Coupe Fiat Coupe LE - Build Thread!

Introduction

Hello all!

New project, black Fiat Coupe 20V Turbo LE.
Done around 88k, brought from JBT at Midlands car servicing, been off the road since 2012.

My main focus when looking for a LE was rust as once you start welding you never seem to stop.

Thankfully this is in really good shape, it was quite heavily modified at some point to over 400bhp.

JBT built the engine with forged rods/pistons and a Garrett GT3071 so it should be fairly potent!

Plan is to recommision the car so i can use it daily and also correct a few of the mods to make it more reliable and cleaner.
I want the car to be as if it was made this way from Fiat.

So, pictures! Not too many of when it arrived, certainly covered in dust..

Pre delivery:
52059437675_d59f18b84d_h.jpg


52058951891_609fd3a55b_h.jpg


52057913512_7219220344_h.jpg


All fairly complete, just needs some work.

Now in my workshop

52057913317_0b72f4a15d_b.jpg


52058951441_5aee74254f_b.jpg


Pre strip down to discover whats undernearth.

52059188669_6cc0044568_b.jpg


Some water injecton kit with a lot of extra wiring... all to go

52057913232_22b13c8dde_b.jpg


Lots of silicon and clamps...

52059437100_276781470e_c.jpg


3" exhaust all the way through but it was hanging off, all the mounts were broken, it was rubbing in places and had no cat.

52058951336_966779ba11_b.jpg


52057913172_cc8f42b842_b.jpg


Lots of pipe joiners and jubilee clips!
52058951296_1896774aa3_b.jpg


AC has seen better days!
52059188504_41545b0d96_b.jpg


Lot's of cracked pipes
52057913072_929d224052_b.jpg


Lots of stuff like this, hoses just capped off...

52058951246_b17222e95a_c.jpg


52058984773_5dd786f6a1_c.jpg


Found the air temp sensor just floating in the engine bay! Not in the inlet manifold?

52058984763_bcd0e586c1_c.jpg


First thing to go was the water injection, wiring was just twisted onto the injector wiring.

52057923662_5c78153c4d_b.jpg


Stripped out

52057923657_e8af807a28_b.jpg


Wiring repaired and heat shrunk

52059447195_2b98bb8dcc_b.jpg


New boot and thats one job done

52058995088_2684ce38a3_b.jpg
OP
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601176005

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Started stripping down to see what else i would find

AC Rad out, well rotten! AC is being deleted, never use it and removes some complexity.

52057923647_21c9c9f517_c.jpg IMG_1015

Oil feed line to the turbo was not ideal, really sharp bend onto the fitting.

52059447225_d4474381cb_c.jpg IMG_1016

52058961756_231fa6d3f0_c.jpg IMG_1019

52058961736_69d27a09ab_c.jpg IMG_1024

Made up a new AN4 PTFE fitting, along with heat protection

52059198819_34fb4471a2_c.jpg IMG_1081

52059198769_78d5afff67_c.jpg IMG_1082

As i was doing the turbo line i noticed the undertray was missing and also the bottom rad support was rotten and bent...

52058995018_9898b8d40b_c.jpg IMG_1084

52058995013_ab7130c4f1_c.jpg IMG_1086

Yummy!

52058961661_b2f0ec9d08_c.jpg IMG_1087

The original FMIC was ok, but needed the front bumper cut, the undertray wouldn't fit and it was rubbing.

So i came up with a plan, i wanted the original undertray on, i didn't want to cut the bumper. So i decided to move the radiator over 30mm and redesign the front end.
This is how it ended up, i used a new FMIC with all custom pipe work, i tilted the FMIC 30 degrees to get it to fit.

