900 Bluebell the 900e Amigo

[fiat500]

Out of interest, are you a welder by trade?
The quality of your fabrications and welding appear to be better than the average enthusiast.

That's very kind of you to say so Gary. I think I take more care than many people to try to reproduce the original geometry of the construction. I am able to break the reconstruction into manageable sections quite intuitively.
I'm not a professional welder but I have done a few restorations already.
There's loads of amazing fabricator/welders out there, but many of them seem to have the luxuries of time and workshop facilities. So I don't do badly all considered.

 

[fiat500]

Bluebell has had to wait for (I just checked) a few months?!!!! as other matters, including my very rusty Fiat 500, have taken precedence.
There is a lull before I build a more waterproof and permanent home for the van, so I am getting all the loose ends sorted.
First up was to weld in the side-panels which had been trial-fitted many months ago. Quite a lot of preparation was need to make all the plug-weld holes and to clean off paint and surface rust prior to weldng.
I was dreading this as the panels were originally spot-welded in channels which must have been tricky even for the factory. But the welder was set just right and the clean steel helped, being spatter-free.
MAL_6069 by Peter Thompson, on Flickr
I'm still doing the butt-weld at the top of the panels. It's a series of tiny welds that I am building up slowly to prevent the panel warping too much.
It's not bad considering what I had to start with, but it's not perfectly aligned. Even so, I'm pleased with the result and can now concentrate on a few relatively micro-areas of repair befor epoxy-painting and starting properly on the passenger side.

 

[fiat500]

After four stints of welding spread over two days, I finally welded up the tops of the side panels.
MAL_6134 by Peter Thompson, on Flickr
This was a marathon, not because the butt-welding itself was too much of a challenge, (although 0.8mm steel is no pleasure end on end)but more to avoid distortion.
MAL_6138 by Peter Thompson, on Flickr
It looks messy because of the dot/dab procedure and this was done mainly from the inside of the van, but no pinholes when viewed from inside. It wouldn't really matter anyway as it's not structural and not normally exposed to water on the inside.
That done, I need to do quite a lot of light grinding to tidy everything up. i've got some 25p, disposable paintbrushes from Toolstation to lay on the epoxy on the seams.

 

[Gary50]

The rate that you are going it looks like over 60% of the van will be new metal - impressive stuff.

 

[fiat500]

The rate that you are going it looks like over 60% of the van will be new metal - impressive stuff.

That might be quite accurate in square meterage as it will also have a brand new driver's door, tailgate, engine lid and rear engine mounting panel. The passenger door will have repair panel at the bottom.
Next week I will be doing some patches around both the driver's side windows and if anyone needs a full, brand-new repair panel for a window surround, I have one surplus to requirements.

 

[Gary50]

Anyone considering buying a 850T/900T/E should read your posts.
The early photo's of Bluebell gave little indication of the work that would ensue.

By comparrison Connie was almost showroom condition - I think that I have to thank the Ziebart rustproofing for alot of that.

 

[fiat500]

Anyone considering that choice should reconsider!

 

[fiat500]

Anyone considering that choice should reconsider!

No, really they shouldn't reconsider....go for it!
I was under no illusion with Bluebell. I had been fully enlightened that the repair work already done was visually poor and that more remained to do, but I decided "in for a penny etc." and decided to go for a better finish.

I had this dilemma with my Fiat 500; you can't be sure that even if you find a good example, it hasn't got lots of hidden repairs or potential time-bombs of corrosion ready to pop.

Having said that, there have since been a couple of opportunities to get a better example but now I'm addicted to Bluebell.

 

[fiat500]

Just showing off and recording for posterity my almost textbook repair on the side-window surround. I had a spare, brand-new one which I cut the patch from, which made things very easy. The same panel will donate sections to repair the other window where the surround has rusted away.
MAL_6403 by Peter Thompson, on Flickr

 

[fiat500]

This evening I felt the need to lay off the grinding as our new neighbours had their doors open and I was getting conscious of the noise I make.
So I did a full dig around in an area that I was going to leave for a while yet, which I knew to be a mess.
Look away if you frighten easily.
MAL_6407 by Peter Thompson, on Flickr
The rust goes up behind the fibreglass roof and has taken out several layers which make up the gutter and the rounded corner.
MAL_6409 by Peter Thompson, on Flickr
I have scratched around with paintstripper and started a treatment with phosphoric acid to see how far it has gone. It will be fiddly but not actually that hard to repair. But I bet there's a days' work in it.:bang:

 

[fiat500]

