Report on (slow) S2 Coupe rebuild progress

[nthomas1]

Did you make your own inner sill/strengthener or buy it in ?

Tempted to do the same when I get to doing the HF

Simon - my welder fabricated it to his own design.  He does a lot of motorsport work so the lightening/strengthening holes were a reflex action for him!  Most of the applications I've seen in the blogsphere have been just flat plates.

[lancialulu]

First sill strengthener fitted this morning.

Nice!

[nthomas1]

Three more pictures of the sill strengtheners: (1) the holes being cut with a plasma cutter, (2) forming the flares around the holes, (c) the final insert ready for fitment.   

[simonandjuliet]

I like that !

Dog has a plasma cutter and I have a press, so should be possible here in rural France as well .....

[DavidLaver]

A couple of times I've come across people with plasma cutters they don't use, a 1mm disk or an air saw being weapons of choice.  Cutting holes that neat is a great example of what a plasma does well... 

Was wondering how big a starrett hole saw went - five inches is the answer...  I expect "if it was me" I'd be trying to get a jigsaw to turn tight enough.

Looking at that press I wonder if it would punch those holes. Found tools at sensible prices for two inches.  That's got to be close?  For a 2in saw £10, £40 for the press tool.  The really big saw is £30.  I wonder how many jig saw blades I'd get through...

Turns out a tool NOT to use is a zip saw:

https://www.amazon.co.uk/RotoZip-XB-MC1-Metal-Cutting-XBIT/dp/B000CEQEZ4/ref=sr_1_9?s=industrial&ie=UTF8&qid=1522793157&sr=1-9&keywords=rotozip+saw

[SanRemo78]

Before Geoff got his plasma cutter he used to punch holes with this sort of kit - inexpensive if you're using them all the time and only doing one size, easy to use.
https://www.ebay.co.uk/itm/BGS-Screw-Hole-Punch-32-mm-For-Stainless-Steel-Sinks-Taps-Etc-3902/272251063721?epid=2255403975&hash=item3f636d8da9:g:7toAAOSwbPxXQdzG
I've never seen him using the press to form the edges though it is the easiest way. Whenever I've wanted to countersink a hole in steel or ally I've used a socket on one size, a suitably sized ball bearing. And a hammer. It works but isn't as precise as what Geoff achieves.
Guy

[DavidLaver]

Ah...so THAT'S the tool for the job...

You got me looking - and I found larger.

https://www.ebay.co.uk/itm/Exact-30515-63-5mm-M63-Screw-Hole-Punch/152940124581?epid=574846079&hash=item239bf119a5:g:JPMAAOSwOhVZtbe8

"Facom" is the other brand I saw, but quite a bit more expensive and still with 63mm as the maximum.  For "money no object" they do a hydraulic driver.

"Q Max" go to 75mm.

At the budget end Frosts have a set, and also sell the flair tools:

https://www.frost.co.uk/set-of-4-knockout-punch-set-circular-punches.html

https://www.frost.co.uk/hole-flares.html

RS have a wide range. 

"Punch/flare" yeilds three part sets like this:

https://www.ebay.co.uk/itm/Allstar-Performance-11076-Punch-Flare-Tool-2-5-8-Diameter-Hole-Steel-in-Black/232685120558?epid=1437060428&hash=item362d1d2c2e:g:4g4AAOSwYRhamhF2

[nthomas1]

Just saw this on Ebay.  My wife thinks it is very appropriate!

[D5177_55A]

Blimey, with all the Fulvia’s off the road, that guy must be a millionaire!

[DavidLaver]

Having browsed a few days ago the internet now throws similar back at me.  From their web page I like this supplier.  The "about" reads well and the opening times has "If you are looking to spend an obscene amount of money we may even open up on a Saturday morning or evening for a private viewing!"

https://www.stakesys.co.uk/hole-punches-hole-saws

Then there's the look-a-likey for a whole set and hydraulic puttler for the price of one punch...how do they do it...?

https://www.ebay.co.uk/itm/Hydraulic-Round-Hole-Punch-Kits-Metalworking-Hand-Tool-W-6-Dies-22-to-60mm/182710936112?epid=2209810059&hash=item2a8a6ba230:g:5wYAAOSwQwBZi~Z2

I still think the "if it was me" would be a hole saw, a hammer, and a bit of pipe, but interesting to see what's out there and how its done properly.  The stakesys write up on the flares was interesting - if you like that sort of thing    "Aircraft flares and automotive flares – what’s the difference?"

https://www.stakesys.co.uk/stakesy-s-sheet-metal-hole-flares

[nthomas1]

Left side almost finished.  Just some fettling to the rear wheel arch.  So that's a new subframe mounting box, half inner sill, two floor patches, sill strengthener, outer sill, and quarter wing sections all fitted, as well as patching to the inner wheel arches. Take a look at the thickness of the lead filler in the first picture....... that necessitated removing more of the wing than was originally thought necessary.

Now to the right side!

[SanRemo78]

Then there's the look-a-likey for a whole set and hydraulic puttler for the price of one punch...how do they do it...?

https://www.ebay.co.uk/itm/Hydraulic-Round-Hole-Punch-Kits-Metalworking-Hand-Tool-W-6-Dies-22-to-60mm/182710936112?epid=2209810059&hash=item2a8a6ba230:g:5wYAAOSwQwBZi~Z2

Cheap tools from China. I'm not saying the quality is bad but you may have to wait a while for them to arrive and will have problems with warranty claims... As with anything on eBay, check out the sellers feedback rating, use a credit card through PayPal so you're covered for non delivery and don't order if you're at all suspicious or need the goods quick. Also check out the item using the same description, there are sellers out there using multiple names that you can spot by their standard feedback comments, especially on negative feedbacks.
Guy

[frankxhv773t]

There might be enough lead to weigh in at the local scrappy and pay for the restoration.

[nthomas1]

My welding guy also builds and sells high-end racing simulators, so I got to drive the Col de Turini in a Fulvia while I was there today.  My car looked on enviously (or perhaps dreading the day when I get behind the wheel of it!)

[lancialulu]

My welding guy also builds and sells high-end racing simulators, so I got to drive the Col de Turini in a Fulvia while I was there today.  My car looked on enviously (or perhaps dreading the day when I get behind the wheel of it!)

I have driven CdT in my white HF with Fulvia friends on the 50th Anniversario rally its worth a go as we went up in semi darkness due to various problems. Stayed the night at the top then went down the other side in the morning sounding glorious on the multiple Fulvia overruns!