S2 fulvia assembly

[Richard Fridd]

I remember a pressurised Fulvia brake fluid reservoir demonstrating immediate paint stripping to a newly finished front wing a while ago.

 Richard

[nistri]

A ball park value for the clutch is to have one inch of free travel at the pedal. Make sure that the cable is greased.

[Keithver]

Richard - It must have been terrible to see the damage - I was then very lucky
Andrea - the clutch takes very late. I have screwed the pedal adjustment about 1/3 out and got a good couple of turns on the wingnut. Which way do I turn the wingnut to get the clutch to take earlier. (the clutch plate and thrust bearing are new)

Am I being slow or is there a trick to fitting the wheel center pieces. I pushed the inner backing plate (with O ring) into the center from behind the wheel and then bolted the chrome logo disk to the outside. I can’t get the wheel onto the hub (front or back). The center backing plate doesn't go over the wheel hub far enough to insert the bolts

[nistri]

To give more free travel to the clucth pedal the wing nut on the cable should be undone. I trust you fitted the correct size clutch disc and cover.
I have not seen your wheels and I assume these are Cromodoras, however there were several reproductions of the wheel centre cup, some of them had studs too short. In this case one just pushes the cups on the wheels, they should not come loose.

[Keithver]

thanks Andrea. The wheels are the standard steel wheels

[nistri]

Hi Keith, for your standard steel wheels I suspect that your centre cups might not be original. I have alloy Cromodoras on all my S2 cars but, if I remember correctly, the steel wheels have a metal brace on the inside to fix the cups. But I could be wrong here without checking my spares. As I am away from home now, I fear I cannot do it immediately. Did you check your spare wheel?

[lancialulu]

Hi Keith, for your standard steel wheels I suspect that your centre cups might not be original. I have alloy Cromodoras on all my S2 cars but, if I remember correctly, the steel wheels have a metal brace on the inside to fix the cups. But I could be wrong here without checking my spares. As I am away from home now, I fear I cannot do it immediately. Did you check your spare wheel?

Andrea you are correct steel hub caps have an inner steel cup through which the centre stud of the outer cap passes so the steel cup holds the cap in place.

[Keithver]

I’m feeling a bit sheepish about the wheel centers. I had them coated so they looked beautiful and new.
After I had persuaded them onto the hubs a couple of times with my rubber mallet, the fit improved. The O ring I used was 5mm thick and didn’t help at all. I need to try a thinner one, maybe 2mm. As you can see in the photo the centers are in place.

The clutch has now been improved. I screwed the adjustment on the pedal side of the cable almost all the way out. (extending the length). I have just over 10mm of cable exposed under the bonnet when the pedal is fully depressed. There is a drawing in the Concise Workshop Manual showing 120mm between the cable end housing and the center of the clutch arm. Now that I have that set up, I have a clutch that feels good

I don't know why some images get rotated by 90 degrees

[Simon B]

Had to buy a new wheel centre cap and some o rings after an emergency puncture repair en route to a ferry, flustered left the centre cap in place and the tyre fitter twisted the stud off  I guess I could have done the same, anyway the replacement o rings from Omicron were 5mm dia.

[Keithver]

Simon - now that I have my 5mm O rings in the correct position, inside the chrome cup, all fits and looks great - thank you

[Keithver]

The good news is that the car is complete. 
I took it for its first short drive yesterday. About 1 km. It is un-licensed, so I didn’t want to push my luck too far.  The engine pulled well up the hill and the brakes worked well down the hill. All very exciting.
I have my temporary permit to drive it to the testing station on Wednesday for its roadworthy test. I need Police clearance as well because I have changed the engine. I re-build the original one (the one from the factory) and have that installed. It seems as if that is just a formality.
At 6’8” tall I am able to fit into the driver’s seat. Admittedly the seat is pushed all the way back and the backrest is well reclined.

[HBG]

Looks great!

[lancianut666]

Nice!

[Keithver]

My problem with the engine not firing on no.1, now seems to be resolved. It was running very rich (Thanks Andrea). Using a Colour-Tune to get a blue flame, I had to screw the Idle/pilot screw all the way in and then back out just over an 1/8th of a turn.
Is this small opening still acceptable?
My dwell angle is at just over 58deg. And the timing sits on the 8deg mark using a timing light.

[Keithver]

Police clearance and roadworthy went flawlessly. She is now street legal and ready to roll.
I have already done 200km. (taking it gently for the running in period of course).
For the first +-50km I had funny gearbox noises. It sounded as if the bearings in certain gears where running dry. After that, almost as if there were air bubbles in the gearbox oil, the noises disappeared. She now runs very quietly and is a pleasure to drive. Cant wait for the running in period to be over to see what she is capable of