- centre console refurbishment - 17, 18
- interior trim parts refurb - 17, 18
- floor insulation and carpet - 31, 32, 33
- trim cards - 33
- map bins - 33
- door top trim pads - 39
- inner window scrapers - 39
- door edge escutcheon plates - 39
- dashboard and crash pad install - 42
- steering column shrouds - 44
- Nardi steering wheel fitment - 50

Seats
- tilt assemblies - 8
- frame restoration - 15
- front seat build-up - 18, 37
- front seat install - 37, 42
- rear seat install - 36
- seat belt installation - 38

Fuel System
- air filter box refurb - 8, 9
- fuel tank connections - 18
- fuel filler neck troubleshooting - 49
- fuel tank filter refurbishment - 18, 42, 43, 44, 46
- fuel tank installation - 35
- fuel inline filter, pump and regulator - 18, 19, 43, 44, 45
- fuel line connection - 49
- accelerator pedal rollers - 44

Electrical - Fuse Panel
- fuse panel overhaul  - 37, 40, 41
- fuse panel trouble shooting - 40, 41

Electrical - Lighting
- steering column lighting stalks - 31, 36
- lighting solenoids - 39, 42
- sidelight solenoid - 37, 40
- headlamp solenoid - 24, 37
- inner headlamps - 29, 30, 37
- indicators - 22, 23
- hazard flashers - 22, 23, 38, 43
- front indicator refurb - 35
- headlamp bowl refurb - 13, 14
- headlamp trim clean up - 13
- rear light cluster repair & refurb - 10, 11, 13
- rear lights install - 14, 
- rear number plate lights - 22, 32, 33, 34
- engine bay light and switch - 32
- boot light and switch - 32
- door-open lights and switches - 32

Electrical - Other
- instrument panel refurb - 33
- rev counter replacement - 43
- horn repair - 13, 14
- connectors - 23
- alternator - 23, 24
- voltage regulator - 23, 24
- coolant solenoid - 24, 32
- other engine bay electrics - 30
- windscreen wiper fittings - 46
 
Heating & Cooling
- radiator inspect & paint -  9, 10
- radiator and fan install - 23
- radiator leak, and new radiator - 47
- radiator hoses - 48
- antifreeze discussion  - 48, 49
- thermostat - 47
- temperature sender - 47
- rad fan cosmetic refurb - 9
- rad fan override switch - 28
- rad fan motor repair - 26, 27, 28
- heater air intake refurb - 8, 9
- heater valve - 25, 26, 28, 34, 35
- heater hoses - 25, 26
- heater dashboard control lever assembly - 25, 34, 35
- heater control cable replacement - 34, 35
- heater air box vents - 35
 
Brakes
- handbrake base plate refurb - 13
- handbrake lever surround refurb - 21
- handbrake install and linkage connection - 46
- servo hose connectors - 25
- brake fluid reservoir - 30, 31

Mechanical -
- oil filler gauze removal - 46
- cam cover refurbishment - 47
- rear shock absorber replacement - 47
- clutch pedal spring - 49
- gear lever reverse detent - 32
- engine start-up - 49

Exhaust System
- installation - 38

Wheels & Tyres
- blast and powder coat -  13
- tyres and tubes - 13
- centre plates - 16

Logged

Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
Various modern cars
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
RDG496
Member
***
Posts: 37


« Reply #1 on: 03 May, 2021, 02:36:39 PM »

Thanks for taking the time,I for one will find it extremely useful as I tackle a few jobs over the summer.

Cheers
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hugh
Member
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Posts: 10


« Reply #2 on: 03 May, 2021, 03:09:47 PM »

Norm - thanks so much for doing this. I fear I shall be an avid reader over the next year or two (or three, or four..). PS Make sure you enjoy you newly-restored car!
Logged

Fulvia 1600HF Lusso      (Previous - Aprilia, Aurelia B20,  Flaminia Zagato Sport, Touring 3c convertible, Flavia Zagato, 2000 Berlina, Fulvia Berlina [sundry], Rallye 1300S, 1600HF)
my69S1
Member
***
Posts: 37


« Reply #3 on: 03 May, 2021, 10:10:21 PM »

Nice job Norm.  That must have been quite a task, but I'm sure will save you time down the road by cutting down on e-mail questions  Wink Grin.
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andyps
Megaposter
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Posts: 234


« Reply #4 on: 04 May, 2021, 12:38:08 PM »

Thank you for the index Norm, I'm sure it will come in very handy. Hope you have managed to enjoy driving the car now.
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GlynW
Member
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Posts: 19



« Reply #5 on: 12 May, 2021, 06:12:03 PM »

Thanks, Norm.  Adding an index was a great idea and a copy should be on every Fulvia owner's garage wall!

Does anyone know if there is an easy way of downloading the thread in PDF format and adding it to the LMC Library?  I am mindful that the Lancisti forum was not able to transfer old threads when they upgraded (moved?) their website and I would not like to see that happen here.

Glyn
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lancialulu
Press Officer
Permanent resident
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Posts: 4219



« Reply #6 on: 12 May, 2021, 07:29:52 PM »

Thanks, Norm.  Adding an index was a great idea and a copy should be on every Fulvia owner's garage wall!

Does anyone know if there is an easy way of downloading the thread in PDF format and adding it to the LMC Library?  I am mindful that the Lancisti forum was not able to transfer old threads when they upgraded (moved?) their website and I would not like to see that happen here.

Glyn

A great question Glyn, and one with an unsatisfactory answer No you cannot do any more than print each page to a pdf file which is tedious in itself but worse is it does not contain any photos/pictures... If anyone knows better I would be grateful!
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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 1.3HFR
1972 Fulvia 1600HF
1972 Fulvia 1600HF
1972 1600 Fulvia Sport
1979 2500 Gamma Coupe
1988 Delta 1.6GTi
1998 Zeta
nthomas1
Rebel Poster
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Posts: 749



« Reply #7 on: 13 May, 2021, 09:32:54 PM »

I've looked into this before and have been unable to find a way to download a complete thread in one step.

On my Apple MacBook I am able to generate PDF files of individual pages, complete with embedded photographs. I do that by opening a specific page and then selecting "File" and then "Print" from the header bar.  In the panel that then appears I press the "PDF" button and select "Save as PDF" from the drop down list. It is a laborious process but I've used it to create copies of other people's threads for my own archives.

I have made a backup copy of my own rebuild thread, and can share it via WeTransfer with anybody that would like a copy.  The folder contains 51 PDFs, one for each page of the thread.

 
« Last Edit: 13 May, 2021, 09:45:22 PM by nthomas1 » Logged

Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
Various modern cars
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
andyps
Megaposter
*
Posts: 234


« Reply #8 on: 13 May, 2021, 10:49:30 PM »

I've looked into this before and have been unable to find a way to download a complete thread in one step.

On my Apple MacBook I am able to generate PDF files of individual pages, complete with embedded photographs. I do that by opening a specific page and then selecting "File" and then "Print" from the header bar.  In the panel that then appears I press the "PDF" button and select "Save as PDF" from the drop down list. It is a laborious process but I've used it to create copies of other people's threads for my own archives.

I have made a backup copy of my own rebuild thread, and can share it via WeTransfer with anybody that would like a copy.  The folder contains 51 PDFs, one for each page of the thread.

 

It is possible to merge pdf documents together - there are a few online tools which do this such as https://combinepdf.com/

I'm not promoting that one specifically, but plenty available and Adobe themselves offer a service but I think you do have to register with them.
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