Fiat Coupe 16V Turbo restoration project
Discussion
Drivers side headlight removal.
Open bonnet.
Undo the two 10mm bolts and two 10mm while supporting the unit.
When undone remove the headlight and unplug the leads.
Should take about a minute.
Passenger side headlight.
Bonnet's still open.
Undo the 10mm bolts, undo the one 10mm nut and swear because the forth lug is held on with black silicone.
Use a putty knife and a rubber hammer to knock the lamp free without breaking the lug itself.
Swear some more because the rear inner lug nearly snaps off.
Trim the excess black silicone off with a Stanley knife.
Repair the nearly broken off lug with Q-Bond.
Swear some more about the pandemic use of black silicone by idiots who don't deserve Oxygen let alone a bloody car.
Should take about an hour depending on how much you swear and if the Police are called out.
Open bonnet.
Undo the two 10mm bolts and two 10mm while supporting the unit.
When undone remove the headlight and unplug the leads.
Should take about a minute.
Passenger side headlight.
Bonnet's still open.
Undo the 10mm bolts, undo the one 10mm nut and swear because the forth lug is held on with black silicone.
Use a putty knife and a rubber hammer to knock the lamp free without breaking the lug itself.
Swear some more because the rear inner lug nearly snaps off.
Trim the excess black silicone off with a Stanley knife.
Repair the nearly broken off lug with Q-Bond.
Swear some more about the pandemic use of black silicone by idiots who don't deserve Oxygen let alone a bloody car.
Should take about an hour depending on how much you swear and if the Police are called out.
So the N/A Coupe postmortem continued to a conclusion today.
But first I had to improvise.
I had let someone borrow my M socket set, they were returned with a broken M12 and guess which one I need to undo the head bolts?
The closest to it is my T55...
...but the fins aren't wide enough and the bit wobbles.
To remedy this I used a folded sheet of kitchen roll...
...to fill the gaps and it worked brilliantly.
So the postmortem.
Some of the head bolts weren't torqued down properly. 1, 2, 9, 10 were to spec', 5, 6, and 8 were nowhere near. 3, 4 and 7 were close enough to be okay. Water had got into cylinders two and four and where the car was sat the liners are ruined. So bad the pistons are rusted solid.
Chances are it only lost enough water to evaporate while the car was in use but filled the cylinders as she was sat. The head looks to be in fine fettle so I'll be pulling the valves out and polishing the ports before deciding what to do with it.
But first I had to improvise.
I had let someone borrow my M socket set, they were returned with a broken M12 and guess which one I need to undo the head bolts?
The closest to it is my T55...
...but the fins aren't wide enough and the bit wobbles.
To remedy this I used a folded sheet of kitchen roll...
...to fill the gaps and it worked brilliantly.
So the postmortem.
Some of the head bolts weren't torqued down properly. 1, 2, 9, 10 were to spec', 5, 6, and 8 were nowhere near. 3, 4 and 7 were close enough to be okay. Water had got into cylinders two and four and where the car was sat the liners are ruined. So bad the pistons are rusted solid.
Chances are it only lost enough water to evaporate while the car was in use but filled the cylinders as she was sat. The head looks to be in fine fettle so I'll be pulling the valves out and polishing the ports before deciding what to do with it.
Ribe M12 I'd lent it out and basically forgotten who to. 
Thanks for the head tip. I'm probably just going to clean it up and mothball it in case I ever loose a belt.
The Coupe has issues starting sometimes. I thought this down to the coilpack, crank sensor or old fuel. The old MOT gives an oil leak as an advisory for the last four tests. I had no idea these were related.
The paint job on the cam' cover is. For want of a more polite term of phrase complete and utter
. As this was where the oil was leaking from and I have the original cam' cover from the N/A car it was destined for the bin from the first time I saw it.
Once I took the plug cover off I noticed a few things. Some of the bolts had no washers and weren't holding the cover down properly (at all). This caused the external leak the MOT guys were advising about and the one in the middle of the cover was tight but about 5mm too long also with no washers. I pulled the spark plug caps off to discover number two and number three plug chambers were full of oil. I took the cam' cover off to see that instead of spending £20 on a cam' cover gasket set and "O" rings my old friend silicone was applied. I pulled the plugs so some of the oil dropped into the cylinder and I could mop the rest and clean the plugs before fitting the newly painted cam' cover.
