Appia furgoncino - A fettler's voyage

[simonandjuliet]

Major step forward today - brakes finished !

The second rear hub was re-assembled, brake pipes and flexi fitted. Still had to finish one front brake line and then fill with fluid and start bleeding.

It took about 1litre of fluid to complete the bleeding, starting at the closest wheel, then the other front before moving to the rears. On Appias, Aprilias and other cars with the plunger system, it is very straight forward to do on your own (Appia duplex are a bit more difficult I found).

Without touching the pedal, lift the plunger, open the nearest nipple and let run out until the plunger drops, close the nipple, lift the plunger and carry on - run until it's clear without bubbles and move on to the next one. Just make sure you don't run the reservoir dry !

I adjust the shoes before starting the bleeding process

Whilst at the back I drained the diff (nice clean oil and no residue on the magnetic plug) ready for refilling. The only leaks on the diff appear to come from around the bottom 4 bolts, so they were removed, cleaned and refitted with a blob of Hylomar to try and stop the oil leaking past the threads

Lastly, the handbrake was refitted. I re-used the cables because they are not frayed and are unlikely to stretch any further. Plus I suspect that the original cables are better quality than modern ones and I have never liked stainless handbrake cable.

Interesting little detail (to me anyway !!) is that the head of the front bolt on the handbrake lever-guide is a lot longer than the rear. I don't know, but I suspect it also acts as a stop for the lever. Typically Lancia

Last picture shows a very welcome sight to pre-Fulvia owners - a plunger that stays up .....

[lancianut666]

looking good!

[the.cern]

Well done Simon, looking so very good.

                                  Andy

[Parisien]

Last picture shows a very welcome sight to pre-Fulvia owners - a plunger that stays up .....

Its hard to beat an erect plunger.............

 


But great work as ever..........hoping to update my B12 thread with good news very soon

P

[simonandjuliet]

Thanks gents - haha Frank !

You can tell "my girls" are away, I got some more time in the garage today !

First job was to fill the diff with Penrite Mild EP oil. It takes just over 3litres, approx twice that of a standard Appia diff. It took an age to fill - hence the long pipe and funnel to make it more comfortable ... indeed it took the 9 minute, long-version of "Purple Rain" (Prince RIP) to do less than half

Next up was dismantling and cleaning the rest of the handbrake mechanism. The wire from the dashboard goes around 3 pulley wheels before reaching the lever. Each pulley was cleaned and lubricated before refitting

The only problem is that I am missing the pinch-bolt at the end of the handbrake pull lever - Can anyone help ?
I tried to make one by cutting down and drilling a head-stud, but they are made of amazing stuff and I blunted 3 drills before admitting defeat !
The head-stud has metric fine thread because I wanted to use the correct 14mm nut

Last thing was to clean up and loosely refit the gearbox supports. Plan is to do a trial gearbox/propshaft fit this weekend.

[simonandjuliet]

More today........

Fitted the propshaft and rear shocks. Everything cleaned and painted as necessary. I put the propshaft back as it came out. It would almost be better to put the long bolts (spider/rubber/prop) back the other way so it would be easier to remove the prop without disconnecting the other end first.

The bolts have been tightened and pinned but not finished, just in case I have to take it off again to aid 'box/engine fitting

I am planning to fit the 'box from below and then drop the car and fit the engine second - any thoughts ?

No photo, but what took longest today was cleaning the threads on the lower shock absorber bolts. They are the lowest point on the car and subsequently either get caught underneath, or get used as a jacking point. Consequently the very fine thread gets damaged.

Normally I just run a tap/die over the threads but they are an odd size - appear to be M15 or imperial - and I don't have the tools, so some very careful filing got them cleaned up and working again.

Final job was to clean and "paint" the petrol tank.

The tank has not had fuel in for MANY years, so has some minor surface rust, but I don't think enough to warrant "slosh-tank" (I am not averse, I have had many good experiences with it) so I added some stones, shook it, blew it out and then swilled with a bit of diesel ! I have a nice new tank drain plug and filter, and if I put in a discrete inline filter as well, hopefully it will be OK

If it all goes pear-shaped it is easy to remove and redo .....