I'm itching to get more done on the van but work and the logistics of building a new garage and tiny workshop have got in the way. The garage is tailor-made to the minimum size for the tiny vehicles and they just fit.
I've had to decant all my spares and the two vehicles from the crumby, temporary carport and from a garage that I'm having to vacate.
As you can see, I'm a long way from being completed with it and I have stuff everywhere, but at least the vehicles are home and dry.
The Amigo hasn't moved since last summer and was jacked up on five concrete blocks at each corner. So it was a pain to get it on its feet again. But with a quick clean of the points and a charged battery, it started once the petrol got through from a temporary can.
It looks a real mess with surface rust starting on the new and stripped metal. So the next stage is to prime all of the repaired areas so far whilst I have a reasonable chance of warm and dry weather.
MAL_9276 by Peter Thompson, on Flickr

 

[Gary50]

It looks like the new home for your pair of Fiats will be worth it in the end.
Will you be towing the 500 to use as a run-around when camped up?

PS.
I can sympathise with work, other projects and life in general getting in the way of the restoration - I haven't had time to work on Connie for ages

 

[fiat500]

Will you be towing the 500 to use as a run-around when camped up?

I am not sure that the 900e will have enough breath to move itself under a full load, never mind towing a 500?
Maybe do the reverse to use the camper as a caravan??
The attraction of the Amigo for me is partly the fact that it can go anywhere a car could access.

 

[Gary50]

Just been checking, the 500 is quoted at 499Kg. Whereas the maximum towing weight for the 900T is 350kg - from what I gather this is un-braked. However, even with brakes, towing much more would be a challenge - although the low gearing means you should be able to get up most things - albeit slowly... and with a hot engine

As a weekender the 900T should be ideal but for anything longer the confines may well be more than most (I) can cope with - especially with British summers. I've been checking out some of the small trailer tents for longer term holidays. There is quite a selection under 300kg and as you wouldn't need the cooker and sink the weight saved can be used for storage etc.

But that is likely to be one for next year.

 

[fiat500]

I hope that I can enjoy long tours in an Amigo, otherwise it's going back on EBay.
With the lid up, Bluebell is enormous, but I suppose I'll not be sure until I try it.
It really isn't much bigger than an estate car. with an upstairs to it.

 

[The Cad]

Hello Peter

I have just been reading the posts on your restoration with great interest and renewed enthusiasm for my '82 900E Amigo which I bought off eBay in a moments madness. I of course broke all the rules and bid last minute on something I hadn't seen or even phoned up about, needless to say it was in far worse condition than described.

The last and only restoration I have done was my '72 500L about 25 years ago which is still going strong but it was relatively easy as all the panels were available where as the 900 has rotted in places that I assumed would be impossible to repair and certainly beyond my abilities.

I am fascinated to see how you repair the roof/gutter, inner panels and particularly the upper inner rear quarters as the photos look exactly the same as mine. The panel that the tailgate gate hangs off has also "disappeared" on mine!

So I'm off the the garage tomorrow to take another look at my Amigo and decide where to start!

Can anyone recommend a good welder/restorer in the South East of England?

Thanks for the inspiration.

Regards

Pete

 

[fiat500]

Hi Pete, are we living in parallel universes?

I wasn't quite so reckless when buying Bluebell, but pretty close, ie. unseen and via Ebay. But I did have a very honest seller; even so, there has obviously turned out to be a lot more wrong with the bodywork and chassis than I had hoped for.

I'm not too phased by the rear, curved gutter rot as I have now looked at the construction and having a shrinker/stretcher tool, I know it can be done. The big, curved panel inside the rear quarter is very simple. The rear tailgate mounting area is dodgy on mine as well but at least the section is just straight folds. But if you have those issues then I guess you have much more rot below it.

I would love to see photos of your van and I'll set the repair of the gutters as a priority job after I've primed and protected my repair work so far.

 

[The Cad]

Yes, a parallel universe at opposite ends of the country.

Below are a few pictures I took before I pushed TJ in the garage in defeat.

I look forward to seeing you you tackle the gutters as I have so much to learn.

Pete

Seems I cant post pictures yet

 

[fiat500]

Pete

Seems I cant post pictures yet

Pete....just reply to this, maybe start a new thread of your own to introduce yourself more widely and after a total (I think) of five posts you can upload images.

 

[timmycm850]

Hi guys

I recently purchased a pair of the panels that fit below the bumper corners behind the rear wheels, i only needed the battery side one but hence have a spare one for the exhaust side. if this panel is useful to someone please let me know.the pair cost me £100 delivered so i would consider a fair price to be £50 plus postage if rqd. i am based in high wycombe area

Tim Milnes

massage me if you are interested