It's still the wrong colour (I had some wheel silver left in the shed) but a million times better than it was (make that a billion when I put the new belts and original cover on as well) and now it won't leak oil as I've used the right bolts and washers with a new gasket set I bought with the money from the gash spoiler (yep some mug bought it). With clean plugs she starts first turn of the key. She smoke like Molly Bindley for a while. Next I'll fix the flexi-pipe and fit the more grown up exhaust so I'll stop setting car alarms off in the next village.
Thanks for the head tip. I'm probably just going to clean it up and mothball it in case I ever loose a belt.
The Coupe has issues starting sometimes. I thought this down to the coilpack, crank sensor or old fuel. The old MOT gives an oil leak as an advisory for the last four tests. I had no idea these were related.
The paint job on the cam' cover is. For want of a more polite term of phrase complete and utter
. As this was where the oil was leaking from and I have the original cam' cover from the N/A car it was destined for the bin from the first time I saw it. Once I took the plug cover off I noticed a few things. Some of the bolts had no washers and weren't holding the cover down properly (at all). This caused the external leak the MOT guys were advising about and the one in the middle of the cover was tight but about 5mm too long also with no washers. I pulled the spark plug caps off to discover number two and number three plug chambers were full of oil. I took the cam' cover off to see that instead of spending £20 on a cam' cover gasket set and "O" rings my old friend silicone was applied. I pulled the plugs so some of the oil dropped into the cylinder and I could mop the rest and clean the plugs before fitting the newly painted cam' cover.
It's still the wrong colour (I had some wheel silver left in the shed) but a million times better than it was (make that a billion when I put the new belts and original cover on as well) and now it won't leak oil as I've used the right bolts and washers with a new gasket set I bought with the money from the gash spoiler (yep some mug bought it). With clean plugs she starts first turn of the key. She smoke like Molly Bindley for a while. Next I'll fix the flexi-pipe and fit the more grown up exhaust so I'll stop setting car alarms off in the next village.
I would like to say I've taken the old exhaust off the Coupe and fitted the one from the donor car; but I would not describe what removed as an exhaust. At best I would call it a tragedy.
The middle box had been replaced with scrap yard bends that went under the handbrake cable instead of over it so that's why those need replacing.
Pigeon crap welding that my nephew could have done better when he was six whilst wearing a blindfold. My guess is it was done on the car by someone who thought welding was something you need a pre-nup' for.
And of course the Chavesty back box was held in place with silicone before being pigeon crap welded.
It's more than fair to say the donor car paid for itself today.
Once fitted my mood was lifted so I finished the cam' cover. I filled the scripted sections with blue enamel paint yesterday and rubbed the silver from the blocks so it has a straight brushed Aluminium effect (not good enough metal to mirror polish) and where some of the silver paint has dropped into the blue it looks aged. Almost like it's supposed to be there.
While I was under the car I noticed a few holes in the floor that need addressing. Where the wiring loom has had clips drilled into the floor water has got in and between the metal and the under-seal so I have a couple of playing card sections to cut out and weld up. I'll need to take the carpet out and go from inside lap welding a slightly bigger patch and lapping from underneath as well.
Now do I bother putting the carpet back or fit bucket seats?
The middle box had been replaced with scrap yard bends that went under the handbrake cable instead of over it so that's why those need replacing.
Pigeon crap welding that my nephew could have done better when he was six whilst wearing a blindfold. My guess is it was done on the car by someone who thought welding was something you need a pre-nup' for.
And of course the Chavesty back box was held in place with silicone before being pigeon crap welded.
It's more than fair to say the donor car paid for itself today.
Once fitted my mood was lifted so I finished the cam' cover. I filled the scripted sections with blue enamel paint yesterday and rubbed the silver from the blocks so it has a straight brushed Aluminium effect (not good enough metal to mirror polish) and where some of the silver paint has dropped into the blue it looks aged. Almost like it's supposed to be there.
While I was under the car I noticed a few holes in the floor that need addressing. Where the wiring loom has had clips drilled into the floor water has got in and between the metal and the under-seal so I have a couple of playing card sections to cut out and weld up. I'll need to take the carpet out and go from inside lap welding a slightly bigger patch and lapping from underneath as well.
