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Plating and Transmissions





Boosters, Bushings, and a Heater Valve

April 26, 2015


9727_37

I took the booster out of the SII 330 so it could be rebuilt. Finding a reliable and consistent rebuilder has been very hard, so I’ve resorted to learning how to do it myself. Through the generosity of a long time brake rebuilding mentor, I’ve been learning the tricks, problems, and traps to rebuilding these Master Vac boosters. Although they seem pretty simple in design, there are a bunch of pieces that can easily break and many things to watch out for when taking these units apart and putting them back together. I’ve been given a set of tools made specifically to work on these boosters that were designed by my mentor through trial and error throughout a 40 year career. I’m very lucky to have this insight, and hope I can make him proud of his teachings!

9727_38

The process of rebuilding a Master vac starts with disassembly, but once the two halves are separated, they need to be stripped and sent out for gold cadmium plating. My plater has been taking 2-3 weeks to turn around a pair of cans, so the rebuilding process is not a fast one!

booster5

Before any of plating is applied, the old plating has to be removed. First, the parts need to be degreased and cleaned.

booster6

This booster was in decent shape, so the bead blasting didn’t take too long. I lightly bead blasted the surfaces to remove most of the plating, but will leave the rest of the stripping to the acid tank in the plating process.

9727_40

I got down to work getting the rear transmission mount out of the transmission case. The sleeve to the bushing was very tight, so the easiest and least damaging method was to cut it out.

9727_41

I started by drilling out the remaining pieces of deteriorated rubber bushings along with the inner sleeve.

9727_42

I carefully cut two slots in the outer sleeve with a reciprocating saw to relieve the collar so it would push out. A little bit of hammer and chisel work and the bushing was out of the transmission case. We’ll make or borrow a insertion tool to put the new one in, but we’re waiting for the new bushing’s arrival in the mail!

6099_99

The parts to rebuild the SI 330’s heater valve arrived in the mail, so I started disassembling it. Notice the broken tabs by the Phillips head screws. Two of them were broken, but a reasonably priced reproduction top cap is available to fix this problem.

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The one part that is not available is the center shaft. It’s probably not hard to fabricate if you have some skills on a Bridgeport milling machine, but luckily ours was in good shape.

6099_102

I was watching the clock as I started this little project and saw a little more than an hour burn away by the time I was finished. Matching screws needed to be found and cut down to length, the valve needed to be cleaned and bead blasted to clean up the dirt and oil, and gaskets needed to be made to seal it onto the engine block.

14163_2

I’m trying my best to keep up with the work flow, but so another car was dropped off at the shop this week. The owner has been patiently waiting for a long time for us to rebuild his transmission. This car has been owned for many years by the same family and has now passed from father to son. Gianni has memories sitting in this car in a specially made child seat blasting down i95 from CT to Florida to see the races!

14163_3

The condition of this car would be considered a “driver,” but that would be an understatement. After we sort out the worn synchronizes, there will be more driving to do! The tradition continues now that Gianni is the steward of this car, and it was only fitting that his 21 year old son was giving his dad a ride back from the shop. Next week, the trans-axle will be pulled.

 

May 2, 2015

The Radcliffe/Tomyang.net Car Show is this week!

I’m very excited to do this again, and look forward to see old and new friends at this annual event. Richard Garre and I have hosted this car show to celebrate all types of machinery, focusing on Italian Cars. There’s parking for about 100 cars and we will always try to accommodate late comers, but if you want a guaranteed  spot call Richard to preregister!

Radcliffe Motorcars

12340 Owings Mills Boulevard
Reisterstown, Maryland 21136
Phone: 410-517-1681

See you there!

 

 Monterey Car Shows

I’m all registered and ready to attend Concorso on Saturday 15th of August and the  FCA event on Monday August 17th. Please contact Concorso, or the FCA to register for their respective events.

We’re planning a tailgate party after the show at Concorso to avoid the traffic leaving the show. There’s nothing worse that sitting in bumper to bumper traffic watching the car overheat trying to leave Concorso at the end of the day, so since all the GTEs and 330 Americas will already be parked together, we can stay a little later and leave when the traffic dies down. As always, everyone is invited!

