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> Lancer's 1995 145 1.7 Boxer
lancer778544
post 10th April 2019 20:57
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



Hi all,

About a year ago, my brother, dad and I rescued a 1995 145 from one of my brother's colleagues over in Bristol. It had been standing since about 2010 and it wasn't a pretty sight:











We got it home and it scrubbed up well:







We got it running and after changing the CV joint and a burst brake pipe, it was thrown into an MOT where it did fail on quite a lot (mainly brakes and some odd things) but no rust issues. We did a compression check after trying to diagnose a misfire and 3 of the cylinders were at 170-odd psi but one was down in the 120-130 range. We were planning on dropping the engine out anyway to do the cambelts and clutch so it was moved from my brother's house down to mine and we set about taking the engine out and the results were not pretty:









A piece of the piston and rings had broken off, had a rumble around and presumably got shot out of the exhaust. It's left its mark on the way out, making a bit of a mess of the head but the bore has come out completely unscathed thankfully. The most amazing thing was it had very little blowby, nothing concerning and it didn't burn any oil so really surprising. I did notice that once the exhaust manifold was taken off the two cylinders on this bank were running very lean so I wonder if that is how part of this piston has broken off and been blown out. I'm planning on a new lambda sensor and getting the injectors sent off to be checked in case it was detonation and lean running that caused the piston to fail in the first place.

That was September last year. In the meantime, the piston has been replaced, the valves removed, ground and new valve stem and cam seals on the affected bank. The other head was removed and checked over and all pistons in tact but that head got new seals while it was off as well. The engine is still out of the car while we slowly go through it with last weekend having a new set of timing belts, pulleys and water pump fitted. We'll also be doing the core plugs while its out. I did send the Bosch 2e ABS pump off to be checked over since access is less terrible with the engine out but unfortunately the company I sent it off to wasn't able to check it (I presume due to it's age). That's been reinstalled along with new copper brake lines under the bonnet to replace the remaining original ones and I'm currently de-yellowing the brakes:





A few specs for you:

~ 124,000 miles
Monroe shocks & Apex springs (lowering springs I presume)
Ragazzon exhaust with 4-into-1 (I think) manifold
Some cheap ebay pod air filter that will be replaced with something different
Momo quick-release steering wheel
Momo cheese grater handbrake (will be going also)
Momo pedals (may be fitted, not sure at the moment)
Momo gear knob
Goodrich brake hoses
17" Excite multifit wheels (would prefer the later Teledial Speedlines but MOT first)

Plans are to get the engine in and running by the 4 day bank holiday weekend coming up. As you can probably see in the pics, it does have some body rust, mainly on the rear arches and the corners of the bonnet and some lacquer peel here and there along with a weird discoloured paint patch on the driver's door. Not sure what the plans are for that yet, I want it driveable first. My other car is a stage 3 2005 Saab 9-5 Aero (295bhp/420nm) but I'm really looking forward to driving the Alfa.

This post has been edited by lancer778544: 10th April 2019 21:48
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hazeyblue
post 11th April 2019 05:56
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1.6 16v
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Nice job, so far. Great to see a Boxer being preserved...
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dante giacosa
post 11th April 2019 09:45
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1.6 16v
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Hey Lancer-

Welcome along- what an incredible effort you've managed to put into that!

Is the dashboard and centre console a different colour to the other trim? It appears light-grey? You don't see a lot of induction-kits on boxers! It'd be great to hear that car running now it's nearly running as intended.

Does the boxer have a catalyst? Do you really think that section of piston ring cleared th exhaust system?

What is the mileage on the car?

Terrific results so far- looking forward to hearing how the big-push goes...
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lancer778544
post 11th April 2019 10:08
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



QUOTE(hazeyblue @ 11th April 2019 06:56) *
Nice job, so far. Great to see a Boxer being preserved...


Thanks, still a way to go yet but we're getting there slowly. Howmanyleft.co.uk says there are 22 145 1.7s left with only one of them being licensed so I'm hoping to make that 2.

QUOTE(dante giacosa @ 11th April 2019 10:45) *
Hey Lancer-

Welcome along- what an incredible effort you've managed to put into that!

Is the dashboard and centre console a different colour to the other trim? It appears light-grey? You don't see a lot of induction-kits on boxers! It'd be great to hear that car running now it's nearly running as intended.

Does the boxer have a catalyst? Do you really think that section of piston ring cleared th exhaust system?

What is the mileage on the car?

Terrific results so far- looking forward to hearing how the big-push goes...


Thank you. It's been a bit of a battle, especially the first blown brake pipe from the master cylinder to the ABS pump, that was pretty fiddly to do with the engine in but we've since routed it better now we have better access.

Do you mean the dashboard strip in the middle? In the before pics is does look light grey because I think it was bleached by the sun. It was painted black by my brother while in was up with him which does look a bit nicer but it'll need doing again as it has gained some pimples!

The induction kit was taken off for something and replaced with that cheap ebay pod filter. I think I have the original air box so I may convert it back but it does make a nice noise lol.

It has a "cat shaped object" in the system. I say that since it may have had the innards removed but I'll check it over before the engine goes back in.

