Kev's workshop projects

[KevJTD]

this is a handy little bracket for the gravity fed spray guns which are a bugger to load up with paint.
filter funnel sits on top and paint just flows nicely into gun pot.
had to try and balance it all in the vice before getting this, best few quid i've spent in a while

[KevJTD]

got a few more hours in this afternoon.
started off doing some sanding, quite a tedious and boring job but good exercise
drivers front wing to front panel repairs about done.
front doors got the trims and handles etc removed then sanded back any dead bits.
passenger door wasn't too bad but drivers one had a dent or two along the trim line so needed more work. looks like there's a ton of filler in it but it's really only a skim to sort one what couldn't be knocked out

[KevJTD]

after all that sanding i thought i'd have a look at what i'd been putting off for a while...the boot lip.
with a trim across the back edge it looked like a new angled edge section would be needed across most of the boot lip but it being curved in both directions meant it looked a tricky job, hence me putting it off for a while.
looking again more closely it was apparent that it wasn't a clipped in trim piece like the side mouldings but a "U" shaped trim over a seam, not unlike those on mini's
once it was carefully prised off the corrosion damge was visible

[KevJTD]

once the knotted wheel had attacked it the damage wasn't as bad as it looked
by no means the whole lip needing replacing and just a few sections of the underside

[KevJTD]

started off the repairs on an easy bit, right hand end of the upper part.
lower part was ok there.
doing it in smaller sections should help stop and distortion building up.

bit awkward to chop it all out without runing the remaining lip but was done a repair patch was made up and welded into place. spot welded on the lip and mig around the rest.
once ground back the repair has blended in pretty well.
hopefully the rest of the boot lid will go as well

[KevJTD]

got to try and figure out how the weather strips come off at the door tops, would have been simpler to leave them on and mask round but it's not as neat a job, and besides which there is rust spreading underneath the trims so they've got to come off.
had a look under the seals and there are some small screws and even smaller nuts holding them on, look like about 4mm spanner size! will need by little socket set on that job, and some crossed fingers...

[Kegsti66]

Boot repair went in nice Kev.
Will you paint the Lancia in Celly or 2 pack paint ?
Enjoying your progress mate.

[KevJTD]

2 pack paint mate.
steadily coming along, wish i could spend more hours up there....guess i could if i tried harder

[Alfasixnut]

More good work there Kev!

[KevJTD]

another weds afternoon and some more progress.

first job was to try and remove the outer weather strips from the front doors so the rust under there could be attended to.
the stainless trim is held to the door by a series of very small nuts, 5mm socket size as it turned out. amazingly they all came undone despite it looking like a very fine thread on about a 2mm stud, or should i not be surprised anymore by how well made this car is?

although the rust looked bad with the trim on it wasn't at all bad once i could get at it. didn't even need any new metal letting in, just cleaned up and treated.

doors were then given a going over with a fine pad and cleaned thoroughly before being masked off
2 pack etch primer was sprayed on then which gives the next layers something stable to adhere to, stope paint flaking off which can happen on bare steel areas that aren't treated.

[KevJTD]

whilst the doors were outside drying off i did some more to the boot lid egde.
another similar sized patch near the centre which needed the top part repairing plus the underside lip needed making up. made up to overlap each other for strength rather than a joint in the same place, bit like building a brick wall
once in place i decided to carry on and finish the bottom lip up as most of it needed replacing across to the n/s edge. kept the odd inch or so of the original where it was still good so as to make sure of decent alignment.
i'll finish the rest off next time.
happy with the way the boot is going though, looked like it might be an awkward one to repair as it curves in 2 directions across its' width.

[KevJTD]

boot lid all welded up at last, n/s edge had to have most of the upper part replaced. not as easy as it could be due to the way it curves in 2 directions but happy enough with the result
got a layer of filler on it but due to the heat today it wasn't easy, was going off before you could get it applied well!

[KevJTD]

nice afternoon for sanding filler down....
had to be done though, need to keep ticking along.
took a few blends to get the shape consistant plus also noticed the top edge had a ripple near the centre, don't know if it was there before or if it came from the welding. either way it's smoothed out now.

almost down to the last bits of welding repairs now.
lower rear panel has a few bits that need repairing, a new panel would have been nice but there just aren't any anywhere so repairing what we have is the only way.
lower n/s/r 1/4 panel needed to lose the bottom few inches along with a few inches of the rear panel. new seam joint made too, no point in trying to save the rotten bit.
not a very pretty repair but it'll come right.

got some etch paint on the boot to seal it all in until the primer goes on

[KevJTD]

as we're near the end of the welding i attacked the engine bay today.
plan is to get it all painted out so it looks nice and presnetable.
trouble is there are cables and wires everywhere.

took a lot of effort but happy to say that every item got either removed completely or pulled back into the car.
heater box needed to come out which wasn't that easy being tucked behind the lower dash which had to come out first, but once that was out the wiring loom could be pulled into the car.
loads of other items to remove but all came out nicely, only 2 stubborn bolts that needed grinding out

most of the engine bay has come up ok without anymore welding needed, bit more cleaning in the awkward areas before any paint can go on

[KevJTD]

not quite all the welding caught up with..
the n/s bonnet hinge had sheared off some time back so it needed welding back into place.
there was also a crack in the panel which got welded first off.

the hinge was then carefully measured and lined up before being welded back in place. i made up a bracket to link the 2 hinges together to make sure that it would move in line together to also double check alignment. once happy it got some decent welds all around.

