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Old 16-04-2020   #31
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Re: My New 2009 100HP

Had a bit of fun the other day replacing the passenger side headlight as it was smashed when I bought the car. The seller gave me a replacement and just hadn't got round to fitting it himself. I now know why.

After finding all the necessary bolts to remove the bumper I realised it wasn't going to be as easy as I thought as the bumper has never been off. I was fighting against 11 years of corrosion and dirt build up but I eventually got there and made it look like it has been in a huge smash.

Passenger headlight out and promptly put in the bin. The bolt holding it to the inside wing snapped on the way out so it was off to the random bolt drawer in the shed and a replacement found.

The drivers had an LED bulb inside that was just rattling about so that was removed too.

While I had the bumper off I replaced the pink Fiat badge with a new one also provided by the previous owner. The fog lights were tinted yellow and the covers restored with some Turtle Wax gel that I bought from Halfords a few weeks ago.

I one of the fogs was attached with a zip tie so I've ordered a replacement chimney nut along with new stainless fixings instead of the old rusty screws I removed. Just waiting for them to turn up now and I can get everything put back together and start restoring the plastic trim on the whole car.

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Old 20-04-2020   #32
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Re: My New 2009 100HP

I hit a deer at 60mph. It shattered the bumper and the radiator/headlights frame, bent both radiators and cracked the air filter box and one headlight. Amazingly the bonnet and wing were ok.
Calling the 100HP front panel a bumper is frankly a lie. It offers zero protection to important parts of the car. They are also very expensive to replace while ordinary Panda bumpers are cheap as chips and a fair bit tougher.

Paint the middle section black and few will notice the difference. You will then have your original bumper safe and sound for when you sell the car.

I fitted a standard Panda bumper. I chose to remove the front rubbing strips and fill the holes but that is a much bigger job than it looks. The bottom splitter/spolier wont easily fit a standard bumper but the wheel spats fit fine. Measure the three fixing holes from the 100HP bumper.
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Last edited by DaveMcT; 20-04-2020 at 10:30.
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Old 20-04-2020   #33
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Re: My New 2009 100HP

I did notice it's more of a cover than a bumper, just there to make it look pretty!
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Old 20-04-2020   #34
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Re: My New 2009 100HP

The basic models have a two piece bumper with grill that makes the whole thing a bit stronger but makes additional bumper hoops harder to fit.
The 100HP radiators would benefit (a lot) from some steel tubes welded to the front cross beam. They could be done quite easily and would be completely hidden under the plastic. That would stop anything that does fly through the plastic from destroying everything behind.
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Old 20-04-2020   #35
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Quote Originally Posted by DaveMcT View Post
I hit a deer at 60mph. It shattered the bumper and the radiator/headlights frame, bent both radiators and cracked the air filter box and one headlight. Amazingly the bonnet and wing were ok.
Calling the 100HP front panel a bumper is frankly a lie. It offers zero protection to important parts of the car. They are also very expensive to replace while ordinary Panda bumpers are cheap as chips and a fair bit tougher.

Paint the middle section black and few will notice the difference. You will then have your original bumper safe and sound for when you sell the car.

I fitted a standard Panda bumper. I chose to remove the front rubbing strips and fill the holes but that is a much bigger job than it looks. The bottom splitter/spolier wont easily fit a standard bumper but the wheel spats fit fine. Measure the three fixing holes from the 100HP bumper.
I don't think bumpers are allowed to offer any protection thesedays with the cushioning needed to pass passenger collision tests
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Old 20-04-2020   #36
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Re: My New 2009 100HP

I am not suggesting anything on the outside.


A huge steel crash beam, mandated by crash protection rules, runs across the car under the bumper (inside if you like). It transfers crash loads across the car, but fails to protect the radiators or the engine air box. There is space above the beam but UNDER the plastic to add a metal tube under the bumper which would protect the radiators.

