my new integrale

[Kevinlincs]

The long studs you may have spotted poking out of the boot floor I'd made from a couple of spare bolts then welded some threaded bar to them to make the extra long studs...

[Kevinlincs]

The reason for making them was that again, working on my own I have to try and plan things so jacking up the rear subframe with diff attached and trying to stop it falling off whilst trying to line up the mounting bolts, that didn't fill me with hope of a happy outcome!

Solution was to fit the studs into the mounting holes in the car then the assembly could be very simply, and safely jacked up to the car floor.

[Kevinlincs]

With it jacked up against the underside of the car it was easy to remove a stud and fit the correct bolt with no fear of it falling or being out of line, worked a treat!

I'd actually done this before with these studs but on an Alfa 155 rear axle after I'd done some welding to it, homemade tools used twice!

[Kevinlincs]

Rear hubs I'd already cleaned and painted after fitting new bearings, driveshafts got new rubber boots.

[Kevinlincs]

Suspension arms also readily painted with new bushes where needed, new rear load compensator was sourced as old one was totally seized, I have also added the diff guard which is also said to stiffen the inner suspension mount points on the diff subframe, also powder coated. 

[Kevinlincs]

The brackets for the rear anti-roll bar on, new powerflex bushes not out of vanity but because they were available...

[Kevinlincs]

The brake compensator mechanism I may actually have fitted wrongly, seems different way up now I've looked at old pictures so may have to alter that..

The front tracking adjuster arms I have welded a large nut onto so I can adjust it much easier, you can see it here..

The pivot bushes for the compensator arm I struggled to find, at the time...since then of course I've found some..didn't fancy using the Brass bushes on offer
So I measured the holes for what I needed then found a company selling nylon bushes in the size to suit. 
All fitted well so hopefully will do another 30 years

[DavidLaver]

Some cars get displayed on a turntable.  Yours I'd have at a show on a powered rotisserie.

[CasualSaint]

Fantastic work and having done it myself i know the shear amount of it you will have had to put in!

Bushes are becoming increasingly difficult to locate, i think Beilstein in Germany have some sets, but they're expensive along with a few other European suppliers.
Go careful though your not on the rear jacking points, you've got the axle stands under the production line locators ( there should be 2 more on the front floorpans ), they are only there to stop the vehicles bumping into each other on the conveyor belt as you load the weight back into the shell you could damage them! I always have to tell MOT inspectors not to jack on them.

[Kevinlincs]

Cheers guys, it's been a load of work that's for sure!

The parts where the axle stands are under on the rear were rotten so I built them up with strong steel to use as jacking points, the original ones half way down the sills I didn't redo. So I've now got 4 good strong jacking/axle stand points at each corner near the sill end. You're right about the original location points being flimsy so I did away with them.



Don't know about it being on a rotisserie in the future, this car will get used as intended so it won't stay this clean and tidy for long 

[simonandjuliet]

Really enjoying this thread!!

[Kevinlincs]

A good while ago the engine got fitted to my engine stand in my shed at home awaiting the time to be taken apart, I didn't want to have it done then sat waiting for the car.
It ran OK but as was now around 30 years old it was due a refresh at least!

[Kevinlincs]

The water rail along the back of the engine had rotted out so a good used one went on the list to be found, managed to get a rust free one which I got powder coated so hopefully it'll last another 30 years!

[Kevinlincs]

Generally everything looked tired and ready for new seals etc

[Kevinlincs]

Head came off without too many dramas, I took it off to have a quick look in the bores to see what the wear was like (very minimal thankfully) but also so I could slide it under my workbench where it would sit until nearer the time when I needed it, which would mean 18 months or so later!