The outside of the tank is undersealed and in good nick, so it was just a case of wire brushing to remove the dust and then paint with black Waxoyl to make it look nice.

She is back on her feet again for the first time this year, may push her out of the garage tomorrow so she can get a tan

ps plunger still erect !

[simonandjuliet]

An hour today after lunch ..... in France it is best to do easy things after a Sunday lunch !

Petrol tank fitted, but not as straight forward as you would think, it is v tight against the propshaft and I had to disconnect the handbrake cable to get an extra couple of mm, plus remove the filler cap. If the prop was fixed to the gearbox I am not sure it would come out .....

Last year I had had to replace the damaged sender cable that runs through the sill, so I put a 3 core instead of the original 2 core - just in case I decide to retrofit an electric pump. Otherwise, the new cable feeds a non original furgoncino fuel sender (it is std Appia) because the original never came with the car - one of a surprising short list of lost pieces.

Next to the fuel filler cap you can see the breather pipe that fits across the top of the tank, forms a loop on then vents at the side of the tank

[simonandjuliet]

Rear lights for "LANCIA" .....

Carello codes are as follows:

Rubber : 12.327.505
Chrome frame : 12.630.135
Lens : 126 TO

Although these appear to be the original lights, when you fit them, the lenses are sideways - ie the writing on the lens is not top and bottom.

My lenses are new, so I wonder if there was another option with holes in different places ?

When I fit mine I plan to file 2 more grooves on the body so that I can fit the lights the correct way up and if I find the "correct" lenses then I can rotate the frame(s)

Maybe they were always sideways ....... who knows ?

Distance from the bottom of light aperture to bottom of the body is approx 15.4cms

[LANCIA]

GRAZIE SIMON MI SEI DI GRANDE AIUTO.............GRAZIE.

[LANCIA]

DOVE HAI TROVATOI FANALINI POSTERIORI ?    VORREI ACQUISTARE ANCHE    IO UNA COPPIA.  IO  HO TROVATO QUESTI ....SONO COME I TUOI ?

[simonandjuliet]

"LANCIA" - I have sent you a separate email, my lights came with the car

More progress this week, in between other things I have done a trial fit of engine/gearbox on the bench and then this afternoon fitted the box to the van.

I have shown a few detailed pictures of the clutch mechanism. As with my 3rd series and Aprilia, I fit the clutch to the gearbox and then once the engine is in place, bolt the clutch cover to the flywheel. This is what Andy was talking about on his post .

What I don't know, is how easy it is to fit the engine afterwards - having only fitted the engine/box as a unit before. Time will tell

I have fitted all the propshaft bolts but not finished the split pins, just in case it all has to come off again .......

I reckon that my car-lift paid for itself today, fitting the box and prop have been so easy, still takes time, but very straightforward. The long piece of wood at the back of the box was to hold the back up whilst I climbed a ladder and fitted the through bolt !

I might try and make an engine test rig next week, it would be good to run the engine before I fit it

[Parisien]

Top marks again Simon, great to see it all coming together


P

[LANCIA]

CIAO SIMON , SE POSSO SUGGERIRTI IL PIATTO MOLLE LO DEVI MONTARE VICINO AL VOLANO  CON IL DISCO FRIZIONE  ED UN CENTRATORE PER FRIZIONI    E POI INSERISCI IL CAMBIO E LA FORCELLA PER ULTIMA CO IL SUO BULLONE DA   11-  12.   IO SULLA VETTURA HO MONTATO MOTORE E CAMBIO UNITI.  HO TOLTO L'AVANTRENO........E LO HO FATTO SALIRE DA SOTTO. 

[stanley sweet]

Must be very satisfying watching it all build back up. The engine looks tiny compared to the gearbox. Lovely little thing.

[simonandjuliet]

Thanks everyone

I am sure that most people are aware that the furgoncinos( and camioncinos and I think Jolly's) have a 5 speed box unlike all other Appias. The 4 speed box is identical (?) in size to the 5 and is part of the reason that there are so few vans/pickups left. A number were supposedly scrapped just for their 'box which was then swapped for the 4-speed

I am getting around to fitting the screen but have not yet found a screen rubber - can anyone help ? Please ??

Will post photos as I have them !