Now do I bother putting the carpet back or fit bucket seats?
Hectic month with my sister sprogging and the addition of a Fiorino van to my nest I've been ferrying around, faffing about or at work.
I have finally given up all hope of finding a 16V turbo air box. So I've had to cut the outlet side off a 20V one and fiberglass the cut and shut pipe minus the chav filter to it.
It's worse than it looks. Doing anything in this heat reminds me why we have Winter projects.
I have finally given up all hope of finding a 16V turbo air box. So I've had to cut the outlet side off a 20V one and fiberglass the cut and shut pipe minus the chav filter to it.
It's worse than it looks. Doing anything in this heat reminds me why we have Winter projects.
Boxy lady.
It would have looked better if I wrapped the pipe with black tape instead of paint but it will do for now. None of the 16V turbo's being broken for parts in Europe has the air box. They have all been chav'd.
On a hot day like today I look at the amount of work the Coupe needs and the amount of work I have done to my Bravo and think. Hmmmmmm, engine swap. It would be quicker, cheaper and the net result would be more practical but there are only twelve 16V Turbo plus Coupe's left and the Bravo HLX is almost as rare.
Sorry I missed your post and the yellow one has long gone anyway.
Plans, we all make them, some of us break them but we all tend to try. This Summer I was looking to spend my last Tax rebate (they'v sorted my code now so I'll have to save myself like a proper grown up) on a car I could take to job interviews without feeling silly. Bravo t-jet was top of that list until I bought a Punto GT and Alfa Spider.
So I have a new plan. Restoring the Coupe as a classic is less of a viable option due to being clocked but I have always had a soft spot for the Coupe and the 16V Turbo is in my opinion the best of the bunch. So why not keep the bloody thing for myself, make sure everything is done to my standards and fix the tachometer?
Good plan and just in time to be a Winter project.
So on the forth warmest day of the year I finally did the second part of the first job. The long removed pleb spec' spoiler holes are now welded, skim of filler and the whole boot lid in grey primer.
So it begins.
Again.
Plans, we all make them, some of us break them but we all tend to try. This Summer I was looking to spend my last Tax rebate (they'v sorted my code now so I'll have to save myself like a proper grown up) on a car I could take to job interviews without feeling silly. Bravo t-jet was top of that list until I bought a Punto GT and Alfa Spider.
So I have a new plan. Restoring the Coupe as a classic is less of a viable option due to being clocked but I have always had a soft spot for the Coupe and the 16V Turbo is in my opinion the best of the bunch. So why not keep the bloody thing for myself, make sure everything is done to my standards and fix the tachometer?
Good plan and just in time to be a Winter project.
So on the forth warmest day of the year I finally did the second part of the first job. The long removed pleb spec' spoiler holes are now welded, skim of filler and the whole boot lid in grey primer.
So it begins.
Again.
...and I've been distracted again.
I have a charity track day next month and wanted to take my nephews in a Cinquecento 899 I took as a part exchange on a Punto TD I tarted up with spare GT parts after I sold that.
And breathe.
Okay the Cinquecento is a no go due to being the most dangerously bodged together car I have ever owned and as my Bravo has the Michelin Pilots I'd better get that ready instead.
Yep. As my engine has never leaked oil I was under the car painting the front subframe to keep the surface rust at bay.
I made a hole and welded it up.
Tool of the job today was my big hammer.
But not because I used it to hammer anything but as a mount for my bike lights as it was getting dark.
Now it's lighting my shed as I put my tools away.
I have a charity track day next month and wanted to take my nephews in a Cinquecento 899 I took as a part exchange on a Punto TD I tarted up with spare GT parts after I sold that.
And breathe.
Okay the Cinquecento is a no go due to being the most dangerously bodged together car I have ever owned and as my Bravo has the Michelin Pilots I'd better get that ready instead.
Yep. As my engine has never leaked oil I was under the car painting the front subframe to keep the surface rust at bay.
I made a hole and welded it up.
Tool of the job today was my big hammer.
But not because I used it to hammer anything but as a mount for my bike lights as it was getting dark.
Now it's lighting my shed as I put my tools away.
Another distraction.
Another Bravo HLX
But not just any old Bravo. This is a one owner from new, 63,000 mile, Tolstoy history filed, show stopper. That's pretty well known on the Fiat Forum.
