Author Topic: And So It Begins....  (Read 55920 times)

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Offline SanRemo78

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Re: And So It Begins....
« Reply #460 on: April 17, 2025, 10:56:59 AM »
Christmas arrived today - a shipment from Australia containing a set of four Bangin' Headlights. Beautifully packed, nothing damaged and it got through HM Customs without attracting any extra Duty ::).

I grabbed a set of Carello headlight assemblies plus a Siem trim ring and they are a very nice fit. I'll be using the Carello assemblies as i have a better set of those (I may have scrapped the rough Siem ones..). I will need to find a few fixing screws as it looks like the assembly will protrude about 5mm further away from the bowl. I can live with that. The Carello lights have the plastic backing cup and there is enough room in there for the back of the headlight projector too. Only slight concern will be heat so it may be wise to run without these for added ventilation.

Picture attached with the trim rings fitted, top is Carello and bottom Siem.

Guy

Alex, the three little bobbles on the headlights don't foul the trim rings!

I may have to wire up a headlight this weekend and see what they're like compared to a standard headlight!

Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #461 on: April 17, 2025, 03:11:13 PM »
Ignore the comment about the Siem rim.. I have no idea what the lower one in the last picture is off! I just found a set of reasonable Siem lights and the exposed rim looks like the Carello one but the back is different. The headlight adjustors fit into the clip on the back of the headlights on the Siem ones. The Carello ones fit into slots on the side of the nest.

I may have some new and old headlights available soon for beer tokens... I need to replenish the paint fund as I just put the first scratch on the body. Caught a boot on the door sill edge. Not much but it's deep and there and I know about it. It was always going to happen... Not quite as pissed as I thought I would be. Hey ho.

In other news the headliner is clipped in place and looks good but won't photograph yet! I need to stretch it into it's final position, trim the edges further, fit the grab handles, mirror mount, visors and courtesy light first. I also want to put some foam padding on top of the sound deadening underneath the headliner to give it a better feel. The carpet also went down today, temporarily, it also needs some padding underneath to replace the felt that came out two years ago. I think some closed cell neoprene should do nicely.
Guy
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline WestonE

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Re: And So It Begins....
« Reply #462 on: April 17, 2025, 06:11:19 PM »
I like the look of the top one. The rounded lens looks right for the period. I am waiting to see what they look like installed. 

Offline A Ross

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Re: And So It Begins....
« Reply #463 on: April 18, 2025, 09:18:42 PM »
They look great Guy - glad there's no fouling of the bobbles on the rings - it wasn't quite clear to my eyes from the Bangin' Headlights webpage photo. Can't wait to see them fitted up on the car.
1979 Beta Berlina 1300 (late) S2 - Rosso Nearco 2024 -
1980 Beta Coupé 1600 S2 FL1 Metallized Blue  2023 -

1979 Beta Berlina 1300 (late) S2 - Ascot Verde 1979-1989
1988 Prisma 1.6 i.e. - Lancia Blue 1988-1991

Offline SanRemo78

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Re: And So It Begins....
« Reply #464 on: April 19, 2025, 08:41:10 AM »
Patience young man! I stripped the headlight assemblies back to their component parts yesterday now that I know it will all go together. They'll be off for powder coating on Tuesday (with a few other bits) so I may get them back towards the weekend. Following week I'm off to Gerrys for a week. I may get a chance to assemble them and do a trial fit soon though. I've ordered some M3 stainless cap head bolts to replace the rotten Phillips head ones that secure the bezel, they need to be 6mm longer. My only slight concern is going to be the plastic headlight surrounds now - how much clearance is there? Will they foul the three tabs on the rings now they're slightly further forward. Time will tell.

Carb to airbox mount rubber/spacers/plate in the post to you this morning Alex!

Guy
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #465 on: April 23, 2025, 07:05:45 PM »
A little progress in the last few days. I bought some closed cell padding, 15mm thick for the headlining to create a pad underneath the Alcantara and that landed this morning. Unfortunately I should have bought 30mm thickness pads.... I've started fitting double layers of it and it's gone very well so far, just the bits infront of the first rib to do and then I can think about a little contact adhesive and final trimming leaving just the pillar covers to contemplate.

The headlight assemblies are being powder coated now, collection on Friday. Some Allen socket screws arrived today and are marginal on length. I think, for the sake of £3, I'll buy some longer ones. Hopefully I'll get a chance to assemble everything on the bench before I go to Gerry's next Monday!

Lastly I dragged out the exhaust heat shield. It was a bit battered and bruised but a little persuasion with some suitable tools has restored it's correct shape. I think. It was also covered in years of crud, underseal, oil and road dirt. A day with a filler spreader carefully removing it all and then a bit of sanding have restored it nicely. I may drag the polishing kit out to get a mirror finish on it and protect that with some lacquer but there are a couple of splits in it that need a slight welding first and a spot that's been rattling on the front pipe to centre clamp that needs more careful attention.

Lastly, a question for those that know!

How thick is the felt padding that sits between the carpet and floorpan?

The carpet is loosely in but it's very "baggy" so I need to replace that too. Another job for the closed cell foam but this will be stuck onto the back of the carpet rather than the floor I think.

Guy
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #466 on: April 23, 2025, 08:12:06 PM »
It's these mats that I'd like to know the thickness of. Obviously I threw these straight in the bin, they fell apart when I removed them and stank! Held a lot of water too....
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline Nigel

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Re: And So It Begins....
« Reply #467 on: April 23, 2025, 09:42:11 PM »
Guy, I reckon it was about 15mm. That's roughly what I put
back in mine.