52058994998_0c3a76a9f6_c.jpg IMG_1110

New mounts welded to the removable front panel

52059447075_8acd9c4862_b.jpg IMG_1111

Pie cut and welded, this wraps around the radiator:

52058961631_e4972c9400_b.jpg IMG_1112

52059447040_dabdd2af98_c.jpg IMG_1113

Very tight but 15-20mm of clearance all around

52059198679_4c3e4233d6_c.jpg IMG_1117

Here you can see the intercooler pipe now sits inside the undertray out of harms way

Second boost pipe made to connect the intercooler to the manifold

52059447030_19a25374ea_c.jpg IMG_1114

52059198694_47a1fddb79_c.jpg IMG_1115

Wanted to use the original airbox as previous testing has shown the airfilter is unlikely to cause any restrictions

52058994918_e213dc6ec8_c.jpg IMG_1116

Next up was oil drain for the turbo, someone had used some kind of chemical metal to hold it in place but it was leaking.

52058994903_84d35d77f2_c.jpg IMG_1118

52059446970_df1da52af7_c.jpg IMG_1120

52057923367_fe5ba7a000_c.jpg IMG_1122
 
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Stripped down the front of the engine so i could give it a clean and also fit the non AC mount

52058994883_f4eb6a3d72_b.jpg IMG_1121

AC and Non AC
52058961541_ce29f295c7_c.jpg IMG_1208

Mount removed and block cleaned

52058994853_c901134a4e_b.jpg IMG_1210

New mount on

52057923337_5ed1c16fab_b.jpg IMG_1214

Change the PS bearing as both were worn

52059446885_abf7b0a971_c.jpg IMG_1211

52062339261_9fa616ea82_c.jpg IMG_1600

Fitted

52062339241_20426164d3_c.jpg IMG_1601

Next was to sort the maniold as it was cracked

52058994818_2e717779d7_c.jpg IMG_1215

Can just see them here

52058994803_f4e4ac11f0_c.jpg IMG_1216

Ground out

52057923282_b26f815d34_c.jpg IMG_1218

TIG welded up

52059446840_52f9a9510f_c.jpg IMG_1219

Next i wanted to sort the manifold bolts, these had been done up too far and had pushed into the oil passages, so stripped cleaned, new studs and threadlock to stop them weeping.

52059446825_f743edf06d_b.jpg IMG_1222

52058961436_4f7fb3517b_c.jpg IMG_1224

All studs replaced

52059446780_9889947bba_b.jpg IMG_1225




Next i wanted to sort the wheel arches, the brake pad sensor wires were cut off and there was cable ties everywhere.

52058961391_0d2c71ca51_b.jpg IMG_1227

After with all the wiring back in place along with all the correct clips

52058994128_5a6864a4b2_b.jpg IMG_1273

Pass side

52059446455_62c79af913_c.jpg IMG_1247

52058994213_74cf13fd81_b.jpg IMG_1253

52059197944_5f3d94a8a4_b.jpg IMG_1270

Re-routed the shock canisters into the engine bay

52058960931_158066bed3_c.jpg IMG_1249
 
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52058992148_c04e0ebe19_c.jpg IMG_1533

52057920932_013cf1e47c_c.jpg IMG_1534

Some good news though, very clean! Zero rust!

52058994258_bb6bf5f269_c.jpg IMG_1250

52058960916_37e31c35fe_c.jpg IMG_1251




The drivers side front tower was rusty so changed that.

52058961351_1191b10ea0_c.jpg IMG_1229

Was some rust behind the tower so drilled that out also so i could treat and re-weld

52059198404_7f5e3684bc_c.jpg IMG_1231

52058994603_3fc9c7f4fd_h.jpg IMG_1233

U-POL zinc primer on first

52057923077_0d5dc8d3c2_c.jpg IMG_1234

Back side also

52059446625_fea7373e66_c.jpg IMG_1235

Re-welded

52058994513_f08c066eac_c.jpg IMG_1236

Old and new

52058994493_d034360b1d_b.jpg IMG_1237

52058961121_382685ca87_b.jpg IMG_1238

52058961106_0b7f6c7cba_c.jpg IMG_1239

Gave the new tower and chassis leg a spray

52059198219_346eb9e3e0_c.jpg IMG_1240

One side done

52059198199_44040617d3_b.jpg IMG_1243

Pass tower was ok but the leg was scabby in places

52059198184_de35fb0a26_c.jpg IMG_1244

Primed

52059446510_9d8095c822_c.jpg IMG_1246

Painted and re-assembled along with all stainless hardware, gave the battery tray a paint also