She felt a bit tail bias on the way home last night and I didn't think much of it. Just tyre pressures where she's been stood perhaps. I opened the tailgate to find a boot full of parts...
...worth more than twice the "undisclosed" sum I paid for the car.
A few minor issues...
...patch on the end of the driver side sill and rear half of the passenger side sill. I'll be after two new ones though (road trip to Italy to get those) and the lower valance panel...
...needs a little attention. I know I'll have to make that from scratch.
One major issue with the Bravo is my yellow one has a CD multi-changer under the back seat and this one doesn't so I had to change CD's like a ruffian.
Another Bravo HLX
But not just any old Bravo. This is a one owner from new, 63,000 mile, Tolstoy history filed, show stopper. That's pretty well known on the Fiat Forum.
She felt a bit tail bias on the way home last night and I didn't think much of it. Just tyre pressures where she's been stood perhaps. I opened the tailgate to find a boot full of parts...
...worth more than twice the "undisclosed" sum I paid for the car.
A few minor issues...
...patch on the end of the driver side sill and rear half of the passenger side sill. I'll be after two new ones though (road trip to Italy to get those) and the lower valance panel...
...needs a little attention. I know I'll have to make that from scratch.
One major issue with the Bravo is my yellow one has a CD multi-changer under the back seat and this one doesn't so I had to change CD's like a ruffian.
Okay today did not according to plan at all. I was going to get the small hole done on the driver side sill and then tackle the section that needs replacing on the passenger side.
First step as always is get the car up on ramps.
Jack up the side you're working on and turn the ramp a hundred and eighty degrees.
Now the car won't roll anywhere (even though she was in gear and the handbrake was on you never know) inspect the area you are...
Wait...
...what? Okay added to the list.
I have a length of Rover SD3 sill left over from my old car so that'll come in handy on the passenger side. The Punto wing in a bit of a cheat.
Move the plastic trim out of the way and see what twenty years of muck looks like.
Looks like the gel layer has been a water trap...
...time for a poke around...
...Hmmmmmmm.
Cut away as much rust as possible.
Tidy up the mess you've made.
Cut a section from the top of the wing.
And use the curve to make a sill repair patch.
Not bad but not to my standards so I cut it all out and started again.
First step as always is get the car up on ramps.
Jack up the side you're working on and turn the ramp a hundred and eighty degrees.
Now the car won't roll anywhere (even though she was in gear and the handbrake was on you never know) inspect the area you are...
Wait...
...what? Okay added to the list.
I have a length of Rover SD3 sill left over from my old car so that'll come in handy on the passenger side. The Punto wing in a bit of a cheat.
Move the plastic trim out of the way and see what twenty years of muck looks like.
Looks like the gel layer has been a water trap...
...time for a poke around...
...Hmmmmmmm.
Cut away as much rust as possible.
Tidy up the mess you've made.
Cut a section from the top of the wing.
And use the curve to make a sill repair patch.
Not bad but not to my standards so I cut it all out and started again.
Rules of filler.
The instructions suggest you should "Use a pea of hardener for every golf ball of filler". If you ever need a golf ball of filler you should give your welder to a charity shop and never go near a car again.
I hate the stuff. But because I didn't like how using the top if the Punto wing turned out and started again today my welder ran out of gas. I don't get paid again until the 15th and will be cycling to work because I have no fuel budget for my commute.
Fiats eh? If I had spent as much over the years on alcohol or drugs I would be interesting, married or dead by now.
So I hang my head in shame as I share the first filler photo'.
What you won't see is the sanding, etching, filling, drying, sanding, etching, filling, drying, sanding, priming, drying, sanding, priming, painting waiting, waiting, waiting, lacquering, waiting, waiting, waiting, lacquering and swearing at a cat for rubbing up against the wet lacquer.
I hate filler!
The instructions suggest you should "Use a pea of hardener for every golf ball of filler". If you ever need a golf ball of filler you should give your welder to a charity shop and never go near a car again.
I hate the stuff. But because I didn't like how using the top if the Punto wing turned out and started again today my welder ran out of gas. I don't get paid again until the 15th and will be cycling to work because I have no fuel budget for my commute.
Fiats eh? If I had spent as much over the years on alcohol or drugs I would be interesting, married or dead by now.