[PETROLHEAD]

Top man!

Bet you're glad that boot has come out the way it did, spot on.

Remarkable isnt it, how far from the reputation and rumour this Lancia had turned out to be, pretty bloody marvellous!

Richard is having a cracking 2015 i reckon!

[KevJTD]

engine bay got etch primed last time out, i'll carry on under there again soon.

this afternoon i started another dreaded job....cleaning off all the old underseal and crud from the rear wheel arches and boot floor.
happy to report, no amazed really, that i found no more rot! mega car this little 70's lancia

mind you, i did look like a coal minor after about 4 houirs with the grinder and scraper, messy job to say the least.

a little more cleaning up to do then etch prime it before protective stoneguard going back on.

[Spacenut]

Who would have thought, 1970s Italian rust-proofing that actually works!

That is going to be one sweet motor when it's done

Lauren

[KevJTD]

unusual friday night, managed to get a couple of hours up at the unit which should help alleviate the need to do a few hours on sunday morning.
will still go up there to do some seam sealing before having an hour or 2 at cadwell which is handily 15 mins away from the unit, my nephew is racing an R1 i think, or an R6 at least, plus the superkarts are on so want to see those missiles around the mountain

so tonight i welded up the rear arches where the lower edge had rusted away.

decided then to mix some more etch primer up and give everywhere a layer or two.

[KevJTD]

i'd sorted the engine bay last week or before, can't remember when, all blends into one nowadays. think it was last saturday...
took an age to rub it all down and treat it, certain amount could be done with sanders but a lot had to be done by hand.
anyway, it's got etch primer on it now to prtoect it whilst other jobs get done

[KevJTD]

so the bit of progress today was to sand down the front panel on the outside face to see hoow much repairing was needed, thankfully and amazingly it is all in very good condition.
this little 70's lancia really is made of stern stuff and is doing all it can to keep me motivated
the n/s wing bottom always looked to have a bit of rot but didn't look as bad as the o/s one was, so it turned out. most of the wing bottom was still very solid, just a bit on the arch edge and the return underneath.
must be pretty near the end of the welding now.
know i've not touched the rear doors yet but i've had a good look at them and they won't need any new metal letting in
just depends if anything else creeps in when the body is sanded off, but we're pretty much ready for the paint prep stage

[Kegsti66]

Kev, do you know the history of this car? As it has been well cared for.
Should be great when it is done.
Top man.

[Bluesuit]

looking good Kev,

Did you see Car SOS the other day? - they restored a Lancia Flavia - looked nice at the end. Though I wasn't keen on the red wheels which I think would have looked better in Silver - interesting to see some of the bodges they found on what seemed a solid car!

[KevJTD]

bodywork on the menu today.

there was a crease in the o/s/r 1/4 where something had dropped on it i'd guess, who knows when.
first off i sanded the paint away with the long block to see where any high points were then hammer/dollied it fairly straight as luckily the inside was accesible. didn't need much more than s kim of filler to set it straight so a nice easy job

[KevJTD]

front wings were on the list then as i need to get some more grit to blast the rear panel, so working on opposite ends isn't as daft as it sounds, honest

passenger wing didn't look too bad around the arch lip and across the main part but looks car often be decpetive. it had a good 1/4" of filler all across it.
once i'd ground it all away i found some more holes, surprise surprise
didn't take long to weld in some plates though then give it a layer of fibre-glass

that takes a bit longer to harden off so left that side for now

[KevJTD]

the drivers side wing was much better, arch lip in great condition but just a few dents to strighten out along the trim line and arround the headlamp edge.

did a few more smaller areas so the bodywork is ticking along nicely now.

[Kegsti66]

[KevJTD]

boot lid has now been removed to clean up the water channel around the seal, it was full of lod pine needles so could have been hiding all sorts of issues.
thankfully, and not unsurprisingly given the great condition of the car, it wasn't too bad.
just the bottom corners near the rear panel needed some attention.

usual process, cut out the rot.
make a patch,
weld it in
grind it smooth

[KevJTD]

not quite as bad on the drivers side, further along to the back but not continuing up the side.

it may seem like overkill to repair what will be covered by the boot seal but if you don't then water will leak into the boot.

[KevJTD]

the fulvia badge had been hiding some rot around its right hand pin so a big square was cut out and a plate welded in