52059197934_da57fbaf85_c.jpg IMG_1271

Also painted all the front side bumper supports and all the brackets

52058960796_da3707efb0_c.jpg IMG_1304

Fitted up with stainless fixings again

52059197909_099ba80986_c.jpg IMG_1305
 
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601176005

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Messages
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Location
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52058960766_b5a1b71c9a_b.jpg IMG_1307

52057922737_70544f53e6_c.jpg IMG_1308

52059197879_da8f099815_b.jpg IMG_1309

Drivers side with new horn brackets

52058960736_4c0399468b_b.jpg IMG_1311

52057922692_15250a3d14_b.jpg IMG_1312

Nice simple job, bonnet, new handle and cable

52058994008_4a9ebafe3d_h.jpg IMG_1314

Fitted

52059197799_8e5808148e_b.jpg IMG_1315


Next was sorting the underside sills, rot free! But had been jacked up on them... Annoying!

52059198004_d9ebeaf994_c.jpg IMG_1265

Underseal removed and sill straigtend

52059197984_54cc21075f_b.jpg IMG_1266

Re-underselaed

52059446375_947c21c75d_c.jpg IMG_1269

Same on pass side

52058960391_0e98296627_c.jpg IMG_1336


Moving onto the rear now

Corrosion check, all looks good!

52058993878_bee392c0c0_c.jpg IMG_1318

52058960606_ccd7c72075_c.jpg IMG_1319

52059445955_400512710e_c.jpg IMG_1331

52057922387_3e347f7d6b_c.jpg IMG_1332


Stripping the rear arch liners off

52057922537_785c26ba00_c.jpg IMG_1321

Looks good!

52059446015_d71cb81f04_b.jpg IMG_1324

52057922437_7202381346_c.jpg IMG_1326

52058993628_c73b23c5a9_c.jpg IMG_1341

52057922252_42feeb6f2d_b.jpg IMG_1342
 
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601176005

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Messages
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Location
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Boot floor

52058995218_18ce3b055c_c.jpg IMG_1383

Pass side tower is a bit scabby

52058960561_f8c1be889d_c.jpg IMG_1322

Drivers side has gone

52058960436_518a178c03_c.jpg IMG_1333

Cut off and new one welded in

52057922372_2f6468ee70_c.jpg IMG_1334

52059445885_9e31cc3697_c.jpg IMG_1337

Few little scabby bits where the underseal has lifted

52058993778_40d5561eeb_b.jpg IMG_1325

Boot floor edge, gave that a clean up and even found a pound!

52059445970_4697e8de37_b.jpg IMG_1327

52057922412_389ac8e977_b.jpg IMG_1329

Wanted to preserve the car so cavity waxed the life out of it.

52057922322_e22fdba4da_b.jpg IMG_1338

Rear end done

52058993658_7a87dcacd7_b.jpg IMG_1339

52058960341_3708e236f5_b.jpg IMG_1340

52059197509_b754483932_c.jpg IMG_1344

Rear jacking points still good!

52059197474_09a3be6cbb_b.jpg IMG_1346

Even clen inside! All now protected

52057922197_6a292edffb_b.jpg IMG_1347

52058993543_56737bdf9b_c.jpg IMG_1351

52059445735_5c408edc9d_b.jpg IMG_1352

52058960191_a68d0a7148_b.jpg IMG_1353

Can see in the pic here where i removed the hole plugs to cavity wax

52059197384_3927f37f3a_b.jpg IMG_1354

52058960136_362a516ba5_c.jpg IMG_1361

Boot floor still mint

52057922022_c09ab39746_b.jpg IMG_1364
 
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601176005

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Messages
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Location
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52058993308_99884c2614_c.jpg IMG_1366

52059197124_cdfea6138f_c.jpg IMG_1367

Front end protected also

52058959901_969f4f05d6_b.jpg IMG_1368

52059197084_16c00423af_b.jpg IMG_1370

Cleaning up and refitting the arch liners

52058959861_c4c7693f80_c.jpg IMG_1371

Painted the bumper mounts

52058993163_5280d69636_c.jpg IMG_1372

Foam back on

52057921807_9b99689e37_b.jpg IMG_1374

Fitted

52059197034_168c65085a_b.jpg IMG_1375

52059445350_7abc423e50_c.jpg IMG_1377

Rear mud flaps fitted with plastic fittings rather than the rivets

52058993073_92f255b7e3_c.jpg IMG_1381

52058993098_7b89b5cfdf_c.jpg IMG_1379

52058959796_27a2fc0807_c.jpg IMG_1380

Silly thing but also got new clips for the rear lights as they were missing

52059445220_955cd5daf0_c.jpg IMG_1389

52058959701_a72fa4c471_c.jpg IMG_1390

Boot done!

