Series 2 Coupe Restoration

[nthomas1]

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

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

[RDG496]

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

Cheers

[hugh]

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!

[my69S1]

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  .

[andyps]

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.

[GlynW]

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

[lancialulu]

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!

[nthomas1]

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.

 

[andyps]

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.

[nthomas1]

It has just been pointed out to me that there are two ways of displaying posts: in chronological sequence, or most recent posts at the top.  I developed the index based on the chronological format.  I wasn't aware of the second option!  My apologies if I've confused those of you who use the other format as the page numbers will be incorrect.

If you have opted (in your profile settings) to see most recent posts at the top you'll need to subtract the page number that I've shown 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).

[Scott]

Thanks Norm for all that detailed work.

Another potentially useful tip for folk because Norm included lots of images is to instruct, say, Google to specifically look at this forum site and Norm's topic thread. Copy/Paste the following line into Google's address/search bar:

site:http://www.lancia.myzen.co.uk "report on (slow)"

Click on Images at the top of the search once results returned. Google tends to limit initial images returned for fast response time so opt for See more anyway that appears as an option below displayed images.

You should now see all Norm's images!

Click on the one that takes your interest. Depending on your operating system that image then shows enlarged in a right-hand panel; click on that image (and you may have to confirm 'visit') and it should take you straight to the appropriate page in Norm's thread. [You're taken to the head of the specific page so will have to scroll down to locate image and thus associated words].

Hopefully above instructions make sense and may be useful to someone.

[EVOCCR]

Hi, I have a similar white series 2 which I have just acquired, was the paint you used the original colour and if so could you confirm it was Bianco Saratoga.
Many thanks