Fuse Board

Long Overdue Update

Finally found some time to update the blog. Following the last post re the clutch lever, my friend Nigel got to work with the welder and fixed the upright permanently. I now have this primed and painted.

Next item to tackle was the starter motor, which was fouling the engine mount bracket on the left side. A small cut out has solved this issue.

I've also been looking around various auction websites and other blogs to find a lower profile engine sump, as the standard FIAT Argenta sump is very deep, which would have needed some serious modifying to prevent bottoming out. (I know that the standard Zero Zetec needs a sump mod to prevent the same issue)......Eventually found one on a FIAT blog site, which was for sale by a chap from Milan. Amazingly it's an OEM item, with a flatter winged lower section and I also found that he had a matching oil pump and a new clutch lever seal, so great opportunity. Sent him a note and eventually agreed a price, so I am very happy with this outcome.

 

 



Nigel's input continued earlier this year when he donated his car support trolleys to my project, these are a superb addition as they allow me to move the car from side to side as required, which, in a tight garage, makes things so much easier to access.

 

 

Next task was to sort out an alternator, the clearance between the FIAT block and the steering column was minimal, so I set about trying to find an alternative. Finally settled on one so that clearance is maximised. This meant I needed to fabricate a new tensioner bracket and find the right belt length to suit the new pulley diameter. All worked out well in the end........another wee challenge overcome. Thanks to Nigel again for getting his hands on some angled mild steel to make the bracket from.

 

 

Next job was the brake pipes, I did some research mainly on other Zero bloggers sites (thanks guys) and settled on the routing for the pipes. Also used transparent plastic pipe to protect the brake pipe from chaffing at bends etc. All good, just need to clip these after I get the fuel pipes in and finalised.

 

 

 

Next job was to pre-fit some of the luggage compartment panels, I'll leave the two outers until after the fuel tank is in for good and I have the loom fitted. These though, were easy to get sorted out, I'll use some rubber sheet as gasket material under the horizontal centre panel which is removeable.

 



 

I've also got the fuel pump and filter mounted, ready to route the pipes to the tank and the engine.

 

 

I've also had the interior panels etch primed and painted to stop corrosion, chap from work did the painting and made a fine job, so now starting to get these installed finally.

 

 

The latest plan is to install the two stainless side panels. Everything was in place to do this yesterday, but I opened the sealant tube to find that the sealant was partly set, so that was the end of that. Check the expiry date on these tubes and ensure they are still in date. the tubes available from Kit Spares just say 'at least one year shelf life'..........which isn't much good but there is an etch printed date on the top, so check this is very recent if buying from here..... I've managed to buy some locally so hopefully get these on soon, which will let me get all the suspension on and start thinking of the rear panel install.......

 

More soon........

Wiring Diagram

Clutch Lever

Been checking all round the engine for clearance issues over the piece and there are two issues to deal with. One being the alternator, which, if I use the original FIAT item, will foul the steering column. More on that later, but definitely not insurmountable. Second is the clutch lever . This protrudes quite a bit from the bell housing and would foul the chassis vertical section at the inboard front corner of the passenger footwell. So it has been cut out, you can see the mock up clutch lever in cardboard to indicate the issue. This photo shows the new position, after a new piece is welded in. Shouldn't affect anything structurally.

So some panel modification will be required, but nothing that will cause a problem.

Inside crescent panel, N/S.

Got round to drilling off the passenger side crescent panel. All good and ready for a coat of paint prior to install.

 

Only the passenger side footwell panels to go, but more on this shortly.....

 

I've also mocked the bonnet in place to check for clearance to the carburettors, I made sure the engine was central (it is not fully committed in terms of position yet) to the chassis, using the crankshaft pulley as the datum. All looks well, although I will need the usual cut out for the air cleaner on the nearside.

 

Front Hub Assembly

Managed to acquire a pair of front hubs, unused, old stock. Decided that I should paint these to stave off corrosion.

Have now mocked these up as part of the front right suspension assembly. Noted all the spacer/washer stacks and positions, then disassembled until after the side panel is finally fitted.

 



Update: Differential In

An update to get this blog up to speed again.....

After some measuring and checking other blogs (thanks Richard and David S) and a chat to Simon & Richard at GBS, I have finally fitted the Lobro type differential.

I did have to carefully trim a small amount from the side support bracket on the left side to clear the diff but this was no problem.

I purchased some spacers online and got the whole thing bolted up.

The left driveshaft is shorter than the right and all looks well as I'll mention later.

 

 



Driveshaft & Stub Axle Renovation

Got the driveshafts online also. These needed some freshening up, as did the stub axles and hub carriers.

I had these cleaned up and painted them. Last job required is to grease up the CV joints and fit the new rubber boots.