N.
1984 2.0 Carb HPE [ex Aus] Grigio Finanza.
2007 Mazda 6 2.3 [current daily, highly recommended]
The past:
1980 2.0 HPE White in South Africa [hope it survives!]
1976 1.6 Coupe Lancia Blu [PFG 76R] [probably deceased]
oh,and an Uno Turbo 1997 also in SA [stolen,never recovered]

Offline SanRemo78

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Re: And So It Begins....
« Reply #468 on: April 25, 2025, 07:02:40 PM »
Headlining and carpets take a step back when shiny stuff arrives... A batch of stuff went off for powder coating this week and they did a great job of it once again.

The strut to slam panel bars took about 5 minutes to install. No surprises there and then it was time to start some headlight reassembly!
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #469 on: April 25, 2025, 07:09:26 PM »
First step is working out which side I want to do - and since the backing plate is handed, but can be flipped upside down, I decided to do the left side. Put the backing plate on the table, identify the mounting holes for the bucket and fit the plastic retainers then screw them in place with some nice shiny stainless self tappers.
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #470 on: April 25, 2025, 07:12:51 PM »
Then fit the plastic plugs for the adjuster rods and the rods themselves, clip the nest into the adjuster rods and fit the tensioning springs.
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #471 on: April 25, 2025, 07:16:44 PM »
Then clean up the retaining rings and fit the headlights into the nest. As you can see they fit very nicely with nothing poking out the back.
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #472 on: April 25, 2025, 07:18:35 PM »
And the plastic covers clip on too!
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #473 on: April 25, 2025, 07:22:31 PM »
And this is where it went tits up. I mounted the unit in the car and it's sitting way too low. I need to remove it fully, have another look at it and see where I've gone wrong. There's no way the surround is going to fit that.

It'll be something simples won't it?
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline HFStuart

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Re: And So It Begins....
« Reply #474 on: April 25, 2025, 11:34:14 PM »
You haven't put the RH unit upside down on the left side have you?

Offline SanRemo78

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Re: And So It Begins....
« Reply #475 on: April 26, 2025, 08:16:33 AM »
I don't think so Stuart - I have three backing plates to build the light units up and they all have the same number stamped on them. There are holes stamped in them to allow the headlight buckets to be assembled either way up so one part does both sides. I suspect it's a panel alignment issue. The valance is slightly off centre as the two upper mounting holes in front of the radiator aren't screwed in and the lower brackets to the subframe are also out of kilter and not attached by the bodyshop. The outer brackets to the wing/inner wing were fitted by the bodyshop and I suspect there is an alignment issue with them pulling the valance in the wrong direction.

Plan for today is to pull the first light unit off and build up the second one. Then I'm going to offer up the headlight surrounds and see if they fit and look correct. If not I'll pull the bumper off and remove the front valance and try to refit it starting at the middle mounts, top and bottom, then the wing joints and then the outer brackets. And if that fails to correct the issue I'll try the second valance I have and pray that fits better! I'd better find my masking tape...
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #476 on: April 26, 2025, 11:24:40 AM »
Had a really close look at the photographs i took before disassembly and built up another left side unit and swapped them over. I think I had the buckets mixed up for high and low beams. The second unit slotted in and there's more clearance now, enough to get the trim on, it's not fully home yet but will go in once the valance is properly nailed down and the plastic cups fitted to receive the tags.

Phew.
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #477 on: April 26, 2025, 11:33:13 AM »
And the more observant of you will notice that the grille is making an appearance! in the photo above.

Took the first assembly attempt apart, flipped the mounting panel over, popped the plastic plugs out and reassembled with the correct bowl position and fitted the new lights and dropped it in, trim slides over it and will also drop into position with a little persuasion once the receivers are put into the valance, grille looks like a great fit too.

The plastic is now all off the car until the end of the build. One thing I hadn't thought about until this morning is that the Bangin Headlights have an indicator function built in but no sidelight. I think I might use these and dispense with the one in the bumper which will give me a chance to fit a fully clear lens into the bumper and double up on the sidelight bulbs. If I can find any that is.
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline SanRemo78

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Re: And So It Begins....
« Reply #478 on: April 26, 2025, 04:54:59 PM »
And to cap off the headlights I have found the missing covers this afternoon lurking in another box which raises a small query! There are two types with different number inside. I have a set of 4 with the tag at the top to squeeze to remove the cap easily whenever needed and a pair without the tag. At first glance I assumed the tables ones were merely broken but they never had the tag on them. So, a question! Should I be using 4 with tags or 2 with and 2 without and if it's a mixture, which is the inner and which the outer? And does it matter! All these, and more daft questions to come as the rebuild continues!

Guy
Hawk HF3000 - Square Arch Stratos Replica - owned since 1988.
Skoda Superb Scout 2021. Believed 1of 1 in the UK!
Fiat Panda 100HP and now -
A Lancia Beta Coupe 1981 2 Litre

Offline peteracs

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Re: And So It Begins....
« Reply #479 on: April 26, 2025, 05:14:09 PM »
Hi Guy

Never seen the tagless ones. Do your bowls have the required indent to accept the tags?

Peter
Beta Spyder S2 pre F/L 1600
Beta HPE S2 pre F/L 1600