If you want more information, contact

David Wheeler: David@Ferrari250GTE.com

Tom Wilson: tom@ferrari250gte.com

Here’s a rough schedule of events:

 

Thursday August 13th, Tomyang.net Cocktail Party at Quail Lodge 6-9

Saturday August 15th, Concorso Italiano Gathering of the GTEs (and 330 Americas)

Monday August 17th, Ferrari Club National Show and Concours.

 

 

Correcting 330s

April 24, 2015


6099_98

I received the seals from my parts supplier to rebuild the Master Cylinder on a Series I 330 I have at the shop, but I noticed something strange on the order of the seals. This master cylinder is an early Dunlop unit with a dual circuit piston, and there are numerous parts and seals that make up the internals of this M/C. When inspected the order of the springs and seals in this master cylinder, I noticed something didn’t match.

MC_incorrect

There are four seals in this M/C that make up the two circuts of the cylinder, each using two seals. One set of seals had a different spring and spacer arrangement than the other set. Logic would have it that each spring and seal combination should be the same in each circut, so one set must have been assembled incorrectly.

MC_correct

I called my friend that specializes in rebuilding these master cylinders to confirm my suspicions, and he told me the correct order of the seals and springs. He explained this was a common problem people have when rebuilding these old master cylinders. Through the years people have disassembled these units and rebuilt them, but sometimes they’re not reassembled exactly as they were designed, causing all sorts of mysterious problems and failures. I don’t believe this swap in parts caused any issues the owner told me about, but I’m glad I caught the problem.

9727_32

Jumping back to the SII 330 at the shop, I removed one of the headers to investigate an exhaust leak the owner told me about. With the header removed, I could clearly see the burn marks from the leaking exhasut gas. We’ll have to find a way to make this seal a little more air tight.

9727_34

 

The transmission was taken out and given a thorough cleaning. We still have to address the rear transmission mount bushing, but now we won’t get greasy working on the transmission!

 

 

9727_35

The choke bracket under the dash broke and I fabricated a piece to weld back onto the bracket. I was going to take the part home and weld it with my mig welder since Francois only had a gas welder. When he asked me why, I told him I knew my mig welding skills were better than my gas welding skills! He gave me an exasperated look, and asked me when I was planning to get my gas welding skills up without doing it! I sheepishly agreed, and he coached me through it.

9727_36

It didn’t come out half bad, and it’ll actually hold together!

 

Maryland Spring Car Show

Just about a week away! I’m looking forward to seeing everyone this year at our 8th annual show!

May 2, 2015

Richard Garre and I have hosted this car show to celebrate all types of machinery, focusing on Italian Cars. There’s parking for about 100 cars and we will always try to accommodate late comers, but if you want a guaranteed  spot call Richard to preregister!

Radcliffe Motorcars

12340 Owings Mills Boulevard
Reisterstown, Maryland 21136
Phone: 410-517-1681

 Monterey Car Shows

I’m all registered and ready to attend Concorso on Saturday 15th of August and the  FCA event on Monday August 17th. Please contact Concorso, or the FCA to register for their respective events.

We’re planning a tailgate party after the show at Concorso to avoid the traffic leaving the show. There’s nothing worse that sitting in bumper to bumper traffic watching the car overheat trying to leave Concorso at the end of the day, so since all the GTEs and 330 Americas will already be parked together, we can stay a little later and leave when the traffic dies down. As always, everyone is invited!

If you want more information, contact

David Wheeler: David@Ferrari250GTE.com

Tom Wilson: tom@ferrari250gte.com

330 Transmission

April 18, 2015


9727_20

We wrestled the 330 5-speed transmission away from the engine this week. She’s a bit of a monster compared to the 250 transmissions and requires at least 3 old guys or two young whippersnappers without bad backs to move, but therein lies the irony. The two whippersnappers will get bad backs wrestling with heavy transmissions with just two guys! With one guy underneath the car pushing the transmission back, we had two guys up top guiding the transmission ready to catch the weight to turn the unit 90 degrees to keep it from falling on the guy under the car! The parking brake lever gets in the way a little bit, but with two guys guiding it out up top, it comes out pretty easily.

