Fanalone restoration

[chugga boom]

I have now put the crank in. It turns very nicely, so slowly it's beinging to look like an engine again 

Two other activites on the go. The head is having the seats and valves machined. One valve would not lap in as the cut was slightly off center (the valve wasn't bent) and I am deciding what to do with the rocker shafts. Both were worn, the inlet had 20 thou wear in places.

Does anyone have any experience with metal spreying ? I have had conflicting advice on this - one engine specialist said unlikly it can be done as the oilways would become blocked up during the process, the other said it could probably be done. I can get new ones but they are ~£200 for a pair.

What have others done in this situation ?

always been a bit scared of this idea, i'm sure it was my dad that had seen a cam or knew somone who'd had a cam metal sprayed and a piece came off, i suppose its how well its done at the end of it a bit like white metaling, if done propperly otherwise can be disastrous, i think id be more inclined to look for good second hand items, surly the same as 1300??

[ncundy]

A bit more progress. Crank and block are reunited.

Still thinking about what to do about the rocker shafts. I think you are right Chugga. I'm not going to go down the spraying route. Current thinking is to see what the possibility is to make them. Material selection is looking like either EN24 or C35 steel, make slightly over size and hone the rockers. Anyone have any comments on that approach, I'm happy to hear them ?

[Philm]

En24 sounds ok but it will need heat treating, there are better steels though depending on what you want to pay and who is machining them, what is he measurement of the rocker bores?

[DavidLaver]

What's the finish on the block casting?

David

[ncundy]

The shafts are just located in aluminum blocks on the head. The don't turn, they are for support and control only.

The diameter of the shaft is 15.973mm. Thought is to make them 16 dead and hone the rockers to fit (allowing for clearance). The rockers should be 16 dead but mine are slightly worn.The clearance should be about 0.04mm.

Regarding the material I started out thinking about heat treating but I'm not sure the originals are heat treated. I can scratch it with a file (just) which makes me think it is a hard alloy like EN24 but not heat treated. The other reason is that you should really run hard against soft (I know with cam followers and the like this doesn't hold) and I would rather the soft be the shaft than the rocker (easier to get shafts than rockers). I have exchanged mails with a gentleman in Germany who made his rocker shafts out of C45 (a con rod material slightly weaker than C35). He says the are fine. That has a UTS, yield strength and HB about 70% of EN24. He didn't heat treat them.

If I have to heat treat then I imagine I might as well buy some new as the cost would probably be more or less the same.

Whats your thoughts on that approach ?

[ncundy]

What's the finish on the block casting?

David

Sorry David, misunderstood the question 

It's etch primer - you can get it from pretty much any motor factors / Halfords etc. I didn't use any of the advertised block paints as they are all in daft or non-original colours. But this was almost an exact match for the paint on the block, and I had some handy - I gave it a few coats.

Neil

[fay66]

Neil,
It certainly looks better than my semi rust colour, does anyone know if all Fulvia had this colour finish, mine looks like it was black the first time the engine came out and was stripped was at about 28K, so I think it unlikely that it had been out before.


Brian
8227

[ncundy]

Brian,

This is a photo from a 1963 Lancia booklet (Straordinario Fulvia) covering the production facilities of the then new Fulvia (berlina). It is clearly black, so would more or less confirm your conclusion.

Later Lancia technical publications I have (S2 +) all seem to show grey (or possibly unpainted). Photos in various books covering the Fanalones (particularly Altorio) show grey (or again possibly unpainted). Like you, I doubt my engine has ever been out, so am pretty convident that grey was my colour, as black would seem to be your colour.

There is also a thread here on the subject if your Italian is any good , but it does suggest a RAL code (7035) for the grey.

When the change occured and if it is different coupes to berlinas I not seen anything conclusive.

Neil

[fay66]

Thanks Neil,
Just about followed that using Altavista!

Brian
8227

[ncundy]

Seeing all those cracking cars at the AGM (particularly Stans' Fanalone) has got me back into the garage with renewed optimism.

Whilst waiting for the rockers shaft solution I have set about the carbs. Nothing complicated about these (at least not in overhauling anyway) as long as they don't leak. Here is a before, during and after. The bizarre thing I found was that the fuel return passage on the fuel union was not drilled through ! Hmmm, they must have been keen to get away on that day 

[DavidLaver]

...and that claw hammer is for...?

David

[ncundy]

That "claw hammer", as you so undelicately refer to it, is my beautifully balanced repercusive adjustment instrument. Yesterday it was carefully withdrawn from its packaging to adjust the tab washers on the butterfly shaft 

[fay66]

Looks just like my beautifully balanced repercussive adjustment instrument, just one of a set of similar instruments;D

Brian
8227

[ncundy]

The head is almost complete now. After investigating getting some new rocker shafts made (and some good help from a German member of viva-lancia) Neal Shepherd came up trumps. He had had a set made up some time ago which he did not use and was happy to sell them on. As a bonus he had had them made dimensionally as I was considering (about 4 thou oversize to allow the rockers to be honed to take out any wear), and they are induction hardened.

Before assembling I diamond lapped all the bearing surfaces on the cams and rockers to take out the marks (probably water and acid - photo 4) and return to a nice ground finish (photo 5). This takes a bit of time but the result is cams that turn very freely. Then I made up a honing tool for the lathe and honed the rockers to fit. Everything has gone together, fits beautifully with no slop at all.

A note on the cam end bearings. I bought a new set from Cavallito and they needed a few hours fettling before they were good enough to fit. The location hole for the dowel was too small and not de-burred properly and when placed on the cam and turned with fingers it was possible to detect high points as it was rotated (did not spin freely). Some work with very fine (1500) paper relieved the high points, and a small drill end with fine wet and dry wrapped round relieved the hole to a nice fit. So don't assume these things are ready to fit when received.

Also the fuel pump has gone back on having sat on the shelf for a few months.

[DavidLaver]

It looks fabulous - and I expect its been most satisfying to improve all the fits to a silky perfection.

How exactly did you hone the rockers and cams?  Any pics of the lathe tool for the rocker bearings?

David