Making progress on the Lamborghini Urraco

So here are some updates:

1) This is why I appear to make good progress - when others are watching TV I am in the garage with 4 layers of clothing on getting on with the job

2) and 3) a jig shaft to align the original and Volvo strut mounts for marking out and reshaping and drilling the mounting holes

4) had so make a piece to repair a big chunk missing from the heater scoop - not sure how that was broken off, but it would explain why the fresh are intake wasn't so good in summer! Original is made from ABS and the new white piece cut to fit the broken section is glued in with ABS solvent cement (used by plumbers)

5) I found one Urraco/Countach wheel on ebay only 40 miles away - I won it and know I have it It's not so pretty and will need properly cleaning, sealing and painting but I wanted an extra spare...

Lamborghini Urraco front suspension rebuild - new top mounts

So now to rebuild the front suspension.

Cleaned and painted bits going back on. Everything is in re-usable condition.

Made new suspension top mounts from Volvo 240 items as per Tony's website. It's a cheap solution. Not a rose joint, but they are new and £20 each so it's a good compromise. The shock doesn't pivot very much at all at the top from top to bottom travel (and of course the Volvo suspension is very similar anyway).

Ok, it's not a rose joint, but I think for my usage (shows) it will be fine. We'll test for the first time next week. They need an adapter bush machining as the hole in the Volvo mount is larger (diameter) and clearly sunken in a well.

Because I can't use the original large hex washer (which allows you to lock the spindle as you tighten the nut) I had to use two thinner nuts to luck the top mount on. Bottom nut is original machined down and the top one is actually a VW wheel nut machined down, advantage is being smaller you can more easily use two spanners to tighten it.

Last picture is the whole front axle assembly installed now and bleeding the freshly rebuild calliper.

Just the drivers side left...

Lamborghini Urraco brought back to life for 2014!

It's alive! Now the fun stuff.

Finished painting the boot floor with Por-15 then a coat of satin black to match the original and start cleaning everything up - lots of dust.

Spot blasted the earth fixing points for the various applications at the front and fastened them with stainless bolts. Went through all the lamp and motor wiring cleaning dirt/underseal/overspray off (carefully using paint stripper) and replacing hardened PVC sleeving as needed. Re-wrapped some of the cable sleeving joints and fed the looms back through new grommets into the headlamp wells.

Slide the radiator back in through the front and hook it up and add the coolant back in - no leaks yet

Finally started it up after 3 months! Good to hear the engine running and everything appears fine after it's brief hibernation.

Next is building up the front suspension and brakes. I reckon only another week or two and we'll be mobile ready for the UK MOT test.

Lamborghini Urraco front valance finishing 3M textured underseal

Now to add a little filler to smooth over the welds and even up a few imperfections. Not much filler added at all. Then painted with rust and etch primer and finally a coat of textured 3M underseal - nice finish across the whole lower valance now and no rust.

Lamborghini Urraco front valance repair

Original chassis number section #15662 tacked back in as well as the spare wheel support.

I've finished welding on the passenger side (RHD) now moving onto the drivers, a little cutting needed first then the end is in sight. Painted the new metal on the passenger side with POR-15 then I'll stone-chip in black and that side will be ready to build the suspension back up.

Once I had welded the drivers side lower valance the last job was to weld on the centre outer valance flat section, fill around the joins and finish. I'll probably just paint the whole lower valance including grills black and with stone-chip texture as it was and is a typical 70's style finish.