How to fit Punto mk2 tailgate struts onto a Punto mk1.
These struts look very much alike but differ slightly, the mk2 strut is too long in the body for the mk1, and the result is that with mk2 struts fitted to the standard mounting balls you cannot shut the tailgate.
The difference in body length is just 3cm although the overall extended length is very similar, so they can be made to fit if you lower the locating balls on the tailgate by this amount.
Unbolt the brackets that carry the balls from the tailgate [2x10mm nuts each side] and cut off the balls about 1/4" from the base of the ball where it is swaged into the bracket. The cut should be parallel to the 2 locating holes and far enough away from the base of the ball to allow a thin neat weld without burning the ball.
Cut 2 pieces of 3/8" black mild steel rod about 2" long each, to space down the balls on the bracket. Deburr and round off the ends.
Weld the ball to the piece of rod first, then carefully conserving the angle the ball originally occupied [90 degrees from the mounting plate], weld the other end of the rod to the bracket.
The distance from the ball to the centre of the bracket must be 3cm greater than before, so measure carefully before welding. As the brackets are left and right handed the direction of the extension piece in each case is reversed compared to the other side.
Clean up the welds and deburr to protect your clothing from snagging. Paint and refit to the tailgate.
You will now be able to fit the mk2 struts. You will also notice that the tailgate self-opening action is a little stronger, and the tailgate may gently rise unaided when you operate the release trigger.
In Almeria ALL Fiat spare parts earlier than year 2000 have been dumped in the skip by the Fiat agency, so one has to resort increasingly to this kind of trickery.
Best wishes
Roland
These struts look very much alike but differ slightly, the mk2 strut is too long in the body for the mk1, and the result is that with mk2 struts fitted to the standard mounting balls you cannot shut the tailgate.
The difference in body length is just 3cm although the overall extended length is very similar, so they can be made to fit if you lower the locating balls on the tailgate by this amount.
Unbolt the brackets that carry the balls from the tailgate [2x10mm nuts each side] and cut off the balls about 1/4" from the base of the ball where it is swaged into the bracket. The cut should be parallel to the 2 locating holes and far enough away from the base of the ball to allow a thin neat weld without burning the ball.
Cut 2 pieces of 3/8" black mild steel rod about 2" long each, to space down the balls on the bracket. Deburr and round off the ends.
Weld the ball to the piece of rod first, then carefully conserving the angle the ball originally occupied [90 degrees from the mounting plate], weld the other end of the rod to the bracket.
The distance from the ball to the centre of the bracket must be 3cm greater than before, so measure carefully before welding. As the brackets are left and right handed the direction of the extension piece in each case is reversed compared to the other side.
Clean up the welds and deburr to protect your clothing from snagging. Paint and refit to the tailgate.
You will now be able to fit the mk2 struts. You will also notice that the tailgate self-opening action is a little stronger, and the tailgate may gently rise unaided when you operate the release trigger.
In Almeria ALL Fiat spare parts earlier than year 2000 have been dumped in the skip by the Fiat agency, so one has to resort increasingly to this kind of trickery.
Best wishes
Roland
