Report on (slow) S2 Coupe rebuild progress

[my69S1]

Excellent job Norm, it looks fantastic.  I hope mine looks half that good when I finish putting it back together.  I know I'll have lots of questions during the summer.

Have a great summer enjoying your car.

[andyps]

That looks fantastic Norm, I hope you get lots of opportunities to enjoy it this year and hopefully we may meet at an event somewhere soon.

[nthomas1]

Thanks for all the comments chaps!

[Neil]

Well done Norm, it looks fantastic, tou have done a fabulous job on your Fulvia, enjoy!  What's you next project?!

[nthomas1]

Thanks Neil.  I want to concentrate on driving it now! No more restorations, but I do fancy building one of those lovely CMC 1/18 scale D50s.  I've been researching the Fulvia F&M Specials and am wondering about writing a book on them: the Reparto Corse cars, T&S, and subsequent evocations.  I've researched the racing history of barchettas from 1969 through 1973, and I have a spreadsheet of the characteristics of the 14 evocations that I've identified so far, have built a fairly extensive library of photographs, and am in discussion with a couple of people in Italy who have built examples.  It's a fascinating subject (to me at least) but I'm just not sure yet whether I can work my way through the copyright issues on the use of photographs.

[frankxhv773t]

I drool over those CMC D50s too but I think all those cross head screws need replacing with more period slotted screws.

I was delving into the fascinating world of F&M specials myself recently to rescue a derelict 1:43rd scale model. I'm not up to making my own replacement decals yet so couldn't do a body repaint as I would have liked to. Whilst there is much I would have liked to do better it's the best my arthritic hands could cope with at the time.

[nthomas1]

That's nicely done Frank, and a good choice: the "muso blanco" from the Nurburgring.  You need to mount it a couple of centimetres above its base to recreate the famous picture of it.  Will need a driver of course!

[nthomas1]

***INDEX***
This 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.

Format is topic, followed by thread page number(s).

Note that these page numbers are correct if you view the thread posts in chronological sequence.  If you have opted (in your profile settings) to see most recent posts at the top you'll need to subtract the page number from 52 to get the right page.  For example where I've said an item is on page 17, that will convert to page 35 (52 minus 17).

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

[fay66]

***INDEX***
This 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.

Format is topic, followed by thread page number(s).

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

Thank you Norm,
Labour of love in its own right!
Brian
8227