My new project, finally got my integrale.

[KevJTD]

Yes, they did mate.
The early HF turbo 1.6 carb cars had the carb at the front and exhaust down the back, this created too much heat for the cabin and restricted access to the turbo.
Don't think it was just about turbo heat as all models got rotated this way when they went injection.

[alfadave]

Mine is a 2000ie.....with exhaust at the back.

Maybe it was something to do with 4WD?

[KevJTD]

Mine is a 2000ie.....with exhaust at the back.

Maybe it was something to do with 4WD?

Hmn, kind of throws my memories out the window then!

[alfadave]

Mine is a Beta Coupe though.
Maybe there is more room in the engine comp than the Delta?

[alfadave]

Out of interest, I asked Guy Croft why they turned the head round.

His response was " it was to do with the cat light-off temp and emission control.
The distance from the ex valves to the cat converter was critical, and the head had to be reversed so to speak- the distance had to be extended"

So, now we know!

[KevJTD]

Seems a curious thing to do though just to gain length, would be simpler to move the cat surely?
Cats didn't really come into Lancia ways until 92 or later onwards too, the injection cars got reversed heads at the facelift in 1986 well before cats were used by anyone except the odd Volvo, but I can't go too much against what Guy says..

[KevJTD]

Been a bit Ill the last week, why I haven't been up to the unit unfortunately despite the itch to get up there and fit the engine.
One job I've been meaning to do for sometime though was to clean up the propshaft centre bearing guard that was partly covered in underseal but mostly thick rust.
I'd tried cleaning it but wire brushes would hardly touch it and the knotted wheel method would just tear the ribs to bits.
So with the underseal burnt off with a scraper and heat gun it got dunked in my big water tank for some electrolysis rust removal, which given the size takes a few hours but at least you just leave it!


This is a big 40 gallon barrel. Just see the rust bubble off it!

Once out the remaining rust brushes off, in reality it takes two or three goes to get every bit off as some flakes are stubborn but it comes out lovely and clean metal without the risk of damage from grinding or blasting.

Quick coat or two of my favourite spray paint of the moment, Hammerite in an aerosol, and should be good for another 20 years

At least it feels like I've done something...

[Kegsti66]

Your rust removal system seems to work very well Kev.
Looks nasty though

[KevJTD]

Yes, the beauty of it mate is you just leave it to it and get on with something else!
Gives off Hydrogen Gas apparently so bets done in a ventilated area, this big tub sits outside my shed but I've a little bucket that I use inside which doesn't seem to be an issue. Looks terrible though doesn't it! Only washing powder in the water so no nasty chemicals..

Considering how rusted it was it's a great result.

[NUALFAMAN]

That front number plate on the shed wall is a blast from the past Kev.

[rsfruitbat]

Hi Ken
Can you tell us a bit more about your electrolysis process?
You know what I mean?
Peter and Jane do electrolysis.

Rsfruitbat

[alfadave]

The Prev owner of my Beta had it 25 yrs, and has been involved with Lancias for a lot longer.

So, I asked him why the head was turned 180 deg:-

"to package more complex after treatment, turbo's and to control heat management. Also crash safety, lower bonnet line, and 4 WD"

No mention of Cat Converters!

[KevJTD]

Yes, the number plate is a nice reminder mate, 30 years ago now though..!

Peter and Jane???

That seems to fit with what I remember Dave, although the phrase "to package more complex after treatment" could refer to a Cat? Occurred to me also today that maybe just because here in UK we didn't get the Cats in mid 80's it doesn't mean other markets didn't get them? Lot of integrales went to Switzerland (they even got there own model really), guess the HF's etc could have been there earlier, the Swiss love to protect the environment!
Makes sense that the turbo would need to be moved for the 4WD transfer box, the HF 4WD was out around the time of the facelift in '86...

[rsfruitbat]

Obviously a different era Kev
Pete and Jane were a series of books for learning to read. Very basic and very simple language
Make sense now?

Rsfruitbat

[KevJTD]

Obviously a different era Kev
Pete and Jane were a series of books for learning to read. Very basic and very simple language
Make sense now?

Rsfruitbat

Ah I see mate, must have missed that one

Basic and simple, that I can do

[KevJTD]

The electrolysis method is very simple, for those who haven't seen or used it.

You need a plastic tub, NOT metal!
Ideally 4 metal poles down the inner sides all connected.
Fill the tub with plain water with a good dose of washing powder, supposed to be washing soda but I just used some of the Mrs Daz, which makes the shed smell like fresh laundry
Connect an ordinary battery charger red lead to the outer poles/ring.
Hang the piece to be cleaned in the water via a metal hanger, but suspended on a plastic or metal rod so it doesn't contact the outer ring, make sure the piece to be cleaned can't touch the metal poles either.
Connect the black battery charger lead to the piece via it's hanging bracket.
Switch on the charger and wait for the rust to bubble off.

Once it's been in there a while (bigger pieces take longer, smaller pieces can be done in 20 mins or so) take it out and rinse it in clean water using a wire brush to clean off the residue.
All the pitting should be gone, if not just chip off the flaky bits and dip again.


