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Ive got a bit of tricky welding on my fulvia. The rear panel is in fairly good nick except all round the edge is rusty. The worst bit is the first photo above which is the cars right hand side where the rust has gone right through the panel. The rest is along the lip. This lip had a piece of trim that would hold damp and thats why its rusted. There is waxoyl over the inside so that hasnt rusted much. The weird shape of the lip makes it hard to get the shape right. The whole rear panel is available at a price but its actually fine just the edge of the lip isnt. Any ideas how to deal with this as a new rear panel wont sort it as I have only rust and holes to attach it too. would a shrinker stretcher have any use??? cheers
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fulvia series 1 1200. rolling restoration fulvia series 1 1300. definitely in bits golf Mk4 v6 4motion. weekend fun T4 transporter. daily
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vulgalour
Club Retro Rides Member
Posts: 7,079
Club RR Member Number: 146
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tricky panel/welding helpvulgalour
@vulgalour
Club Retro Rides Member 146
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I have a Fulvia now. When did that happen? I think you're thinking of the stalled Flavia project I was helping with. Not touched the thing since about November of 2015 though, it's just sat in the corner under a cover waiting for anyone to give it some love.
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From where I sit, I can't get a full idea of the details, but I would make into four pieces and then trim so that I could make a butt-weld along the CROWN. Yes, a shrinker stretcher would be a good idea.
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rude
Part of things
Posts: 537
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If you can't individually separate the panels by drilling/ cutting, cut out all the affected metal as a whole lump taking into consideration the structural integrity of surrounding panels of which you may have to support and measure/ make templates of angles and set reference points beforehand. Once you have the corner as a removed lump then plan how to dissect it into easer, more manageable parts to reproduce and then as you chop it up you can reassemble it with tack welds, offering it up to the car to check that you are headed in the right direction. Trick is to try and make it out of as less bits as possible and keeping it tacked together until it gets put back on the car. I stared at this bit for months... late at night, you could hear it giggling at me... before I ripped it out.
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1986 Haunted BMW E24 635CSi 1999 Povo spec BMW E36 1.8i Touring Work Hack 2001 Petrol annihilating Discovery V8 2000 Jaguar S Type 3.0 V6 ~NEW~
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thanks for these I have been slowly going through the panels thread. Great stuff.
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fulvia series 1 1200. rolling restoration fulvia series 1 1300. definitely in bits golf Mk4 v6 4motion. weekend fun T4 transporter. daily
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I have a Fulvia now. When did that happen? I think you're thinking of the stalled Flavia project I was helping with. Not touched the thing since about November of 2015 though, it's just sat in the corner under a cover waiting for anyone to give it some love. Ive been lusting after a Flavia for years. A mate had one and it was the coolest car. I hope your new fulvia is good ...got any pics of it?
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fulvia series 1 1200. rolling restoration fulvia series 1 1300. definitely in bits golf Mk4 v6 4motion. weekend fun T4 transporter. daily
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From where I sit, I can't get a full idea of the details, but I would make into four pieces and then trim so that I could make a butt-weld along the CROWN. Yes, a shrinker stretcher would be a good idea. Ive got some more pictures of it. And this is the other side which is easier to see what it should be like maybe I should just dive in and go for it. ?
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fulvia series 1 1200. rolling restoration fulvia series 1 1300. definitely in bits golf Mk4 v6 4motion. weekend fun T4 transporter. daily
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Quote ............If you can't individually separate the panels by drilling/ cutting, cut out all the affected metal as a whole lump taking into consideration the structural integrity of surrounding panels of which you may have to support and measure/ make templates of angles and set reference points beforehand. Once you have the corner as a removed lump then plan how to dissect it into easer, more manageable parts to reproduce and then as you chop it up you can reassemble it with tack welds, offering it up to the car to check that you are headed in the right direction. Trick is to try and make it out of as less bits as possible and keeping it tacked together until it gets put back on the car.
I stared at this bit for months... late at night, you could hear it giggling at me... before I ripped it out.
I really get the giggling at you bit. Mine is out right laughing and pointing the finger too....Hahaha
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Last Edit: Feb 7, 2017 18:23:54 GMT by lukestew
fulvia series 1 1200. rolling restoration fulvia series 1 1300. definitely in bits golf Mk4 v6 4motion. weekend fun T4 transporter. daily
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Start by picking a spot and committing to the job.
I would pick the worst corner, go mental with the wire wheel until I could get a good look at what is left under the paint, filler and rust, and make a plan from there.
Then break it down into whatever small pieces you feel comfortable forming with whatever tools you have, and weld the bits together. God made angle grinders, die grinders and fillers to clean up the rough edges.
first time wont be prefect, but you will get better when you do the other side.
