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Projects and Restorations Building a car from scratch, restoring your pride and joy, building a track car, or starting a long term project? This is your place to document it.

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Old 30-10-2015, 09:24 PM   #21
jas_racing
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So, after discovering more corrosion than I'd anticipated I hatched a plan to deal with the minor/surface stuff myself courtesy of POR-15 but leave anything that needs welding to a specialist to do at a later date (prior to the full respray).

A couple more shots of the corroded areas once I finished scraping & exploring:




The grey area in this one is the factory underseal, the black on the left is the underseal I had done in 2010, so it seems they didn't drop the fuel tank to do it


Onto the POR process, the usual Clean > Prep > Paint stages, a few shots after Prep: (love the way the Prep stuff turns the orangy corrosion grey)





Having learnt the hard way in the past just how difficult it is to get POR-15 paint off your skin I was taking no chances:


Two coats of POR-15 paint were applied, took about 3 hours in total rolling around on cold gravel on my back








Finally, two coats of Dinitrol Underbody Wax:











Mechanicals next
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Old 30-10-2015, 10:03 PM   #22
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To get started on the mechanicals I sent a pile of parts off to the shot-blaster, several weeks later I got them back but they'd already spent some days outside in the pouring rain by the time I collected them:




After POR Clean & Prep:



Two coats of POR paint:




I decided to replace the bearings in the trailing arms too as these do tend to wear on Coupé's and it's dead easy to do when the arms are already off the car. Old bearings out and inner bore cleaned up ready to accept the new bearing:


New bearing kit (for one side):


Pic of one end when the kit was fitted:


For the rear beam and anti-roll bar I decided to go a different route than POR-15 as this project is more about durability than appearance, and where I work we rather fortuitously have both a galvanising plant and powder-coating line

A reminder of how the rear beam looked when it came off the car:


Beam was shot blasted (sorry no pics of this) then galvanised along with the ARB:



Rear beam after powder-coating and with new uprated mounting bushes fittted:



ARB after powder-coating:



Rear beam with new load-proportioning valve and brake pipes fitted:





Brake pipes are copper-nickel and I had stainless steel brake pipe nuts custom-made as I've spent too much time over the years struggling to undo corroded mild steel/zinc plated ones

New Munroe dampers to go on the rear beam (easier to fit with the beam off the car as the bolt is only accessible through small access holes in the rear chassis rails once the beam is mounted on the car):


Ready to fit:


And finally back on the car:

Not easy to do on your own!

Trailing arm fitted on N/S:


And O/S:


Another shot of the beam in place:


You've probably noticed but all fasteners are new too, mainly stainless steel but odd ones that need to be high-tensile are 12.9 grade mild steel.

ARB is fitted behind the beam in this pic (not that it can be seen!) but this pic was to show the new spring fitted connecting it to the load-proportioning valve:


That's pretty much up to date now, great to be bolting bits back on!
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Old 30-10-2015, 10:19 PM   #23
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Amazing attention to detail
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Old 30-10-2015, 11:02 PM   #24
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Nice mechanicals!

Loving the neat brake lines - did you use a pipe bender?

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Old 31-10-2015, 10:13 AM   #25
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This looks like another epic rebuild. I've got a GTV which you'll probably know is based on the same platform and share components, different rear suspension set though.
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Old 31-10-2015, 10:56 AM   #26
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I love Fiat Coupes, will defo be keeping an eye on this thread, keep up the good work mate.
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Old 31-10-2015, 12:56 PM   #27
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Loved these back in the day when I had a Punto Sporting

Look forward to your updates
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Old 31-10-2015, 03:27 PM   #28
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Lovely jubbly, exceedingly good work.
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Old 31-10-2015, 03:32 PM   #29
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That's a credit to all your hard work!!
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Old 31-10-2015, 05:24 PM   #30
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Fantastic work, it'll be better than new when finished
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