101 1300 rebuild 15: almost back together

Goodness I’m tired! Saturday was a long day but I got close to being back where I should be. Let’s see, where to begin. So I got the piston/connecting rod that was in backward out and took it to Norman Racing Group on Thursday afternoon. Dan Marvin agreed to check the rod for straightness and pointed out that the piston was making contact with the head, something Tom Sahines told me to look for. I brought the head along too so they could tell me if there were problems with valve clearances etc which was a good thing as it was needed to cut the pistons down to clear the head. I asked if they could do a one day turn around on Friday so I could reassemble everything this weekend if I got the other three pistons to them first thing Friday morning. They said they would try.

I left their shop and pulled the other three pistons. I can’t complement Norman Racing Group and Dan enough. I had my wife drop the pistons off on Friday morning about 10am and they were ready when I got there at 430 to pick them up. I guess the bag of pastries she brought them probably helped but I doubt they were necessary. He gave the backward connecting rod a clean bill of health. I bought a new head gasket and set of Viton oil passage seals and away I went.

img_7882I guess you can’t really see the orientation in the manual, but I can tell you the offset goes toward the center on 2 and 3. Continue reading “101 1300 rebuild 15: almost back together”

101 1300 part 14: two steps forward and, er, 10 steps back

I’m usually pretty good at analogies. I am thinking maybe my current situation is like flying to Italy and finding out you have to fly home to San Francisco, turn off the oven and then fly back to Italy to get on with your vacation.

Okay, what did I do that is so bad? A total rookie move so it’s a good thing I’m a rookie. I put the number three connecting rod in backward. The Engine ran with a not terminal sounding but noteworthy knock. “The engine ran???” the attentive reader will ask.

It goes something like this…

img_7866I’m not sure why but it is somehow immediately apparent that this engine runs. This was right before the steps back announced in the title began.

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101 1300 rebuild part #13: Weber 28/36 DCD

It was a tough decision, but after weeks of debating, test fitting, consulting experts and looking for patterns in tea leaves I decided to go with a Weber 28/36 DCD that I got from Conrad in exchange for some valuable emergency brake components as used on cars with the big Veloce gas tank. One local expert posited that a 1300 normale with this carb and ‘decent’ cams will out perform the stock Veloce set up of 1959. We shall see. In the interest of thoroughly documenting this rebuild I plan on running this thing on a dyno to dial the carb in and try out a few cam options I have. Anyone care to donate a little dyno time to a good cause? I’ll give you endless accolades in my write ups.

img_7719As always, the teaser picture is actually the near final product. This carb looks pretty good but required $130 in new parts from my local Weber parts dealer. With the phenolic insulator block taking up about 6mm you can see the mounting nuts don’t fully engage the studs. Oh well, this is not a suspension component.

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101 1300 rebuild part #12: The devil in the ongoing details

The build goes ever on. I had been resisting working on the Sprint for the last two weeks and concentrated on organizing and consolidating my parts, tools and the like. Yesterday I had a surprise few hours of freedom so I decided to run to the shop and get back on the Sprint. The first order of business was hooking up the new exhaust front section I got in the mail a few weeks ago. I used M8 x 1.25 stainless socket head cap screws with flat and lock washers I had laying around to bolt the exhaust to the manifold with an NOS copper gasket in between sourced locally. I needed help supporting the exhaust to get the bolts started but after that it was easy. The pipe is closer to the floor than I like so I will have to see if it’s a motor mount, engine mount or pipe bend problem once everything is installed.

img_7741Here’s the new pipe mounted to the manifold with the asbestos heat shield bent out of the way. The oil pressure line is very close to the header with the heat shield in between. I plan on seeing if the pressure line can be bent or turned on the banjo bolt.

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SS details #3: Marelli wiper motor

I mentioned I was digging through my parts organizing them, well I came across this Giulietta SS Marelli wiper motor at the same time as the heater vents. It has been patiently waiting for me to clean it up and test it. It looked pretty good and clean on the outside but you know what they say about appearances so I decided to have a quick peek inside of it. I’ve never gotten into an electric motor besides a Bosch 105 starter that I took apart after it burned up from a solenoid stuck on. Imagining this wiper motor is only used on Giulietta SS’s and Ferrari 250 Lusso’s I went slow and was gentle with the tools.

wiper motor 1This is the before shot. I had been messing around with an old Weber so I had some fresh carb cleaner handy to clean the goo off the outside.