Make sure to dry it straight away once done though, it's now bare steel and will be rusty again within an hour if left to the atmosphere damp!
I use a heat gun to dry and warm it immediately then paint.

[Bluesuit]

Thought it was Janet & John?

[KevJTD]

Thought it was Janet & John?

Remember that on Terry Wogan

[KevJTD]

This afternoon I got up to the unit to button up the last few bits on the engine assembly ready for fitting, new steering rack gaitors went on too whilst access was easy in place of the floppy universal ones I had previously fitted.

I'd calculated that I would just about have enough clearance to slide the lot under the crossmember, as it turned out there was a good inch to spare

Once safely under the car could be lowered down a peg on the stands then the process of lifting the lot could begin, as it had the engine gearbox & transfer box all together it was not only heavy but tight in many areas so care was needed but I got there..

[KevJTD]

Gearbox end tucks under the chassis rail, extra reinforcer bracket thankfully also cleared!

The gearbox mount that fits to the chassis rail is a new powerflex one, all brackets cleaned and painted...know I said I wouldn't...

Said it was tight, water pump replacement is said to be an engine out job....

[KevJTD]

Glad I fitted the new clutch cable before putting the lot in, it fits through the bulkhead behind the brake servo....

The power steering pump takes up the space where the master cylinder would be as I mentioned earlier, would be impossible to relocate the brake servo there...

Alternator replacement isn't easy either so that's why I got it refurbished whilst off, still got the suspension and driveshaft to go in that space too!

This corner is where the engine mount bolts through....solid again, was pretty much floating before!

[rsfruitbat]

Stunning work as always Kev


Rsfruitbat

[junior]

That before photo is quite horrible to look at ! This car will feel great after all this work. Good effort. Glad your being wise as well.

Was out in an MG yesterday and the owner is on about painting around the sills, when you can see it needs some serious investigation and welding done.

Been pointed out to him by wiser people than I yet still going ahead.

[Kegsti66]

Cooking on gas now Kev.
Like I said, that is a lot of mechanical "lump" to squeeze in, especially on your own.
Great result and the car will be sweet when it is finished.

[KevJTD]

Does feel like a corner turned now that's for sure, a small step but a significant one.

Looking forward to getting back to it on Saturday afternoon now rather than it being a chore

I'd been putting off getting the radiator sorted out for some time, another bill that I was in no rush to spend on, all of a sudden I need it!


New radiators are available but £250+

Some very cheap Aluminium ones on ebay but the quality looks awful, from China....


Not so many places nowadays doing recores but handily there was a guy in town who set up a few years ago after working at the towns main place for 30+ years before they packed in.
Dropped it off to him yesterday afternoon and it's done this afternoon.. £160 so not that cheap, but I'd rather put my cash to a local guy rather than a faceless corporate

Got a few brackets to clean and paint from in before it can go in, more lack of planning as it's been sat in the workshop for about 3 years....like I could have done it well in advance of now!

Should be able to button up quite a few jobs tomorrow on it.
A few jobs need doing before it can be started though.
Fuel tank can't go in until the propshaft goes on which again needs cleaning, that itself can't go on until some of the front suspension goes on...

Does feel like the home straight now though...

[KevJTD]

Mixed bag again this afternoon.
Got stuff done but a fair amount of head scratching to figure stuff out..

Electrics are about figured out now, all engine stuff in place at least, most of the rest is kind of falling into place.
Daft stuff like the throttle cable which should be a simple job turns into a mammoth task to try and find the parts for it like the grommets for the bulkhead all take time to think about what's needed and then actually find it!

Got hold of all the pipework now for the intercooler so happy to figure that out.

Fuel filter housing and pipework done, I'll have to wait to fit the fuel tank until the propshaft goes on..

Wanting to do something that makes it look like I've done something at least I set about fitting the exhaust manifold and turbo assembly, again not as simple as it should have been due to some parts I've already fitted getting in the way. The oil drain pipe also got in the way despite being about 2 inches long!

Glad I left it to now to fit though, would have made fitting the engine even more tight as it's a big lump sticking out the front!

In the interests of at least trying to formulate a plan I got the front suspension parts assembled for a dry run to see if I had all the parts, good job I did as I seem to be missing the driveshaft bolts!

At least I can make a list of stuff to find..

Tomorrow I'll clean up the radiator brackets so that will be about ready for fitting next time.

[KevJTD]

Been cleaning and painting loads of little brackets today, finally got myself motivated enough to clean up the propshaft too! It was covered in underseal and grime, not the nicest stuff to get off.
Didn't plan on painting it, just wanted to get it clean and tidy again.
A bit like the engine castings though I uncovered a lovely bit of original stencilling which I guess means 17 June 1989...

[KevJTD]

Just looking over some old pictures from when the car came, still finding things I need to find......it was really in a sorry state when I came home on Shrews' trailer, no wonder the Mrs couldn't see the potential!!

[Kegsti66]

Love the moss mate.
It does look good all messy though, but we can see through all the negatives and spot the good eh

[KevJTD]

We sure can mate, rose tinted specs are always handy


Now the worst is over it is now fun to look back, for so long you dare not even think about it let alone start looking at where you've been...the front cross member was quite a nasty bit!