It's done around 125k miles I think, it's been a while since I've looked.

This post has been edited by lancer778544: 11th April 2019 10:25
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JeremyG
post 12th April 2019 09:01
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That's great work - and amazing that piston failure didn't do more damage!!!

BTW - I may soon have a spare set of Phase 1 QV pepper pot wheels and tyres for sale if you're interested.
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aero_mati
post 12th April 2019 14:14
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Hello and welcome,

Nice work you're putting into it. Good to see another 145 being rescued, specially if it looked like the first pics lol.

Cheers




QUOTE(dante giacosa @ 11th April 2019 06:45) *
Hey Lancer-

Welcome along- what an incredible effort you've managed to put into that!

Is the dashboard and centre console a different colour to the other trim? It appears light-grey? You don't see a lot of induction-kits on boxers! It'd be great to hear that car running now it's nearly running as intended.

Does the boxer have a catalyst? Do you really think that section of piston ring cleared th exhaust system?

What is the mileage on the car?

Terrific results so far- looking forward to hearing how the big-push goes...


Early Boxers (and some diesels I belive) came with grey interiors. Don't know if it was an optional or came as standard


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lancer778544
post 12th April 2019 20:03
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



QUOTE(JeremyG @ 12th April 2019 10:01) *
That's great work - and amazing that piston failure didn't do more damage!!!

BTW - I may soon have a spare set of Phase 1 QV pepper pot wheels and tyres for sale if you're interested.


Thanks and I was amazed (and very thankful) there was no other damage and the head cleaned up well.

Colour me interested in the wheels please, that would be great smile.gif


QUOTE(aero_mati @ 12th April 2019 15:14) *
Hello and welcome,

Nice work you're putting into it. Good to see another 145 being rescued, specially if it looked like the first pics lol.

Cheers


Thank you and it was so satisfying taking a pressure washer to the algae and moss, it came up really well.
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lancer778544
post 14th April 2019 17:46
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



Great news guys, the engine is back in and it runs great. No leaks, no funny noises or anything. Still a bit "poppy" through the exhaust if you give it a bit of a poke but the fuel in it is god knows how old. I've got a new fuel filter to go on and I'll chuck some fresh 98 in there when I can but a major hurdle overcome anyway.

No real dramas getting it started either, fired up first time and idled straight away. Some sparks reported around the starter motor mounting bolts so I'll double check those and maybe replace the ground bar thing with some direct earths to the battery.

My brother also dropped its original 14" pepperpot(?) wheels and a strut brace. The brace is for a twin spark unfortunately as the battery and BBOB are in the way on the boxer so I'll be putting that up for sale soon. Give me a shout if anyone reading this is interested in it.

Oh, the exhaust manifold is a fancy 4-2-1 tubular thing, definitely not the standard one.
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lancer778544
post 6th May 2019 20:51
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



So all the last few odds and sods before the MOT have all been done over the past few weekends. Finally had an opportunity to clean it too so here's some up to date pics for you:













After getting it cleaned and taking the above pics, it decided to have a sulk and not start. Turns out I had knocked the inertia switch under the passenger seat while cleaning and cut off the supply to the fuel pump. Reset and all was well again. Still want to get a new battery for the MOT too but its running much better after some fresh fuel and a new fuel filter.
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dante giacosa
post 7th May 2019 07:30
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inspiring!

other than the cone filter- it could have just rolled out the factory!

MOT this week, Lancer..?


I even quite like those wheels!

This post has been edited by dante giacosa: 7th May 2019 07:33
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lancer778544
post 7th May 2019 14:12
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



QUOTE(dante giacosa @ 7th May 2019 08:30) *
inspiring!

other than the cone filter- it could have just rolled out the factory!

MOT this week, Lancer..?
I even quite like those wheels!


MOT soon, maybe not this week - need to find some reasonable insurance first.

I like the wheels too, they fill the arches well but the conditon of them isnt great and the multifit PCD puts me off a bit. The tyres all have great tread too but all mostly useless since they have pretty big cracks in them from dry rot and one has a pretty bad leak, I'll have to see what the MOT man says about these. If it'll pass without the tyres then fantastic, I can decide wether to keep the wheels and just fit new tyres or go for a different set all together. If it'll need tyres to pass but not much else, then that's pretty much forced my hand then. We'll see. I'm very much a pessimist but I think it may pass with a couple of advisories perhaps. If/Once it passes then I'll start tackling the bodywork and paint then and also sort out the ICE and dump those Alpine speakers in the doors.
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VROOM
post 7th May 2019 18:58
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That looks amazing considering how you found it. Are you going to return to a factory steering wheel with airbag?
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lancer778544
post 7th May 2019 19:48
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



QUOTE(VROOM @ 7th May 2019 19:58) *
That looks amazing considering how you found it. Are you going to return to a factory steering wheel with airbag?