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Last Edit: Feb 7, 2017 19:08:51 GMT by bjornagn
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vulgalour
Club Retro Rides Member
Posts: 7,079
Club RR Member Number: 146
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tricky panel/welding helpvulgalour
@vulgalour
Club Retro Rides Member 146
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I have a Fulvia now. When did that happen? I think you're thinking of the stalled Flavia project I was helping with. Not touched the thing since about November of 2015 though, it's just sat in the corner under a cover waiting for anyone to give it some love. Ive been lusting after a Flavia for years. A mate had one and it was the coolest car. I hope your new fulvia is good ...got any pics of it? I don't have a Fulvia. I don't know why people think I do XD. The Flavia above might be available if you're interested, needs quite a bit of bodywork and the brakes looking at but all the important difficult to get bits are still there and in good order and the floors and inner sills are in remarkably good condition considering how much filler was put on the outside of the thing.
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Last Edit: Feb 7, 2017 19:09:55 GMT by vulgalour
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I don't have a Fulvia. I don't know why people think I do... That would be my fault - apologies to everyone for the confusion I knew there was a Lancia parked at yours that didn't belong to you and thought you might be able to advise OP or suggest where to look for info & parts. It was all done with the best intentions but very poorly worded so folk got the wrong idea. Oops!
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vulgalour
Club Retro Rides Member
Posts: 7,079
Club RR Member Number: 146
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tricky panel/welding helpvulgalour
@vulgalour
Club Retro Rides Member 146
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Funnily enough, there was a Fulvia that stayed with us very briefly, in a pale blue-grey, but that had already had a lot of welding and paint thrown at it before we did anything at all with it so... yeah. All I know is parts are almost impossible for most things, even ordering from Italy, people charge through the nose for anything with a Lancia tag on it and quite often the aftermarket stuff is of such poor quality you're best sticking with the worn or even broken original bits and pieces already on the car.
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Ive been lusting after a Flavia for years. A mate had one and it was the coolest car. I hope your new fulvia is good ...got any pics of it? I don't have a Fulvia. I don't know why people think I do XD. The Flavia above might be available if you're interested, needs quite a bit of bodywork and the brakes looking at but all the important difficult to get bits are still there and in good order and the floors and inner sills are in remarkably good condition considering how much filler was put on the outside of the thing. As much as I would love another Lancia project I'm sure my missus would "cut them off and be wearing them as earings" before I'd even finished the sentence ....theres this guy who has got a great car for sale...
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fulvia series 1 1200. rolling restoration fulvia series 1 1300. definitely in bits golf Mk4 v6 4motion. weekend fun T4 transporter. daily
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Those pieces can be made from flat sheet without a shrinker.
Search 'bedford' in the readers rides section. The roof gutter pieces I made are pretty similar to those and I made them with a vice, a hammer and a bit of pipe.
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Those pieces can be made from flat sheet without a shrinker. Search 'bedford' in the readers rides section. The roof gutter pieces I made are pretty similar to those and I made them with a vice, a hammer and a bit of pipe. just had a look at that. Fantastic work ,Right I'm going to have a go. Very inspirational....exactly why Ive posted about the work on the fulvia to get some MOTIVATION. Cheers big smile on my face.
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fulvia series 1 1200. rolling restoration fulvia series 1 1300. definitely in bits golf Mk4 v6 4motion. weekend fun T4 transporter. daily
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Those pieces can be made from flat sheet without a shrinker. Search 'bedford' in the readers rides section. The roof gutter pieces I made are pretty similar to those and I made them with a vice, a hammer and a bit of pipe. just had a look at that. Fantastic work ,Right I'm going to have a go. Very inspirational....exactly why Ive posted about the work on the fulvia to get some MOTIVATION. Cheers big smile on my face. Glad it helped. If your a little unsure there is no reason you cant try and make a piece first before you cut the rot out. Doesnt matter if it doesnt fit, just a practice piece that might even work out. Draw it our on some card then cut the steel a little big (not too much) and try and hammer the folds in little by little. It will want to bend along its length but you should be able to turn it over and knock the bend back flat. Just have a play and see how the steel reacts to the hammering. As long as you have the flat chisel type body hammer and can create support somehow in the vice so there is a gap under to fold to hammer into, then its doable. Fold the whole length a bit at a time moving the work so the fold you are creating stays paralel with whatever your supporting the work on. Honestly, its easier to do than it is to explain Just in case you happen to be local, where are you?
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Last Edit: Feb 10, 2017 9:36:55 GMT by VW
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Feb 10, 2017 19:30:11 GMT
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Thanks for that I'm in Sussex not far from Worthing
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fulvia series 1 1200. rolling restoration fulvia series 1 1300. definitely in bits golf Mk4 v6 4motion. weekend fun T4 transporter. daily
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Feb 10, 2017 20:09:15 GMT
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Thanks for that I'm in Sussex not far from Worthing Ah, I'm in chesterfield. If I still lived in hove I could have helped more.
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Have you checked with clubs if repair sections are available?
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