Lancia Delta Integrale
Vehicle • Porsche 964 Restomod Murano Green
Year • 2024
Main Materials • Tan Automotive Leather, Tone-on-Tone Alcantara
Zonam carried out the conservation restoration and complete period-correct reconstruction of the interior of an iconic Lancia Delta Integrale. Unlike restyling or restomod projects, the aim was to strictly preserve the original factory (OEM) specifications: the Recaro sports seats and door panels were restored to their original condition using custom-perforated black Alcantara, dedicated backing fabrics, and heat-embossed logos applied using engraved brass dies.
The complexity of the project lay in the re-engineering of the Alcantara perforation pattern (hole diameter, pitch, and center-to-center spacing), combined with sourcing the underlying fabric visible through the micro-perforations and structurally restoring the Recaro seat padding.
PERIOD-CORRECT RESTORATION VS. PASSIVE REPLACEMENT
Redesign
Using old Alcantara upholstery covers as templates for cutting new panels is a common technical mistake. After more than three decades, the synthetic fibers and backing fabrics undergo mechanical stretching, becoming elongated and asymmetrically deformed under the weight of the occupants.
ISSUES WITH ORIGINAL UPHOLSTERY AND THE ZONAM PROCESS
Worn Alcantara ──► Molecular Stretching / Deformation
Passive Pattern Copying ──► Tension Defects / Final Wrinkles
ZONAM METHOD ──► Original Dimension Measurement
Pattern Redesign from Scratch
Dynamic Fitting Tests on Recaro Padding
To ensure perfectly taut, wrinkle-free surfaces across the deeply contoured Recaro seats, Zonam reconstructed every individual upholstery pattern from scratch. Each panel was shaped and tested directly on the restored padding, calibrating the Alcantara tension with millimeter-level precision.
PERFORATION AND BACKING FABRIC RESEARCH
Engineering
The center sections of the seats and the door panel inserts of the Lancia Delta Integrale feature a distinctive perforated pattern. Rather than using generic commercially available perforated Alcantara, Zonam precisely measured the original component’s specifications:
- Dimensional Analysis: Microscopic measurement of hole diameter, spacing pitch, and center-to-center geometry.
- Custom Perforation: Mechanical reproduction of the perforation pattern on the selected batch of black Alcantara.
- Backing Fabric Selection: Light passing through the micro-perforations in the Alcantara reveals the underlying substrate. Zonam conducted dedicated textile research to identify a backing fabric with the correct weave, density, and shade of black, preventing unwanted color variations.
RECARO SEATS AND HOT EMBOSSING OF THE LOGO
Structural Restoration
Padding Reconstruction
Recaro-derived sports seats are prone to polyurethane foam deterioration caused by friction when entering the vehicle. Zonam installed new genuine Recaro replacement foam padding in the most severely damaged seat bases. Sections showing minor wear (upper side bolsters and backrests) were instead carefully rebuilt and reshaped by hand in the atelier, preserving the original material.
Logo Embossing
The original Alcantara backrest features an embossed logo. To faithfully reproduce the factory marking without resorting to inappropriate printing or embroidery techniques:
The exact vector artwork of the original Lancia logo was digitized.
A solid brass die (cliché) was precision-milled using CNC technology.
The logo was embossed onto the new Alcantara panel through hot embossing at controlled temperature and pressure, creating a permanent, tone-on-tone three-dimensional impression.
FAQ
Why is it not recommended to use the old Alcantara from the Delta Integrale as a cutting template?
Over the years, the Alcantara stretched over the seats elongates and loses its elastic memory. Using the old panels as cutting templates transfers these deformations to the new material, resulting in unsightly wrinkles or areas of uneven tension.
How is the Alcantara perforation pattern recreated for the Lancia Delta?
The original Alcantara is analyzed to determine the exact hole diameter and spacing of the perforation pattern. Custom perforation is then carried out on the selected batch of black Alcantara, which is paired with a specific backing fabric visible through the perforations.
How is the embossed logo on the Recaro headrest reproduced?
The logo is reproduced through hot embossing. A custom brass die is CNC-engraved and then heated and pressed onto the Alcantara, creating a raised emblem with the same finish and depth as the original OEM marking.
Do the Lancia Delta Integrale door panels feature the same upholstery techniques as the seats?
Yes. The door panels feature the same perforated black Alcantara and backing fabric used in the seat center sections, ensuring complete stylistic and chromatic consistency throughout the cabin.
CONTACTS