So I hang my head in shame as I share the first filler photo'.
What you won't see is the sanding, etching, filling, drying, sanding, etching, filling, drying, sanding, priming, drying, sanding, priming, painting waiting, waiting, waiting, lacquering, waiting, waiting, waiting, lacquering and swearing at a cat for rubbing up against the wet lacquer.
I hate filler!
Edited by Liquid Knight on Tuesday 1st November 16:58
The blue Bravo is dead.
The passenger side sill rust was a lot worse than anyone could have expected. Half the outer sill crumbled off in my hands, the outer castle rail was all but gone, inner castle rail rusted half way up, the lower section of the pillar support gone completely, the inner pillar structure rusted and crumbling all the way up as far as I could see and there's a half inch gap between the inner wall and floor where the car has started to buckle.
I think the sunroof drain pipe was blocked or come off and water has been trickling down the inside of the pillar.
This can all be repaired but would require a bare shell strip down, mounting on a jig, cutting the outer skin off the pillar, replacing all the rust from inside, weld new floors to the lower pillar, replace the inner and outer castle rails and replace the outer sill. All new parts would have to be made from scratch as nothing is available. Sadly I don't have the time, budget or facilities to do it.
I'm gutted but also relieved the car came to me. Someone else could have bought her, done a cosmetic repair or bodge and she would be a death trap on the road.
The passenger side sill rust was a lot worse than anyone could have expected. Half the outer sill crumbled off in my hands, the outer castle rail was all but gone, inner castle rail rusted half way up, the lower section of the pillar support gone completely, the inner pillar structure rusted and crumbling all the way up as far as I could see and there's a half inch gap between the inner wall and floor where the car has started to buckle.
I think the sunroof drain pipe was blocked or come off and water has been trickling down the inside of the pillar.
This can all be repaired but would require a bare shell strip down, mounting on a jig, cutting the outer skin off the pillar, replacing all the rust from inside, weld new floors to the lower pillar, replace the inner and outer castle rails and replace the outer sill. All new parts would have to be made from scratch as nothing is available. Sadly I don't have the time, budget or facilities to do it.
I'm gutted but also relieved the car came to me. Someone else could have bought her, done a cosmetic repair or bodge and she would be a death trap on the road.
With a heavy heart I was going to strip the front hub assembly from the yellow Bravo and swap it with the blue one toady in the sunshine.
But I got distracted by other M.O.T things...
...finally fitted a rear wiper to the car since I "borrowed" one to get another car M.O.T'd ages ago. The rally style stickers as well for the pretension.
So distracted I only managed to pull the hub assembly off the yellow car before it started getting dark and I need to start getting ready for work. No need to photo that as I have done a dozen times already. Needless to say the hub bearing has about a millimeter and a half play. Enough to notice behind the wheel.
But I got distracted by other M.O.T things...
...finally fitted a rear wiper to the car since I "borrowed" one to get another car M.O.T'd ages ago. The rally style stickers as well for the pretension.
So distracted I only managed to pull the hub assembly off the yellow car before it started getting dark and I need to start getting ready for work. No need to photo that as I have done a dozen times already. Needless to say the hub bearing has about a millimeter and a half play. Enough to notice behind the wheel.
The yellow Bravo passed the MOT with no advisories. 
Tried my Winter wheels...
...I'm not a fan of the Bangle Grinder wheels on the Coupe but the contrast between the rounder body kind of works.
Well worked until I hit a pothole and lost a tyre.
So the 20V turbo Coupe wheels from my Punto GT are on for now.
With different bolts so nobody can try to nick them this time.
Tried my Winter wheels...
...I'm not a fan of the Bangle Grinder wheels on the Coupe but the contrast between the rounder body kind of works.
Well worked until I hit a pothole and lost a tyre.
So the 20V turbo Coupe wheels from my Punto GT are on for now.
With different bolts so nobody can try to nick them this time.
Winter runner for now but plan to take my nephews to track days next season. The Spider is off the road now I have the Bravo to save her from the salt grit. Also a few Alfaisms to address ready to sell in the Spring.
I also plan to work on the Coupe over Winter and maybe do the MOT stuff for my Fantasia.
I also plan to work on the Coupe over Winter and maybe do the MOT stuff for my Fantasia.
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