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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 13-08-2016, 12:36 AM   #51
jas_racing
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Quote:
Originally Posted by wrxmania View Post
Superb.

Love these cars.

Had a Fiat Bravo HGT with the 2.0 20v engine it it from new in 1998 and it was a lovely car - but the Fiat dealer quality and number of things breaking (even at only 10 months old when I sold it) was frightening. Moved to Japanese cars and never looked back.

It had a great sound and drive really well with a few mods too - but the belt change (at 68,000 miles I think) was a 14 hour engine out job!!

Keep us posted - will love seeing this one back on the road as they are very special cars.

Brian.
Hi Brian, I liked the Bravo HGT too, particularly in the dark metallic blue of the time. It's fair to say that in those days Fiat dealers made a meal of cambelt changes on the 5 cylinder engines (why not when the customer is paying I guess?) by making it an engine out job. Not necessary at all as there are specialists around now who can do the job in a morning with the engine in place. Costs about £400 all-in usually, which isn't much more than your average 4 pot engine

Last edited by jas_racing; 13-08-2016 at 12:42 AM.
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Old 13-08-2016, 12:41 AM   #52
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Quote:
Originally Posted by ibiza55 View Post
Yes exciting times, but I'm sure expensive times too.
A few quid here & there yes Well worth it though, Coupé values are on the up & rarer models like Plus' & LE's in top condition approaching 5 figures now
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Old 13-08-2016, 05:30 AM   #53
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Great work on a lovely car.
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Old 09-01-2017, 10:54 PM   #54
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Wow just realised I'm WAY overdue an update!

Here goes...having dropped the car off at F.C.S.S. I continued with cleaning up of parts, starting with the exhaust rear section:

Before:




After many hours of polishing using flap-wheels and scotchbrite:



Very pleased with the finished result I don't appear to have photos of the centre section but it was polished to the same level.

A few bits were sent off for powder-coating (after being shot-blasted & galvanised):


PAS reservoir bracket and pipework cleaned-up, including re-heatshrinking the pipe as the original stuff was damaged,:



A few parts stripped down ready for shot-blasting, galvanising & powder-coating:


While all this was going on I kept in touch with F.C.S.S and their original estimate of end-September was extended, partly due to other workload but mainly due to me suggesting there was no hurry to get it done before Xmas 2016 as I won't be using the car on the road until Spring this year at the earliest. I did however pop over there in November to see how the old girl looked plus drop off refurbed parts and retrieve engine ancillaries for me to refurb at home. When I got there F.C.S.S. had cracked on and got all the welding done, engine & 'box out and interior stripped: (apologies for poor quality phone photos)











Engine & 'box:



I stripped all the ancillaries off leaving quite a pile for me to take home:


The engine as it was left:


I thoroughly enjoyed my Saturday morning at F.C.S.S. submerged in all things Fiat Coupé and was pleased to be trusted by the owner to crack on with things on my own while he buzzed around attending to 101 other things!

The car was transported to the bodyshop in Birmingham the following Monday although with instruction not to start work on it until January.

Meanwhile back home I got stuck into the mountain of parts I'd brought back with me. I thought I'd broken the back of this project until I got to this stage and realised there was MUCH more for me to do!

The cast aluminium engine/alternator/air-con pump/belt tensioner mount was very grotty, covered in a delightful combination of road grime, air-con fluid, coolant and oil:



After LOTS of cleaning:


Fitted a new (SKF) PAS pump bearing as a precaution:


Ready for painting:


In primer:


High temo base & lacquer applied:



After baking in the oven at 90degC for an hour:




That's all for now, it's past my bedtime, but more to come

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Old 10-01-2017, 10:22 PM   #55
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More, as promised

Coolant rail that runs across the front of the head was also covered in gunk:


Cleaned up:


The intermediate driveshaft bearing support bracket was in fairly clean condition oddly, so only needed a light clean to get ready to paint:



Painted:


In the oven:


Finished:


The inlet plenum was also fairly clean but benefited from a spruce up. Before:



During:


After:






Inlet manifold before painting:


During:


After:




Oil catch can also in good nick so only a light tidy needed. Before:


After:


Various brackets and pulleys not looking good:


The heads of the bolts for the crank pulley had deteriorated so needed painting up:


After:


The whole lot after plenty of cleaning, rubbing-down, rust-treating & painting:


Sadly the turbo heat-shield did not come through the galvanising process very well so had to be binned:


PAS pump was really grubby:


After cleaning & ready for painting:



Painted:




That's all for this evening, but still more to post
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Old 20-01-2017, 11:29 PM   #56
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A Friday night to myself for a change so I can finish updating this thread up to current day

The gear selector mechanism rather gunky after 15 years in service:





As well as needing cleaning up I wanted to strip and examine the selector mechanism as the gear-change was always a little notchy and certainly not as slick as other 6-speed Coupé's I've driven. I think it's mainly due to a stiff cable from the gear lever but I also want to make sure the selector mechanism is as slick as possible. Striped down into its component pieces:


All cleaned up:


The eagle-eyed will spot the broken roll-pin in the middle of the above picture. In close-up:


This pin retains the little cast-iron 'L' shape lump on the main shaft that acts upon the selector inside the 'box. Being broken it may have allowed a bit of play which would affect the action of the selector mechanism, but to what degree I couldn't say. Either way a new one was required.

The rubber boot was past its best:


New replacement sourced (listed as fitting an Alfa Romeo but it's the same part for the Coupé):


Everything painted and ready to reassemble, with new seals and bushes:


Reassembled:





Onto the exhaust manifold...



When removing it from the head it was noted that the ports are, oddly, smaller on the manifold than the head and gasket, meaning quite a restriction to exhaust gas flow as it exits the head. F.C.S.S. suggested I port out the manifold to match the head so, given that the gasket is an exact match against the head, I used it as a template to see how much material to remove by taping it in place then blowing over it with some silver paint:



Once removed this left a witness line around the port, showing 2 or 3mm around the perimeter of the port that needed removing:



I invested in some top-quality carbide burrs to rough-cut remove the material; they were so good it only took 5 mins per port, WAY quicker than I was expecting!

After:




Then refined with a stone wheel in the Dremel:


Masked up ready for a coat 'flame proof' paint:



I always smile when I see the fifth branch as it looks like such an after-thought! It's like the Fiat engineers forgot until last minute that they needed a 5-branch manifold so had to rush and just slap a fifth branch onto an existing 4-branch design

Painted & post-baking in the oven:



The downpipe is stainless but you wouldn't really tell from the 'before' pics:




It took hours and hours of polishing and is far from perfect but still looks much better for it:




The same applied to the CAT: (sorry no before pics)



The light at the end of the tunnel is edging closer...
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Old 20-01-2017, 11:34 PM   #57
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Exemplary!

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Old 21-01-2017, 02:12 AM   #58
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You've stuck with it and from what I've seen it is coming together nicely. Most people would have given up after a few hours on that gravel.
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Old 21-01-2017, 08:59 AM   #59
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First time I've seen this thread and

I had a 20VT for a few years and it's the only car I regret selling, always hankered after a plus in that colour too.

I look at classifieds now and again but with prices for decent ones still on the rise, not likely to get one anytime soon but when done, yours will likely be the best around. Loving your attention to detail and really looking forward to it coming together.

Thanks for all detailed posts and keep them coming.
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Old 21-01-2017, 11:05 AM   #60
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Some great work, I'm pretty sure I wouldn't get away with parts hanging around the house with my Mrs though, good luck with engine matey.
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