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Lancia Fulvia – Front Subframe Repair

Julian
Wednesday, 29 March 2023 / Published in Classic Cars, Restoration

Lancia Fulvia – Front Subframe Repair

fulvia-such a pretty car
The Series 3 Lancia Fulvia – such a pretty car, but did you know it dominated the 1972 rally season beating the much more powerful Porsche 911 in the Montecarlo rally by 10 minutes?

Our customer with his pretty Fulvia was back for some more work on the rolling restoration. We knew from previous photographs from this earlier blog post that the Fulvia subframe was the worse for wear. This is a vital component of the car and facetious comments were made about an aggressive launch away from the lights, causing the engine and drive train to part company with the car.

Joking aside though, we did need to remove and repair this part as a priority. As we will see the subframe has been subject to various repairs before. Ideally you’d send it away to get sand blasted but we we’re sure what we’d get back. Making a new subframe would cost about £4-5k. So the plan was to make good what we had.

fulvia subframe removed from the car
Fulvia subframe removed from the car – arguably doesn’t look too bad from this angle because the oil leaks from 50 years of motoring have preserved some parts better than others
outrigger has been seriously weakened
Outrigger has been seriously weakened by corrosion over the years
the other rusty outrigger
the other rusty outrigger
outrigger with some of the worst corrosion cut out shows that it's been repaired before
Outrigger with some of the worst corrosion cut out shows that it’s been repaired before as you can see the original metal inside disappearing as it has been plated over
This is what comes out of the subframe
This is what comes out of the subframe, we always offer a tub full of rust for our customers to take home as a memento, but oddly nobody seems interested
a picture of some more corrosion on one of the outriggers
a picture of some more corrosion on one of the outriggers
another pic of a heavily corroded outrigger
another pic of a heavily corroded outrigger
subframe outrigger first repair section
Subframe outrigger first repair section ready weld in. Note the old metal bottom right of the picture, and the use of rust encapsulator on the old metal inside the outrigger box section. Note also the use of copper “weld through” to ensure the underside of the new metal isn’t corroding after welding
subframe outrigger first repair section welded in place
Subframe outrigger first repair section welded in place
getting ready to commence repairs on the rustier of the two outriggers
getting ready to commence repairs on the rustier of the two outriggers
piece of oval heavy section tube added to ensure the outrigger bush carriers stays in situ
Here we have added a piece of oval heavy section tube, to ensure the outrigger bush carrier stays in the correct place
this outrigger is so rotten we end up remaking it
this outrigger is so rotten we end up remaking it as the next photos show
outrigger taking shape
outrigger taking shape – this is the other side of the subframe – you can just see the piece of oval tube holding the bush carrier in position
more new metal shaped to form the new outrigger
more new metal shaped to form the new outrigger
another piece to make up the new outrigger
another piece to make up the new outrigger
once again note the use of copper weldthrough to protect the underside of the new pieces
once again note the use of copper weldthrough paint to protect the underside of the new pieces
here is one of the outriggers nearly finished
here is one of the outriggers nearly finished
finished outrigger
finished outrigger painted with Gravitex along with all the other repairs on the subframe

So the next task was to get the subframe back on the Lancia Fulvia and then we proceeded to Lanoguard the underneath of the car.

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