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Market #92: Red Sprint Three-fer in Italy

Giulietta Sprints 1493*26018, 1493*26085 and a 1965 Giulietta 1300.  These three cars are all in Italy, all about 25,000 Euro’s, all red and all in pretty nice shape.  I have them arranged in the chronological order outlined above for each group of common view pictures.  26018 and 26085 are from the 1960 interim series that ends at 26200 in Fusi.  The 1965 Giulietta 1300 represents the last gasp for the classic Giulietta Sprint and they only made 428 if Fusi’s numbers are accurate.  Giulietta Sprint production spanned 11 years and if you look at the Sprints contemporaries at the beginning and end of its run you see a great leap forward in automobile design and technology that was just catching up in the early 1960’s to the standard of robustness, reliability and style set by the Sprint.

3396f5be3a1493*26018 is not only 67 cars older than the next car, it is photographed in the same spot.  There are some event stickers on the quarter window which if nothing else indicate this car drives well enough to do a few hundred miles.

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Details #2: SS defroster vents

I was digging through my parts again yesterday trying to organize stuff and get the parts for the SS grouped logically for when I get back on it once the Sprint engine rebuild is complete.  I ran across a set of windshield defroster vents I picked up a while ago and a set I picked up recently and wow, big difference.  The parts book has two vents for the Giulietta SS and 3 vents plus a junction for the Giulia SS.  I guess the Giulietta has problems with the window fogging and the defrost system required a redesign.  Check them out below.

00120-vents-382These are the Giulieta items fresh from the media blast cabinet.  These are contoured at the top to follow the curve of the windshield/dash intersection.  The clamp up top is a cotter pin style and was used to clamp the defroster hose to the vent.

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Brakes #3: The SS Master Cylinder part 1.

I was moving stuff around my space and cleaning up on Sunday trying to organize the parts for my various concurrent projects when I came across this master cylinder that I set aside for use in the SS.  It was under some stuff in a plastic bag from when I took it to Glenn’s shop to get help removing the big end nut.  I hadn’t opened it so I figured it was a good time to peek inside to see if I need to look for another.  Next thing I knew I had spent an hour cleaning it.

mc-openSome rust and crust can be seen here, but I don’t think it’s too bad.  I pulled the seal and that weird washer that allows flow through the array of holes under the seal out and set to work with various implements to clean it up.

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101 1300 rebuild part #11: Marelli Veloce distributor set up

You may remember I earlier wrote about distributors and what I should do for one for this engine rebuild. I had the Lucas unit that was originally in this car in a box so I assumed I would just get it re-bushed, put new points, condenser etc in it and use it. I dropped it off a Jaan’s shop and a few days later he called me to tell me the shaft and drive section was all home-made and that it would not be cost effective to fix it, and that at its best it still wouldn’t be as good as a Bosch or Marelli unit. The next day I started pulling the 1600 apart that is going in the SS and I realized the Marelli distributor installed on it would be perfect for the 1300 rebuild, especially if I ever went with a Veloce spec conversion as it is a 750/101 spec unit.

dirty-marelliHere it is, fresh off the 00121 engine I am going to start rebuilding soon for the SS. It doesn’t look like much but the shaft spins nicely without having any side to side play. I am told these are pretty hard to find and expensive, so I will be careful.

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101 1300 rebuild part #10: hooking it up

I spent rainy Saturday and Sunday afternoons at the shop this weekend working on all the little loose ends that need to be tied in order to start the engine for the first time.  I started out with painting and installing the starter.  Once I had the starter bolted up and looking good I found the gasket and all the fasteners I set aside for the intake manifold and went to mount it.  The height of the engine didn’t allow the manifold to clear the rail in the engine bay so I had to jack the engine up about an inch on the passenger side and this allowed it to slip by.  Once the manifold was on I found the new thermostat and gasket along with the used thermostat housing I bought from Glenn a few weeks back.  This was all straight forward to install.

img_7638As usual, the finished picture first.  The red in the engine compartment came out good.  Not great, just good.  I think the level of finish in the engine compartment will match the rest of the car if I leave the valve cover alone.

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