9727_21

With the transmission out of the way, we exposed the pressure plate and soon, the worn clutch that will need to replaced.

9727_23

There was a big oily mess inside the bell housing of the transmission, so something was leaking. I suspected the seal on the input shaft, and if you look closely, you can just make out a trail of oil from the input shaft dripping down. As the clutch disc wore, the dust mixed with the oil and slung all over the inside of the bell housing. I needed to check behind the flywheel to make sure the rear main seal wasn’t leaking as well because that could be another source of a leak.

9727_22

With the clutch parts and flywheel removed, it looked pretty clean by the rear main seal of the engine. You can see the dirt and oil slinging around the flywheel, but not so much by this oil seal.

9727_27

With the transmission out of the car, I took some time to fix some minor issues. The back cover for the reverse light switch was missing, so I made a replacement out of an aluminum. I cut the rough dimensions and beveled the edges so it would snap into place.  Although it doesn’t show up in this picture very well, the disc was made with a slight dome to it so it wouldn’t touch the contacts. After it was glued into place with some silicone, it was water tight and will do a better job than being exposed to the elements.

9727_28

The next job was to deal with the input shaft seal on the transmission. After removing the bell housing, and the input shaft seal cover that held the seal, I pulled the offending seal. It was hard as a rock, and was no wonder it was leaking. I love finding “smoking guns” to problems in these cars, but I always make sure I check everything else because smoking guns can cause you to not look elsewhere for parallel problems!

9727_29

The original gasket on the back of the bell housing didn’t survive the dis-assembly, so a new one would have to be made.

9727_30

A little time with a ball peen hammer and an exact-o knife and a new gasket was made with some gasket material with a similar thickness to the original one was made.

9727_31

The bell housing assembly was put back together and ready for service.

9727_25

When we took the transmission out of the car, we noticed some safety wire and an extra bushing by the rear transmission mount.

9727_24

On closer inspection, we saw the rear transmission mount was worn out, and a previous shop jammed and secured a second bushing below the mount to help the worn out bushing. Now that the transmission is out of the car, we can try to replace this bushing properly. It looks like a special bushing because it’s not solid all the way through. It was probably designed to flex a little bit so not to transfer too much vibration to the chassis, but as the rubber wore out, it collapsed under the the weight. I hope one like this is available, because a solid bushing might transfer too much vibration. We’ll see.

 

Electric Fans and Pulling a Transmission

April 10, 2015


6099_95

The Silver SI 330 at the shop had two thermostatically controlled fans, each mounted on two sides of the radiator. The 250 cars only had one fan pulling air through the radiator, but I believe Ferrari realized they needed more cooling for the 330s. The pusher fan on this car had a replacement plastic fan mounted on the original motor. The original ones were cast magnesium. The original Lucas motor was intermittent when I sent power to it, so I was seeing a lot of problems with this set up.

6099_96

Fixing an already marginal cooling system seemed like a waste of time, especially when the owner wanted to drive this car in NY traffic. The best solution was to install a pair of modern cooling fans, upgrade the electrical system to handle the power, and put the original parts in the trunk to keep with the car. The dual fan set up I usually buy for this car just fit in the space in front of the radiator and will do a much better job at cooling the radiator down than the two fans Ferrari used to do the same job.

9727_15

I began the transmission removal on the SII 330 on the other side of the shop.These 5 speed gearboxes are monsters, and very heavy, so it’s going to take all hands on deck to wrestle this baby out. Like most Vintage Ferrari passenger cars, the transmission comes out from inside the passenger compartment, so everything inside the car has to removed or cleared out of the way before this greasy, dirty, and heavy beast comes to rest in the passenger side of the car.

9727_17

 

After the interior of the car was removed, it was time to unbolt the drive shaft from the transmission.