I will admit I quite like the Momo wheel and it has the quick release boss too but I don't think I have the airbag ECU (its been removed) and I haven't got the original steering wheel either.
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lancer778544
post 6th June 2019 11:27
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



MOT booked for Saturday 15th June and a reasonable (360 a year) insurance quote found. Will let you guys know the outcome. I think there will be more stuff to do, main concern being the ABS light. It will go out after a couple of quick ignition cycles if it doesn't go out the first time but since we've not been able to drive it any distance, I don't know if it'll stay off when it does go off. My only other concern is the emissions but a new cat and fitting kit can be had for less than 50 delivered so no biggie.
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Ganz
post 9th June 2019 00:19
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You done a great job there mate! It looks fantastic! coolio.gif Hopefully see it at NAD smile.gif


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G A N Z 145

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lancer778544
post 15th June 2019 08:15
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



Well she's in for her MOT. Drove the 7-odd miles to my preferred station without any dramas, no warning lights, gauge at 80 degrees all the way. No clonks or other untoward noises and the only bit of smoke out of the back cleared up quickly. Considering this is the first journey its done in 10 or so years I'm very pleased.

I still don't think she'll pass but at least it'll give us a list of what we need to do but I do think we're a hell of a lot closer than we were last year.

I'll let you guys know the outcome when she's home.

Edit: Yep, it was a fail as expected but we're getting there. Basically tyres, emissions, handbrake/rear calipers and a bit of welding to be done. No ABS issues which I was dreading nor any problems with the headlight aim either. A couple more weeks and it should be ready for the re-test.

This post has been edited by lancer778544: 15th June 2019 10:17
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donutty
post 15th June 2019 20:22
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All the best 145s pass second time wink.gif
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lancer778544
post 18th June 2019 20:12
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



So current plan is to drop the rear subframe, refurb and re-bush it with the polyurethane kit from Bulgaria, tackle the welding with a sill repair panel (and replace the front brake disk shields I didn't realise were missing) from Taros Trade and sort out anything else the MOT highlighted. Pics to follow hopefully this weekend if the weather's kind.

If the above + tyres allows it to pass an MOT then long term plans are remote central locking kit to replace the old Philips alarm, major ICE overhaul (looking forward to this bit) and then tackle the bodywork. After that, rock up to some shows with possibly the rarest car there tongue.gif

While I'm here, any tips on dropping the rear subframe gents?

This post has been edited by lancer778544: 18th June 2019 20:19
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lancer778544
post 25th June 2019 23:19
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1.3 8v
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Driving: 1995 145 1.7 16v
From: Cardiff



So quite a productive weekend just gone. The front wishbones and ARB droplinks were replaced (really should have polybushed the ARB while I was there but oh well) and the cat was replaced as well. The Alfa was then turned around and work started on dropping the rear subframe to refurb and give extra access to the bit of welding to be done at the back of the offside sill. The tank came out without a fight but the fuel that came out did not look too good despite being mostly fresh stuff by now so some fresh 98 will be going back in when its reinstalled. The subframe also came out without a hitch:





There was one snapped bolt on one of the trailing arm ARB bolts from a previous refurbish by the looks of it but 3 more snapped in the process of stripping the subframe. 3 of the 4 came out by welding a nut to the top of the remains of the bolt but the 4th needed to be drilled and retapped. A quick Gumtree scour procured a cheap BNIB needle gun which made light work of the flaky rust and a quick hammerite later had the subframe looking much more presentable:



Still needs a few more coats but it's better than it was. The bushes also didn't put up a fight as they were very past it and the rubber had parted from the metal sleeves:



The polyurethane replacements have arrived from Bulgaria so our hydraulic press will be put into action soon to install them. The only item of concern found was a bodged brake compensator spring which was held together with terminal block but thankfully still seems available from Alfa. No horrors found when the subframe was dropped and the underside of the car will be suitably undersealed before everything goes back in.

Just waiting on the sill repair section and the brake disc dust shields from Taros Trade and some replacement brake hoses which seem to have gone AWOL but happy with the progress so far. In the meantime, I'm gonna get the injectors sent off to be tested and get some new HT leads.
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lancer778544
post 7th July 2019 18:07
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1.3 8v
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Local Time: 19th October 2019 17:58
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Driving: 1995 145 1.7 16v
From: Cardiff



Another productive weekend. The polyurethane bushes from Bulgaria arrived and were pressed in. The subframe was given another coat of Hammerite and looks much more presentable now:



The trailing arms were also refurbished with new bearings and such. One has been replaced before but was done again anyway as they'd got one of the pieces in the wrong way round and just stuck the seal in the end. The other side appeared to be original and was well overdue replacement:







We have also made a start on the sill repair. The repair section from Taros Trade is a great fit and underneath the previously repaired section looks bad, but is still very solid. The inner sill will be suitably rustproofed before the repair section goes back on. You can also see some of the other repair work that was done before we got the car:







The injectors have also been sent off to be tested and one was found to be too badly gone to repair. I stupidly didn't number them on removal so it may have been the injector on the cylinder that had the damaged piston but I guess I'll never know now. Oh well. I've also got some polyurethane ARB bushes that I should have fitted when I did the front end work to go on along with a NOS genuine Alfa AFM and some new HT leads and coil.

Hoping to get it ready for another MOT by the end of July but we'll see how we get on with the welding.
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