52058992963_37625c2dc5_h.jpg IMG_1399

Next up was the heatshields and handbrake mount, heatshields were mangled and mount was rusty..

52058992868_b9516fae88_c.jpg IMG_1405

Second hand one which was cleaner

52058959591_83bdd3a0b3_c.jpg IMG_1406

Cleaned, painted and ready to go

52059445060_97ecbe8354_c.jpg IMG_1409

52057921547_06af64c6fd_c.jpg IMG_1411

Much better, with stainless fittings

52057921542_d819795c32_b.jpg IMG_1412
 
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601176005

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Messages
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Location
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52058959551_fd834440de_b.jpg IMG_1413

52058992548_83e2501ec1_c.jpg IMG_1442

Rear shield was missing, new one fitted

52059196714_c839e78855_c.jpg IMG_1415

Tank straps removed, the rear bumper undertray was ziptied to it, as all the bolts had broken off

52058959501_79c730bc2f_c.jpg IMG_1418

Can see the snapped studs here

52058992753_cb90631fa7_c.jpg IMG_1419

Welded a nut to the broken bit and extracted

52058992738_cedb6458aa_c.jpg IMG_1421

Painted and ready to fit

52057921377_78c31a59e3_c.jpg IMG_1443

Fitted tank protection along with stainless fittings

52062361768_95857e2746_c.jpg IMG_1606

New fixings

52062361748_e59b8be018_c.jpg IMG_1607

Done

52062339126_99ff32e5d0_c.jpg IMG_1609


Next was the rear brakes, not gone too crazy as i will use the car daily.

52058992723_e21b041628_b.jpg IMG_1422

Stripped the whole lot off, this is so i can replace the bolts with stainless

52059444915_c00d60a06b_h.jpg IMG_1423

Repainted backing plates

52057921427_c122119386_c.jpg IMG_1424

ABS and brake line fitting bolts replaced with stainless

52059444805_52abe27e9f_c.jpg IMG_1425

New discs and pads fitted along with the cariers have a quick paint

52058959381_f25126e053_h.jpg IMG_1441

Drivers side

52059444675_2cdda00878_c.jpg IMG_1467

Done

52058992508_7603c9666e_c.jpg IMG_1466

First was the top mount as that was in bits

52059196344_3f2db41532_c.jpg IMG_1470

Inner removed

52059196339_7f5569b5bb_c.jpg IMG_1471

Well gone!

52059444620_248aaca761_c.jpg IMG_1472

New one fitted
 
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601176005

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Messages
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Location
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52058958901_34617e91bc_c.jpg IMG_1532

Full service kit ready to go, cambelt, waterpump, aux belt, new pads, cam cover seals, exhaust manifold gasket