The standard bumper partly does this with thicker, tougher plastic and a top (beneath the grille) that provides some protection where the 100HP has none.
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Old 25-04-2020   #37
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Re: My New 2009 100HP

Thanks for this thread wazzer. We've 2 pandas and I regret not getting a 100HP which seem quite rare now.
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Old 25-04-2020   #38
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Re: My New 2009 100HP

Quote Originally Posted by marc4242 View Post
Thanks for this thread wazzer. We've 2 pandas and I regret not getting a 100HP which seem quite rare now.
Sorry

I believe there are only 2 of the 100HP on our little island, a grey model and my blue one. Not seen the grey one for years though
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Old 25-04-2020   #39
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Re: My New 2009 100HP

well done going so far to pick it up
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Old 29-04-2020   #40
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Great thread this, some really worthwhile things you're doing to the 100. I was bemused when you said only 2 of them on the island as I thought you meant Britain but I've read the whole thread now

Seeing your regulator assembly reminds me I must get out and fix the grinding noise on mine. I don't have any lithium e2 grease can I use copper ease?
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Old 29-04-2020   #41
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Re: My New 2009 100HP

Ha not quite that exclusive!

I used some grease from work which was Dow corning stuff. I'm guessing anything is better than nothing, most of it scraped off and fell in the door anyways. I did check my drivers side and the clip seemed intact so I just regreased, I've kept the clip for the wife's panda as hers is starting to slow down when getting to the fully open position.

Many thanks for the comments, I've got a couple more bits I'd like to sort on there but I've been trying to get my Vespa back up and running this week so haven't really spent much time on the car.

I have ordered a silicone 90 degree pipe for the induction mod and also a Pipercross panel filter though. I doubt it will make any difference to power but I really like the induction noise on the 100HP so anything that amplifies that is a win for me.

I also managed to find some rear interior threshold/arch trims from a breaker but unfortunately they couldn't deliver to the island so I had to have them delivered to my uncles up in Cheltenham. My parents regularly visit him so I'll get them to pick them up for me once all this lockdown has eased a little.

Another bonus was my Abarth 500 handbrake mechanism turning up after a month missing in the wilderness. I found it with black stitching for 15 delivered which was a steal. I would have liked one with red stitching to go with the steering wheel but I wasn't prepared to pay 50.

I was a bit naughty and ordered an underseat subwoofer to complete the install too

I've also painted my rebuilt Alfa Romeo calipers which will go on once the lockdown is done. I've also got the rears to paint at some point but I've been asked to go back in to work next week so no more tinkering apart from weekends now. Not a bad thing though as we're looking to move house soon and being furloughed won't help that.

As usual comments welcome good or bad


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Last edited by Wazzzer; 29-04-2020 at 12:58.
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Old 07-05-2020   #42
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Re: My New 2009 100HP

Been busy over the last few days and fitted a few bits. Sub, 500 Abarth handbrake lever and intake pipe are all fitted, will get some pics tomorrow.

I spent this evening restoring the plastics on the front arches and front bumper. The front grille was extremely tedious but has come out really well.

Finishing the rest of the car tomorrow and possibly fitting the new rear wheel bearing, might service the wife's Dynamic as well.

I also bought myself a bag of the green clips to reattach my rear arch properly then found that they are actually held on with the black clips until you get to the skirt...

I've used the green ones for now until I get some black ones through.

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Old 16-05-2020   #43
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Pictures added from the last few bits done on the car.

Finally got around to doing the rear brakes and wheel bearing today. I'd bought myself a new toy in the week, a Ryobi 400nm impact driver; so I was keen to see if this would help me get the hub nut off. Within seconds it was on the floor so a good result.

I'd bought myself a very cheap bearing puller just in case the bearing I was replacing was difficult to remove. Didn't need to bother, it pulled straight off with hardly any effort. Shows how knackered it was!

Next up was tightening the nut, luckily I had access to a 300nm calibrated torque wrench from work so that was taken care of.

And then it all went wrong... Found the cause of my sticking caliper; the slider pin was seized and does really need to be replaced but as I didn't have a rebuild kit to hand I cleaned and greased it for now. Disc on, pads in and... caliper won't fit. Spent a good hour or so trying to figure this out and then I realised - I'd been supplied the wrong pads.

I've since ordered the right ones again but will have to wait until they turn up to finish the job. So with the Panda out of action and also my Vespa being in bits I may have to dust off the push bike for work next week.
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Old 17-05-2020   #44
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Re: My New 2009 100HP

These are the pads for the 251 mm discs. You'll need the ones for the 240 mm discs, but you already found that out.
Good luck with the job when you get the right parts!

gr J
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Old 17-05-2020   #45
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Quote Originally Posted by A3jeroen View Post
These are the pads for the 251 mm discs. You'll need the ones for the 240 mm discs, but you already found that out.
Good luck with the job when you get the right parts!

gr J
It's even worse that I was supplied the wrong parts; I could have beat myself up for a bit if it was my fault but I've got no one to shout at now!
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