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sanyarcosean
sanyarcosean HalfDork
8/6/25 12:51 p.m.

This thread is probably going to be like one of those books/movies where you jump back and forth in time so much it makes your head spin a little..  That's ok, because for me at least ( and maybe for you all ) the car is cool and it's story is worth telling.  It's got it all..  from languishing on its deathbed to winning races and maybe even a few Hollywood type moments.  It also crosses multiple generations of our families.  So without further ado let's get in the wayback machine ( no really, I used the internet way back machine ) set the year to 2004 and get this story started.


After a very successful entry in the 2004 Grassroots Motorsports Challenge there was much talk between Andrew Nelson and I about what car we would bring to the 2005 event.  Many ideas where considered, but one stood out.  A BMW 6 series that was posted on the message board for sale near us.  After some conversation it was found that the car had been sold to none other than Quasi Mofo…….  Yeah you read that right…  Gotta love screen names!!  

The day we had hoped to go and pick up the beemer, my son Aaron and I went junk yard shopping.  While at a local yard Aaron came to me and said “Dad, I think I found your challenge car for next year”  Keep in mind that my son was only 11 at the time, so I had some doubts, but I went to take a look.

I followed him through the yard, and as I turned the corner and saw the car for the first time I was not sure exactly what it was.  The only badging on the whole car was the center of the horn button.  Aaron had found a Fiat.

 



The Fiat was very rusty and was missing its engine.  It did still have its factory hard top.  It looked like a neat car, but more work 
than it was worth.  I called Andy to tell him about some Porsche 924s that we had found, but nothing that really excited either of 
us.  Then I mentioned the Fiat.  Andy was Very interested!!  Soon after that he had joined us at the yard to look the car over.  While talking with the people at the junk yard we learned that the car was a 1964, but we still did not know the model. (Or as it turned out even the year)

Andy looked the car over.  Measured the wheel base.  Fantastic!!! Its over 90" (92.4" wheelbase to be exact) making it NHRA legal for an engine swap!!  Did you ever notice the gleam in Andy's eyes when he thinks about a high horse small block in anything?

A deal was struck and the Fiat was loaded up and brought to my shop for some paint stripping and cleanup.  Hard to believe a 
car with 34,507 miles could be so rusty.  Definitely not 134K miles.

 

vwcorvette (Forum Supporter)
vwcorvette (Forum Supporter) GRM+ Memberand PowerDork
8/6/25 6:55 p.m.

The Story Of The Meme: As Told By Memes - Studio Culture

Dusterbd13
Dusterbd13 MegaDork
8/6/25 7:21 p.m.

I like the lines of that.

Watching with interest 

wvumtnbkr
wvumtnbkr GRM+ Memberand UltimaDork
8/6/25 8:03 p.m.

Moar!

sanyarcosean
sanyarcosean HalfDork
8/6/25 10:15 p.m.

Ok present day Fiat has a cooling issue.  It's old swapmeet aluminum radiator can't keep up.  There also isn't any core support or ducting to keep air from bypassing it.  Oh and it has an intercooler in front of it.  Time to see what we can do about that.  Out with the old...  

Lets fill that hole with a new 3 pass radiator and a Burndown Silverado fan..  

Looks like it will all fit!  Time to start making core support parts.  Better get some cardboard to make a template

Passenger side mocked up.  Let's get it in CAD, add flanges for mounting, make a flat and maybe an STL file and 3d print it for one final check while we wait for the sheet metal brake to get here.  

That's all for today.  Maybe tomorrow we will continue with some history while I wait to be able to get back to the shop to work on her.

rdcyclist
rdcyclist GRM+ Memberand Dork
8/6/25 11:05 p.m.

Holdonjustaf*ckin'minnit... There's quite bit missing between post #1 and post #2. You gotta fill that E36 M3 in 'cuz there's a big change in appearance there...

sanyarcosean
sanyarcosean HalfDork
8/7/25 12:02 p.m.

