Report on (slow) S2 Coupe rebuild progress

[frankxhv773t]

It would be laborious but to avoid distortion perhaps you could cover the original in clingfilm then lay up a layer of glass fibre over the outer face to provide a hard surface support.

[nthomas1]

Thank you Brian and Frank for your input.  I’ve decided that my parts are not in bad enough condition to warrant the expanding foam treatment and I’ve decided on a less drastic approach. 

1. Cut away any loose foam or backing.
2. Scrape and wire-brush areas where the metal reinforcing plates have rusted.
3. Apply rust converter to the affected areas.
4. Apply Hammerite once the converter has dried.
5. Apply a bead of adhesive along the join between metal and foam to stabilise and limit any further surface breakdown.
6. Fit new hardware ready for installation

The steps are shown in the first six pictures below. The part shown is the lower dash panel that fits to the right of the steering column (on a RHD car).  I’ve used the same approach on the main lower dash panel, the top dash panel, armrests, and top rear trim caps.  I’ve bought new door cards and door caps as mine were beyond refurbishment.

When I bought the car the fuse cover panel was damaged and there were no side wings fitted to the console.  I managed to buy two incomplete console assemblies and have cannibalised them to build up one good one - shown below. It’s interesting to see the design variations between different  consoles: black versus bright heater air grill; large holes (for cigarette lighter etc) either side of grill versus small attachment holes only; different methods of top attachment for the console wings; and square versus rounded bars on the fuse cover grille!   

Now that all of the interior trim has been refurbished it’s time to build up the seats.  The (only) good thing about being in the over-70 Coronavirus high risk category is that my voluntary self isolation is providing plenty of time to work on these jobs!  I don't have any symptoms and my self isolation is just to keep away from any people who might be infectious.  I have to be extra careful as my wife is in an even higher risk category as a result of a long-standing lung condition. I hope all Forum readers are bearing up well at this difficult time. 

[simonandjuliet]

Enjoying all the detail and as you say, there is an up side to being isolated ....

Problem here is that the resto's are all closed as well - imagine how hard the French find this .....

Stay safe !

[nthomas1]

I built up the front seats today.  I reported a while back in this thread on the refurbishment of the frames and sliding/locking mechanisms.  The squabs and backs were re-trimmed by Brian Cates two years ago and have been sitting wrapped up on a shelf ever since.  Of the four pieces of the recliner mechanisms, three are what came with the car when I bought it.  I managed to buy a second-hand replacement for the fourth which was extremely badly pitted and with large flakes of chrome peeling off.  The only fiddly job was repairing, with metal putty, a couple of the black plastic washers/spacers that fit between the seat backs and the recliner mechanisms. 

That's the last of the internal trim jobs done so I'll be back to working on the glass, and seals on the door apertures next.

[nthomas1]

Some fiddly jobs completed.  Bonnet and boot catches cleaned and given a coat of clear lacquer. The boot stay was refurbished and fitted a while back, but I took it off today to lacquer it with the other bare metal parts.

[nthomas1]

I'm now working on the fuel system.  I've de-rusted and painted the filler neck and hose guard, and cleaned up the fuel sender.  The tank is ready to fit, but I have some questions about the filter attached to the drain plug.  I have two tanks: one that I've had refurbished and a spare that's not in such good condition.  Looking at the drain plugs, the one in the refurbished tank has no filter, and the prongs either side are long.  The one with the spare tank has shorter prongs and what looks like a home-made gauze filter, though it looks like it's been sprayed with black paint at some time! It does not look removable. 

My questions are:
1) Are gauze filters readily available, and if so are they a Lancia design, or available as after-market?
2) How would a replacement filter be attached? Do they just clip in?
3) Am I right to assume that the top of the filter should be above the bottom end of the pickup pipe that's visible just inside the hole for the drain plug?

I'd greatly appreciate any pointers as I'm in new territory here!

[lancialulu]

Hi Norman

Yes the filter should cover the pick-up pipe. You can get replacement filter for the in line glass fuel filter - something like this

https://www.ebay.co.uk/itm/CHROME-INLINE-FUEL-FILTER-CHOOSE-SIZE-6MM-8MM-10MM-UNIVERSAL/362841267896?var=631984875716&hash=item547b065eb8:m:mTOvbiZ7TSLTwuMZSD8858A

You need to check the dimensions as there are a few about. But you can wire these in to the ears of the drain plug.

[simonandjuliet]

Hi Norm
It looks like you are planning to replace the Cavis pipes, you can renovate them if you want to - gentle warming to make them supple again and careful cleaning with acetone - it will remove the writing if you rub too hard

The original filters had a gauze and rubber(?) ring around the top that the pick up pushed into, I think I have one on the shelf to photograph

Maybe, as Tim suggests, not get too worried about the tank filter and put an inline filter further along the pipe

[jimbo64]

Hi norm there is a thread  on this somewhere it involves two small oileals and a bit of fine mesh all from eBay I have done this but it’s packed away here’s two pictures from the guy that did it

[jimbo64]

Have a look at these Nitrile Rotary shaft oil seals
inner diameter 8mm outer 19mm, 4mm thick - they appear to be prefect as there is a groove into which the gauze will sit (once I get some)

http://simplybearings.co.uk

[nthomas1]

I do have an in-line filter.  At least I assume that's what's in this picture of my engine bay pre strip-down.  The pipework is far from elegant but I'm concentrating for the moment on understanding what's in the boot before understanding what's under the bonnet......  which is actually all in a cardboard box at the moment!

Jim, thanks for your suggestion.  Looks interesting.

I may go along with your suggestion, Tim and Simon, to dispense with the drain plug filter if I can't readily find/make one.  Always prefer belt and braces though.

Simon, is there any reason to stay with the original Clavis (never heard that term before) pipes, given that I've already bought replacements?

[lancialulu]

Maybe, as Tim suggests, not get too worried about the tank filter and put an inline filter further along the pipe

Just confirm the inline filter I mentioned was because you can buy replacement cartridges that fit the Lancia drain plug assembly.....

[neil-yaj396]

Norm, trust you will be replacing all those plastic fuel lines? They don't look ethanol proof.....

[Neil]

Norm, will you be using a stand mechanical pump or the extra one you have in the photo.  Omicron stock the Cavis pipe, it starts off blue then turns more green over time it is quite flexible to start with but does harden, as for ethanol proof unknown.

[nthomas1]

Tim, thanks for the clarification on the filter.  I admit to having been confused but that’s not unusual!  I’ve ordered one of the replacement filter elements from the company you mentioned and will see if I can fit it to the drain plug.

Neil P,  yes I’ll replace the pipes.  The blue Cavis pipes for the boot expansion box that I showed in the earlier picture were bought from Omicron, so I’ll go back there for the engine bay ones.

Neil S, I could very much do with some advice on the fuel pump situation.  The car came with the Facet electric pump shown below, with the see-through fuel filter one side of it and the silver Sytec FreeFlow device the other.  Is that Sytec device also a filter, and, if so, does it make sense to have two?

Also, does the electric fuel pump replace or supplement the standard mechanical one?  I’d assumed the mechanical pump stays connected.  

Finally, Does the electric pump get wired in for continual use, or via a switch so that it is only used to supplement the mechanical pump during engine starting?

Help with all of this much appreciated.