WFSZ16 02

The left wing is bent and very hard to move.

Sandblasting begone

Hello everyone. Last monday is started work on the fulvia zagato

At first i put the doors back in the car to get an idea of the shape of the bodyshell

The innerwing/chassisrail was broken loose so i drilled the spotwelds that were still attached to take it off completely

The Apillar with the doorhinges was badly repaired in the past

So i cut it out completely

Because there’s still some old damage and poor repairs on the car decided to make a jig with factoryreferences to be able to make the new subframemounts in exacrly the correct spot in all directions, length, width and height

Start of the rearmounts

Start of the frontmounts

A bit offset and angled to create acces to the bolt and a tight fit in the subframemountingbox

The boxprofile from left to right is exactly level to the referencepoints for the body on a fixed height

Diagonal crossbars fixate both front and rear referencepoints. And a few extra bars to fixate the length. Together with Wainer we took our time to make sure to level the car out on the concrete floor that wasn’t level so the car is now completely level and fixated on the jig

The innersill and floor on the driversside is now accessible to replace

Last week ik started on the zagato again

Previously removed damaged parts from the driversside frontcorner

The first new piece for the innerpanel at the Apillar

Removing more damaged panels

The front section of the innerpanel behind the Apillar and attached to the firewall

Marked all profiles and shapes

The next piece. Part of the chassis next to the transmissiontunnel

The reinforcementplates made new

Lower part of the firewall

Start of the new Apillar. In the car was a very rough welded over pillar from a first series zagato do i copied the passengerside and mirrored it

Starting to get some shape and adding the details

Reinforced the pillar to make the tophinge a bit stronger

Making a new boxsection for the subframemount

The new floor needs some modifying because it’s lacking some shapes and details

Starting to get there

The cablegutter in the innersill was to long so the subframebox could not get high enough in the innersill so i shortened it

The rear of the innersill was 16cm to long

The front of the floorpan was missing some details like a supprt for the throttle

All of the old innersill removed

Supported the car on jackstands

Started to put all the new panels i made in with little selftappers to check for fitment

I had some outersills made and added the details it needs

First fitting of the door. Vertical line was good. Just a little modification needed on the Apiller to allow the tophinge a bit towards the center

Started making the closingpanel for the frontwing

Shaping the panelgap with the door

Added the details to give enough clearance for opening the door

I made the gap 6mm to allow for the 1mm frontwingsection to be folded over the edge

Another week on the Zagato. Making a new subframebox for the passengerside

Starting on the new Apillar

Made recesses for the hinges

New Apanel for the passengerside

Getting there with all the shapes and details

Started drilling and cutting out all the rot and older bad repairs

Firewall, transmissiontunnel and dashboard put on the side until the car has got some strength back

Starting on fixationpoints on the rearmounts of the rearsuspension so that what’s left of the body is perfectly in place

Crossbar to fixate the mounts square and in place so the body is perfect straight and level

Another week on the zagato. First i cut out the frame that was weldeld in when the car was not straight

Made new cornerpieces for the end of the panel under the rearseat

New reinforcementplates for the floorpan

Trialfitted the floor

Adjusted the driverssidefloorpan

The pressing of the passengerside floor was way off. The footwells didn’t line up on both sides

So marked and with a hammer and a dolly i reprofiled the footwell

Cleaned the old parts of the floorpans on the bulkhead

And started making a jig for the front and middle subrame mountingpoints