9727_18

I noticed a castle nut was replaced by another nut on the drive shaft. It was a perfectly useable replacement, but I think Francois has a correct replacement in his box of spare parts that we can use to make this car correct again.

 

Maryland Spring Car Show

I spoke to Richard Garre this week about the 8th annual Tomyang.net/Radcliffe Spring Car Show, and he’s about 70% booked up with the spaces. We will always try to accommodate late comers, but if you want a guaranteed  spot, call him to preregister!

May 2, 2015

Richard Garre and I have hosted this car show to celebrate all types of machinery, focusing on Italian Cars. There’s parking for about 100 cars, so call Richard early to register a space.

Radcliffe Motorcars

12340 Owings Mills Boulevard
Reisterstown, Maryland 21136
Phone: 410-517-1681

 Monterey Car Shows

I just received my update from the people at Concorso Italiano and it looks like 6 GTEs are registered for the event. I have been distracted with my other projects that I have yet to register my car for the event, but plan on doing it this week. I’ve already applied for the FCA event later that week. Please contact Concorso, or the FCA to register for their respective events.

If you want more information, contact

David Wheeler: David@Ferrari250GTE.com

Tom Wilson: tom@ferrari250gte.com

 

Brake swtich Mod

April 8, 2015


6099_66

A couple of weeks ago, I was working on the Master cylinder for a SI 330, and the brake light switch was broken. The original switch (pictured below) has a metric thread that is no longer available. So I made a modification that readily accepts a standard brake light switch with a tapered pipe fitting.

brakeswitch1

I chucked the original switch in my lathe and cut out the switch internals. The switch is pretty simple with a rubber diaphragm that pushes a spring loaded disk into two contacts that completes the circuit of the switch. The failure points must me at the rubber diaphragm.

brakeswitch2

I cut the shoulder of the original switch down so it would not interfere with the mounting of the new switch and drilled out the center so I could put pipe threads into the old switch.

brakeswitch3

The new switch threaded perfectly into the old switch shell. I’ll seal the pipe threads with some Teflon tape and reinstall this set up on the master cylinder with a copper washer on the side of the old switch. The switch I’m using is made my “Painless Wiring,” and is a “low pressure” switch. I wanted to try this out because one complaint I have with other switches I’ve used is the brake lights won’t come on unless you were stepping moderately hard on the brakes. We’ll see if this switch is more sensitive.

330 Hydraulics and Choosing a Blue

April 4, 2015


9727_11

The new parts arrived in the mail for the clutch hydraulics and a new push rod came with the package. The original one was a cut short, but when I compare the dimensions, there were other discrepancies. With the new parts of the slave cylinder in place, I found the longer push rod was hitting the floor pan of the car near the transmission, but there were more problems. Since the old clutch slave had failed, I could not check the amount of free play in the clutch, but with the new slave in place, I could see the clutch adjustment was at it’s wear limit. There was not a lot of life left in this clutch. I don’t know what was worse, telling the owner he was going to need a new clutch, or that I would have to wrestle this huge 5-speed gearbox out of this car!

9727_12

I took the brakes apart for this 330 for rebuilding. They will get rebuilt with new seals and sleeves if necessary. The frames and brackets will get cleaned and plated as well.

9727_13

Since the interior would have to come out to move the transmission, I went ahead and removed the seats for my upholsterer to take a look at what could be done with the seats. On closer inspection, we could see the whole interior was dyed to match a replacement cushion, but we couldn’t find a good color to match. I started to wonder how close this dyed interior was to the original blue interior that came with the car. I remembered I have blue interior in my parts stash, and I was pretty sure it was un-dyed, so I grabbed a piece and brought it down to the shop.

9727_14

The dyed interior is significantly darker than the original color. I know the original panel is a little dirty, but what a difference. I’ll have to speak to the owner to see what direction we’re going from here.