In reply to rdcyclist :

To be fair, I warned you about the time jumps.  devil  If you want to skip ahead in the story, you can go HERE for a sneak peek.

Or sit back and enjoy as I pull from the old Sanyarcomotorsports web site as well as ramble through my memories. ;-)

sanyarcosean
sanyarcosean HalfDork
8/7/25 12:16 p.m.

Back to 2004...

After some research, and contact with the Fiat Cabrio Yahoo group we found that the car was a 1962 Fiat 1200 Cabriolet.  The car itself is not very rare, although you do not see them all that often. It is one of 11,851 made between 1959 and 1963.  The rare part turned out to be the factory hard top.  It is thought to be one of less than 300 in the WORLD and may be one of the only ones found on a 1200.  At that point it was decided that the top would stay with the car instead of being sold.  According to the experts on the Fiat board "You could spend $20,000 to restore the car and have something worth maybe $7,200 with a $2,000 hard top. Or, you could spent $2,005 and make a race car that would be worth $10,000 with a $2,000 hard top.  The car does not have much value, but the top does."

With that, we began to strip everything from the body, sell anything usable to Fiat 1200 enthusiasts, evaluate the cars condition, and remove the old paint and rust.

Look how small that engine bay is.  
Whatever will we do.......


sanyarcosean
sanyarcosean HalfDork
8/7/25 5:42 p.m.

May 2004 Build Pictures

vwcorvette (Forum Supporter)
vwcorvette (Forum Supporter) GRM+ Memberand PowerDork
8/7/25 6:47 p.m.

Please tell me you changed out that "steering" system. Looks very Rube Goldbergian!

rdcyclist
rdcyclist GRM+ Memberand Dork
8/7/25 7:28 p.m.
sanyarcosean said:

In reply to rdcyclist :

To be fair, I warned you about the time jumps.  devil  If you want to skip ahead in the story, you can go HERE for a sneak peek.

Or sit back and enjoy as I pull from the old Sanyarcomotorsports web site as well as ramble through my memories. ;-)

I shall sit back with my refreshment of the moment and follow along. Thank you for the ramblin'...

sanyarcosean
sanyarcosean HalfDork
8/7/25 8:24 p.m.

In reply to vwcorvette (Forum Supporter) :

Yep, whole fire wall went away and was replaced further back.  Steering is rack and pinion now.  The Original Fiat steering was well... "original".

sanyarcosean
sanyarcosean HalfDork
8/8/25 10:36 p.m.

June 2004 Pics

sanyarcosean
sanyarcosean HalfDork
8/8/25 10:47 p.m.

July 2004 Build Pictures

wvumtnbkr
wvumtnbkr GRM+ Memberand UltimaDork
8/8/25 10:51 p.m.

Moar!

sanyarcosean
sanyarcosean HalfDork
8/8/25 11:06 p.m.

July 2004:

Honestly, my part of this build was all grunt, While Andy had the plan and the skills. With this car unlike the Nova, we wanted to be competitive in the Drag, Autocross and concours.  For Autocross, the front suspension was going to need some attention. Plus, those fiat brakes weren't going to cut it. Andy used that skill to graft 68 Nova control arm ends to the factory Fiat arms. That let us use Nova spindles and drum brakes.  Easy on the budget and plenty of stopping power for a car this light.

 

 

sanyarcosean
sanyarcosean HalfDork
8/12/25 1:53 p.m.

Present Day Fiat Progress..  

3d printed the passenger side core support to check my fit/design before I make metal parts.  It fit up pretty good, but still needs some tweaking..

Also, this showed up over the weekend...

Should make life a bit easier...

sanyarcosean
sanyarcosean HalfDork
8/12/25 11:16 p.m.

Back to 2004 and we needed a hood since the car didn't have one when we bought it. Andy gave me the task and I found that needle in a haystack not too far from home.  It wasn't so much a hood.. it was more like the idea of a hood. This thing was ROUGH!! With a lot of patience, scrap, tube and a scoop cut off of a cheap swap meet Chevy truck hood Andy created a hood for us.

