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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:
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All fairly complete, just needs some work.

Now in my workshop

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Pre strip down to discover whats undernearth.

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

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Lots of silicon and clamps...

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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.

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Lots of pipe joiners and jubilee clips!
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AC has seen better days!
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Lot's of cracked pipes
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Lots of stuff like this, hoses just capped off...

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

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

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Stripped out

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Wiring repaired and heat shrunk

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New boot and thats one job done

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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.

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

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

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

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Yummy!

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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.

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New mounts welded to the removable front panel

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Pie cut and welded, this wraps around the radiator:

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Very tight but 15-20mm of clearance all around

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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

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

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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.

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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

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AC and Non AC
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Mount removed and block cleaned

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New mount on

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Change the PS bearing as both were worn

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Fitted

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Next was to sort the maniold as it was cracked

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Can just see them here

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Ground out

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TIG welded up

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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.

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All studs replaced

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

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

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Pass side

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Re-routed the shock canisters into the engine bay

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Some good news though, very clean! Zero rust!

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The drivers side front tower was rusty so changed that.

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

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U-POL zinc primer on first

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Back side also

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Re-welded

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Old and new

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Gave the new tower and chassis leg a spray

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One side done

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Pass tower was ok but the leg was scabby in places

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Primed

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

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

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Fitted up with stainless fixings again

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Drivers side with new horn brackets

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Nice simple job, bonnet, new handle and cable

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Fitted

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

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Underseal removed and sill straigtend

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Re-underselaed

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Same on pass side

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Moving onto the rear now

Corrosion check, all looks good!

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Stripping the rear arch liners off

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Looks good!

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Boot floor

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Pass side tower is a bit scabby

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Drivers side has gone

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Cut off and new one welded in

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Few little scabby bits where the underseal has lifted

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

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

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Rear end done

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Rear jacking points still good!

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Even clen inside! All now protected

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

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Boot floor still mint

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Front end protected also

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Cleaning up and refitting the arch liners

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Painted the bumper mounts

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Foam back on

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Fitted

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Rear mud flaps fitted with plastic fittings rather than the rivets

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

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Boot done!

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

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Second hand one which was cleaner

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Cleaned, painted and ready to go

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Much better, with stainless fittings

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Rear shield was missing, new one fitted

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

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Can see the snapped studs here

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Welded a nut to the broken bit and extracted

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Painted and ready to fit

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Fitted tank protection along with stainless fittings

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New fixings

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Done

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

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

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Repainted backing plates

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ABS and brake line fitting bolts replaced with stainless

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

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Drivers side

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Done

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First was the top mount as that was in bits

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Inner removed

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Well gone!

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

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Timmed up and locking blocks on

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Water pump removed

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New pump, tensioner and bearing

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New belt on, re-tourqing the camshaft caps

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Cover re-fitted with stainless fixings

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

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Manifold refitted with brass nuts on everything

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New oil filter on

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New DS engine mount

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Oil cooler mount cleaned up and painted

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Both mount and oil cooler bracket fitted

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Bit of a pointless one but fancied a new oil dipstick

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Turned down in the lathe

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New end welded on

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And done, nice blingy aluminium one

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Also sorted my water pipe to header tank pipe work

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AN12 fitting squared up

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

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

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And new drain completed and fitted

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

Missing the mounts

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First up was to add some proper mounts to the downpipe

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Made a V-Band drop in 400 cell Cat

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Moding the downpipe

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Cat mounted

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New centre mounts made to support the mid section

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Another new mount to pickup the side mount

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Rear mount created as this was only using 1 peg

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The original exhaust was at an odd angle

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So re-made

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All completed and fully supported

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

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

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

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New Riv-nuts added to the subframe and towers

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Trial fitting of the new undertray

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More coming in the next few days!
Thanks all
 
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