52059445090_ab46d6270c_c.jpg IMG_1407

52062574239_091b98cd3c_h.jpg IMG_15699

Timmed up and locking blocks on

52059196314_8d1430d217_c.jpg IMG_1475

Water pump removed

52057923687_872c3b5e59_c.jpg IMG_1474

New pump, tensioner and bearing

52059198914_0bf974308b_c.jpg IMG_1476

New belt on, re-tourqing the camshaft caps

52057921287_32c5c443d1_c.jpg IMG_1477

Cover re-fitted with stainless fixings

52059196274_d4bed28d51_c.jpg IMG_1478

52059196254_7e7f2fc112_c.jpg IMG_1479

Getting ready to re-fit everything now, non AC water pipe fitted

52058992403_2ff89dcd46_b.jpg IMG_1489

Manifold refitted with brass nuts on everything

52058959126_80f8e46b91_b.jpg IMG_1494

New oil filter on

52059444535_f7ccff1d63_c.jpg IMG_1496

New DS engine mount

52059444500_d54c0514e1_b.jpg IMG_1497

52058992268_5149c1768a_c.jpg IMG_1507

52057921162_3415ebd246_b.jpg IMG_1503

Oil cooler mount cleaned up and painted

52059196179_7b74be79d9_c.jpg IMG_1500

52057921172_38c4d51bbf_c.jpg IMG_1501

Both mount and oil cooler bracket fitted

52058992283_c7712875f5_b.jpg IMG_1504

Bit of a pointless one but fancied a new oil dipstick

52057920897_69963cdefe_c.jpg IMG_1535

Turned down in the lathe

52058992088_073ee346f7_c.jpg IMG_1536
 
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601176005

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New end welded on

52057920842_7733a653e0_c.jpg IMG_1537

And done, nice blingy aluminium one

52059444245_60677f6cc0_c.jpg IMG_1538

52058958801_9418aa484f_c.jpg IMG_1539

Also sorted my water pipe to header tank pipe work

52058992053_8a8341def2_b.jpg IMG_1540

AN12 fitting squared up

52059444195_39680fa7d5_c.jpg IMG_1541

Turbo had no support so made one up that mounts on the block and gearbox

52057920702_1688a5a506_c.jpg IMG_1551

Made a new oil drain on the lathe, this will slide into the hole in the sump

52058958696_ccb51db131_b.jpg IMG_1553

And new drain completed and fitted

52058958676_6a89b67f74_c.jpg IMG_1554

Next was sorting the 3" exhaust
Few issues with the existing, not mounted correctly, rubbers perished, rubbing the handbrake cables

Missing the mounts

52062829330_6e9da35fb1_b.jpg IMG_1569

52061299577_22c0b3136c_b.jpg IMG_1570

First up was to add some proper mounts to the downpipe

52062362058_7e830487f6_c.jpg IMG_1571

52061299477_a153965844_b.jpg IMG_1588
Made a V-Band drop in 400 cell Cat

52062829320_b25467d51a_c.jpg IMG_1572

Moding the downpipe

52062339461_938db5b0e1_c.jpg IMG_1573

52062829280_6cf68c2799_c.jpg IMG_1574

Cat mounted

52062574709_bdb8176858_b.jpg IMG_1592

New centre mounts made to support the mid section

52062829265_f2901150a4_c.jpg IMG_1585

52062339306_0bae636807_b.jpg IMG_1596

Another new mount to pickup the side mount

52062361973_8b34c3c0aa_c.jpg IMG_1586

52062829190_b24d57649c_b.jpg IMG_1595
 
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601176005

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Location
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Rear mount created as this was only using 1 peg

52062339301_c0f9ce4c2b_b.jpg


The original exhaust was at an odd angle

52057913317_0b72f4a15d_b.jpg


So re-made

52061299542_1e505c5711_c.jpg


52062574654_82a1e3da41_b.jpg


All completed and fully supported

52061299267_3283223224_c.jpg


52062829110_aa1d21a34b_b.jpg


Oil cooler re-fitted along with a custom rubber support i made to steady the pipes

52061299332_493932fee8_c.jpg


52062828975_908575733f_c.jpg



Also completed the bottom radiator support, this moves the rad over so i can get the boost pipe around it

52061299077_eee2e7343d_b.jpg


52062338976_2f75360917_c.jpg


52062338976_2f75360917_c.jpg


52062339006_43711ce755_c.jpg


Protection added to the chassis leg to protect the moved PS pipes

52062828725_5b3ed4eba7_c.jpg


New Riv-nuts added to the subframe and towers

52062828845_504ceb754b_b.jpg


52061299237_1e13ffa85c_c.jpg


Trial fitting of the new undertray

52062828775_1de83eae6b_b.jpg




More coming in the next few days!
Thanks all
 

ben

The Boss
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Messages
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Location
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This is an amazing thread! I have converted it to a garage item for you, works the same way but can be found easier :)

Keep up the great work!
 
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