Technical note:
I will try to take more of these pictures next time after I white balance the camera to lock in the color. Most of us set color balance on our digital cameras on auto and forget about it, and it works pretty well most of the time. Photoshop can fix slight variations, but when taking pictures like this which is predominantly one color, the camera will try to over compensate which will throw out the color balance. Look in the lower left corner and notice how yellow it is. The CCD in the camera was adding a lot of yellow trying its best to get the blue in the picture to go neutral. So what you’re seeing in this picture is the difference between the two blues, but not the actual blue. I’ll re shoot next week with a locked in white balance for a truer color.
I’m amazed how many color decisions are made with photos taken with a digital camera, and worse a cell phone, but maybe having a degree in photography is knowing too much!

 

It’s already April, so don’t forget about the 8th annual Tomyang.net/Radcliffe Spring Car Show!

May 2, 2015

Richard Garre and I have hosted this car show to celebrate all types of machinery, focusing on Italian Cars. There’s parking for about 100 cars, so call Richard early to register a space.

Radcliffe Motorcars

12340 Owings Mills Boulevard
Reisterstown, Maryland 21136
Phone: 410-517-1681

 

The Monterey Week in August is starting to build momentum. I heard there will be at least 15 GTE/330 Americas scheduled to attend Concorso. If you want more information, contact

David Wheeler: David@Ferrari250GTE.com

Tom Wilson: tom@ferrari250gte.com

I just registered my 330 America for the FCA event and booked the transport!

A new 330

April 1, 2015


9727_1

A car I’ve known for many years arrived at our shop for some work. She’s owned by a good friend on mine, and I’m looking forward to sorting out a few things.

9727_2

This car is a Series II 330, and looks pretty nice. She doesn’t look like she’s missing much in the engine compartment, but there are a few minor issues that need some attention.

9727_3

The interior is pretty clean as well, but the seats are starting to show some age. The bottom cushion on the driver’s side was previously replaced, but all the other seating surfaces on the front seats are starting to wear through.

9727_4

The hope is to match the color so we won’t have to replace the complete interior, but I’ll let my upholsterer assess the situation.

9727_7

The biggest problem with this car was the clutch was starting to feel funny to the owner, and by the time the car was delivered to the shop, the clutch was in full failure mode. The clutch pedal would only hold for about 3 seconds before loosing pressure and releasing the clutch. I managed to make it into the garage under power, but just. You can see evidence of the leaking clutch slave from the brake fluid damage to the paint on the belly pan.

9727_8

With belly pan removed, the culprit was revealed. There were some non stock items installed on the clutch slave cylinder which we’ll address while we’re refurbishing the system. The push-rod doesn’t seem right, and the washers that space the clutch slave out from the bell housing should be solid aluminum spacers. I’ll look for some aluminum stock around the shop to make the correct spacers.

9727_9

The slave cylinder on these cars does not clear frame rail and fuel lines when studs are installed. These cylinders were probably installed on the transmission while it was on the bench but it’s a lot harder to use these studs when the transmission is mounted in place. The only way to remove the slave with this set up is to remove the stud. Installing it in reverse is no easier. Our solution is to replace these studs with bolts. Access is much easier, with a lot less cursing.

9727_10

The thread pitch on the transmission side is 1.25 while the nut side is 1.00 pitch. I used the stud to match a bolt with a 1.25 pitch end. The next time someone has to replace this clutch slave many years from now, they will thank me for making his job a lot easier. You’re welcome!

 

It’s already April, so don’t forget about the 8th annual Tomyang.net/Radcliffe Spring Car Show!

May 2, 2015

Richard Garre and I have hosted this car show to celebrate all types of machinery, focusing on Italian Cars. There’s parking for about 100 cars, so call Richard early to register a space.

Radcliffe Motorcars

12340 Owings Mills Boulevard
Reisterstown, Maryland 21136
Phone: 410-517-1681

 

The Monterey Week in August is starting to build momentum. I heard there will be at least 15 GTE/330 Americas scheduled to attend Concorso. If you want more information, contact

David Wheeler: David@Ferrari250GTE.com

Tom Wilson: tom@ferrari250gte.com

I just registered my 330 America for the FCA event and booked the transport!