 

sanyarcosean
sanyarcosean HalfDork
8/13/25 12:27 p.m.

And that door...  

Before


After

sanyarcosean
sanyarcosean HalfDork
8/13/25 7:50 p.m.

Back to today in Fiat History..    I got an hour or so after work to fine tune the core support.  Should be ready to make the last prototype then on to Aluminium.  I'm probably being anal about it, but the car deserves anal...  

I also got to put my Burdown Garage Silverado fan together and mark the shroud to get cut.

I still need to decide on a Fan Controller.  I'm leaning toward the Lingenfelter unit.  Time will tell.

sanyarcosean
sanyarcosean HalfDork
8/24/25 10:22 p.m.

Back to present day Fiat...

I've been collecting some low dollar tools that hopefully will be a huge help for me.

First purchase was a HeroCut 45i plasma cutter from Amazon.  It had some favorable YouTube reviews and for right around $100 for it seemed like bargain. 

Also, Eastwood had a portable plasma table on sale.  It fits on a fender/bodywork stand.. for $53.00 count me in...

But the big one is my 24" Vevor Finger Brake.  As well, this has some favorable YouTube reviews and will handle 20 ga carbon steel and 16 ga aluminum. For $215 delivered how could you go wrong?  

I also grabbed a rolling Vevor 18 x 36 Welding Table..  it's really solid and I look forward to using it! That set me back a whole $85 delivered..

Next up, Some Cleco clamp goodness!

Then I got myself a Vevor Rivnut tool kit for $43..  gotta be able to bolt things together...

Last but not least... a couple of 18" x 24" sheets of .060 aluminum. 
 

Now that we have that all out of the way... let's make some parts..

I fine tuned my core support design for the passenger side and made one final 3d print to do a fit check.

Happy with my prototype, I let Solidworks make a flat pattern from my model.  I added slots to the flat on the brake lines and then 3D printed the flat to use as a stencil to layout my part on the aluminum.  My driver side part should be pretty much the opposite of my passenger side. ( thankfully true.. you'll find out why a little later ) So one template will do.

Then it was off to the plasma table to cut the part. I used a piece of aluminum bar I had as a guide for the straight cuts and did the curve free hand.

Like butter...

Time to tryout the brake!  I checked my prototype to make sure I bent everything the right direction... and.....

Nope... broke it backwards. That's ok though, a couple trims with the plasma and cut-off wheel and it's magically a driver side core support...  Fits like a Glove 

When I get to the shop next, I'll repeat the process and make the Passenger side part. 

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) GRM+ Memberand MegaDork
8/24/25 10:25 p.m.

Dang, you made some nice additions to the tool collection.

sanyarcosean
sanyarcosean HalfDork
8/25/25 8:59 a.m.

In reply to AngryCorvair (Forum Supporter) :

Honestly probably the BEST $500 investment I've made in the shop in years.  Only thing I need to redo is the table I have the break on. It's WAY too light and flimsy.  I can repurpose it for my chop saw, so not a big loss.

sanyarcosean
sanyarcosean HalfDork
8/25/25 7:53 p.m.

Had a couple minutes after work so I made the Passenger side core support.  The pair fits great and it should block off the air that was bypassing the radiator on the sides.  Next to make something to close off the top.

sanyarcosean
sanyarcosean HalfDork
8/28/25 12:01 p.m.

Hope to get a TON of shop time over the long Holiday Weekend to make progress on the Fiat, but until then..  back to 2004...

August 2004 build photos

https://www.flickr.com/gp/34826274@N06/10Jbv34M00

September 2004

https://www.flickr.com/gp/34826274@N06/a96F6186h3

October 2004

https://www.flickr.com/gp/34826274@N06/5d1814Ju5n

November 2004

https://www.flickr.com/gp/34826274@N06/5bkyMA6y01

December 2004

https://www.flickr.com/gp/34826274@N06/824Q7126q0

2005 Pre Challenge testing and interior

https://www.flickr.com/gp/34826274@N06/a4j53G5G7S

 

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