Kevinlincs
Permanent resident
Posts: 1615
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« Reply #120 on: 12 November, 2021, 10:28:51 PM » |
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The exhaust system has been a bit of a quandary, new systems for the turbo don't seem to exist anymore.
I do need one of course even if eventually a stainless one can be made to suit.
I bought a combined middle and rear one piece for a Fiat Tempra TD as it had the largest bore size but still not quite as the Dedra one. It also had a nice rolled tailpipe rather than just a cut end.
It wasn't until it arrived and compared to the original one that it dawned on me that although it fitted around the suspension etc the same, as they are the same underneath, the problem came that the Dedra (and Alfa 155) have a section added on to the rear chassis rail to extend the rear out, so the tailpipe was about a foot too short!
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #121 on: 12 November, 2021, 10:36:46 PM » |
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After exhausting (pun intended) all avenues for the supply of a correct middle and rear I just had to make do with what I had.
The bore sizes turned out to be the same so it wouldn't sleeve over the front silencer so a joining sleeve was needed, handily I had some suitable pipe to hand.
The middle box had a missing hanger so that needed cutting off the old system and welding to the new so then I could hang it where it needed to be.
With that settled and the tailpipe cut off the new system I could line it up with the bumper outlet and make up a length to join the pieces up. Hanger brackets also needed to be made up for the rear support.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #122 on: 12 November, 2021, 10:44:04 PM » |
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Once back on the car I'm very happy with the results. It will last a few years being mild steel, 4 or 5 years without being used in winter at least. Once that fails I'll get a stainless one made.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #123 on: 12 November, 2021, 10:46:44 PM » |
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Chuffed with my afternoons work, doesn't look out of place at all, even got the undertray back on!
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Flavia 815 coupe
Delta integrale
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fay66
Permanent resident
Posts: 6231
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« Reply #124 on: 13 November, 2021, 02:00:32 PM » |
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Chuffed with my afternoons work, doesn't look out of place at all, even got the undertray back on!
Looks great Kevin👍 Brian 8227  |
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Own 1966 Fulvia 2C Berlina since 1997, back on road 11-1999.Known as "Fay"
2006 Renault Megane 1 5 Dci Sports Tourer
Dedra Technical Adviser
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lancianut666
Permanent resident
Posts: 1777
Slow but rough
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« Reply #125 on: 13 November, 2021, 06:04:31 PM » |
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Nice work...I like the rolled edge on the tailpipe...
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Fulvia Coupe S2 Flavia Coupe 1967 1.8 Kugelfischer Prisma 1.6 carb Y10 Fila Y10 Touring Dedra 1.8 Dedra 2.0 Turbo Appia S1
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #126 on: 28 November, 2021, 12:38:41 PM » |
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The rear spoiler I had intended to repair before the car went to paint but as ever things never go to plan and time ran out.
The issue with the spoiler was all but one of the mounting lugs twisted out when it was removed due to the brackets being rusted after 30 years of British weather.
My solution was to cut out the rotten steel that was imbedded in the spoiler and make some new brackets.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #127 on: 28 November, 2021, 12:44:38 PM » |
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The 4 brackets were made to size to suit the spoiler and shaped to follow the bootlid contours, bolts welded to the topside and holes made in the spoiler so the bonding agent could grab on better rather than just a flat surface.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #128 on: 28 November, 2021, 12:48:47 PM » |
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Masking tape laid on the bootlid to protect the paint and also to stop excess bonder glueing it down then I left it for a week to set properly.
Important to do it this way rather than just bond each individual bracket when off the car so it ensures the bolt alignment is in place but also that the brackets will sit straight when it goes back on once painted.
A layer of neoprene will be used to make gaskets.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #129 on: 28 November, 2021, 12:52:23 PM » |
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Yesterday I took the spoiler off and happily it had all set nicely.
The brackets have set really firmly but still with a degree of flex so it won't crack away.
Now they are all set in place I can tidy them up and apply more sealant to make them watertight and neat.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #130 on: 28 November, 2021, 12:54:11 PM » |
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Nice when a few bits go back on too, small steps to get it back on the road.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #131 on: 11 December, 2021, 09:27:13 PM » |
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Another sideways step it may seem.. One day all the jobs will be done and the car will be done, but until then I'll carry on taking sideways or what seems to be backwards steps!!
I have a list of jobs that need doing under the bonnet, a fuel leak somewhere within the pipework to the injectors, an oil leak or two, a power steering leak, etc etc plus the cambelt to change and I want to check the clutch so the simplest solution is to drop the whole lot out.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #132 on: 11 December, 2021, 09:34:27 PM » |
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I can also now clean all the engine bay and check for any signs of rust in the chassis rails and underside of the strut towers. Engine and gearbox will be able to get much cleaner too, some parts will get cleaned up and some powder coated. I recalled the integrale having a steel water pipe down the back of the engine which was showing signs of corrosion so that one got blasted and powder coated, I'll do the same with this one assuming it survives..
There was a potential for disaster which I'm surprised hadn't gone wrong before now, one of the heater pipes which is completely hidden from view looks to have had a jubilee clip digging into it for years, I'm amazed it hadn't already blown!
Not sure if I'll be able to repair it with a joining sleeve or even find a replacement, but as there is a reasonable amount of room to reroute it I may just do that.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #133 on: 11 December, 2021, 09:39:07 PM » |
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The car does have a different breather unit to the integrale though, and from memory my old Dedra turbo didn't have this either. It's like a catch tank setup, 3 pipes to it from the oil separator unit behind the manifold then others to the turbo intake and bavk yo the sump. Is this usual for the Dedra?
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1615
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« Reply #134 on: 19 December, 2021, 02:55:28 PM » |
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As I'd taken the engine out to do a few jobs and found the rear water pipe to be fairly corroded inside I contemplated taking the head off to assess the waterways, the cambelt and both manifolds were to come off anyway so rude not to...
Plus I could then lap the valves in and change the stem seals which wouldn't hurt.
With the engine on the stand a friend Terry asked if I was going to check the bottom end out too, seeing as I'm almost there anyway...
So much for doing a few little jobs!
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Flavia 815 coupe
Delta integrale
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