Recommisioning

[lancianut666]

Have you any pictures of your issues as I have not yet come across a hole being too big for the bolts?
Clarkey

[Spider2]

pictures will not really help.
The hole in the engine block that the generator attachment bolt goes through has either been widened/damaged/worn by the bolt moving in it or an insert/bush is missing. The result is the generator can rock from side to side if the top stay is loose. When the top stay is tightened it pulls the front of the generator towards the engine block so the pully is not aligned with the crank pulley. It works but it must be putting a large load on the front generator bearing.
I will try and draw a diagram to explain the problem

[Spider2]

I think I probably have a simpler reason for this problem: maybe the wrong generator is fitted. The generator attachment bracket holes are smaller than the hole in the engine block.

[lancianut666]

Some pictures of a recent strip down of a S2/3 engine showing the bottom dynamo mounts.
Clarkey

[Spider2]

That is very useful. It confirms that the bolt fitted should be larger and that the generator is not from a S2. I will be enlarging the holes on the bracket to accept the bigger bolt.
I also note the rear hole in the engine is threaded. Does any one know the bolt and thread size?

[Spider2]

i meant the rear hole of the dynamo.

[TonyK]

This is  common problem with Appias, mine included. I went with drilling then reaming the hole to 10mm. Of course the holes in the generator mounts need to be enlarged as well. Longer term, I'm thinking of either re-bushing the hole back to standard or fitting a lightweight alternator.

[Spider2]

Hi Tony
I am relieved that I am not the only one with this problem.
The generator is the correct part number. Simply speaking the two holes on the gen to accept the through bolt are smaller than the hole through the block.
Either there should be a sleeve/bush in the block or the hole in the block has worn itself wider of the decades. (unlikely).

[chriswgawne]

On Aurelias, early cars can have just the drums removed (usually with just a little help from a hammer) whilst leaving the hubs in place whereas later cars where the drum is very securely attached to the hub itself require that the hub and drum are  removed in one piece.
To do this one uses a puller which  screws into the thread on the hub where the large castellated nut has been removed so there is no concern about putting any pressure on the brake drums themselves.
If one is changing brake shoes or wheel cylinders the hub itself really needs to come off anyway to gain proper access.
Photo to follow.
Chris

Apologies for the delay in posting the photo of my front hub puller. You can see it doesnt distort the front brake drum at all.
Chris

[Spider2]

Nice piece of kit. I'll bet a correct Lancia tool. Would it fit an S2 Appia?

[Spider2]

Had the S2 on the road this week after recommisioning:
1/ Electrics and lights now all work with help from a S3 loom from the consortiom
2/ Dynamo needed an overhaul
3/ Brakes: Master cylinder and two brake cylinders needed O/H kits. Now after a LOT of bleeding they are not bad. Pressure comes after about 40% pedal travel. Is that about right? Other brake cylinders probably need doing as well.
4/ Indicator switch fixed
5/ Wheels sanded and repainted
6/ Oil and flter
What is needed and can be put on the 'to do list'
1/ Speedo not working. Changing the cable does not look easy.
2. Horn needed
3/ Mega Internal clean
4/ More brake work
5/ Someone put a new headlining in and covered over the roof light
6/ Rad flap thrmo

If I knew how to post pictures  I would do so.
It drives really nicely so the plan is to drive it 500 miles and see what the bugs are. Am not interested in a concours car, just a fun, reliable hobby car.
Cheers
Simon

[lancianut666]

The progress sounds amazing well done! The Consortium will have a horn and possibly a new radiator shutter thermostat.
Clarkey

[Spider2]

Not having much luck in posting some pictures. Must be doing something wrong

[lancianut666]

Looking very nice!

[Sliding Pillar]

Looks very smart, looking forward to seeing it on the next Sliding Pillar 😄.
You need to resize your photos, the file size is too big ✔️