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> The Red Devil's Progress Since April 2014, Project..
sanitary
post 18th February 2017 11:19
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1.3 8v
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From: Lardtown, 'ulll



Well cool biggrin.gif



san
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Ganz
post 19th February 2017 21:17
Post #142 | Print


1.6 8v
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Local Time: 25th May 2017 17:20
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Driving: 145 Cloverleaf 2.0L ts
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QUOTE(sanitary @ 18th February 2017 11:19) *
Well cool biggrin.gif
san


Cheers buddy


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aero_mati
post 21st February 2017 20:58
Post #143 | Print


1.3 8v
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Local Time: 25th May 2017 13:20
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Driving: Alfa 145 Cloverleaf
From: Buenos Aires, Argentina



QUOTE(Ganz @ 17th February 2017 21:22) *
Just an update on January and Feb 2017.

[attachment=17100:Exhaust_polys.jpg]
Got my Polyurethane exhaust bungs.


Hi,

What's the benefit of using poly hangers?

QUOTE(Ganz @ 17th February 2017 21:22) *
[attachment=17102:Variator.jpg]
Finally.. after nearly 10 years I finally brought a brand new variator!!


If you don't mind me asking, how much did you pay for it?

Cheers




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Ganz
post 21st February 2017 22:48
Post #144 | Print


1.6 8v
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Member No.: 10,640
Driving: 145 Cloverleaf 2.0L ts
From: uk



QUOTE(aero_mati @ 21st February 2017 20:58) *
Hi,

What's the benefit of using poly hangers?
If you don't mind me asking, how much did you pay for it?

Cheers


The benefit of using poly hangers is they look uber coool lol! Also probably less chance of deterioation. I've seen a lot of tie-wraps on exhaust bungs on Alfas.

The variator cost 119 from eBay.

Hope this helps.

G A N Z

This post has been edited by Ganz: 21st February 2017 22:51


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Ganz
post 22nd February 2017 00:09
Post #145 | Print


1.6 8v
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Local Time: 25th May 2017 17:20
From: East Mids
Member No.: 10,640
Driving: 145 Cloverleaf 2.0L ts
From: uk



Attached Image

The variator cost 119 and the variator shells about 35 from Shop4Parts (I think)

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Old cambelt tensioner with 140K on the clock and the new Dayco one

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The cam tools needed all found on eBay. I got the pulley tool and the cam locks really cheap. I think I paid 15 for both!! The tensioner tools also sourced on eBay.

http://www.ebay.co.uk/sch/i.html?_from=R40...ol&_sacat=0

http://www.ebay.co.uk/sch/i.html?_odkw=Alf...ol&_sacat=0

Attached Image

Cam, balancer, auxiliary tensioners and water pump.

This post has been edited by Ganz: 22nd February 2017 00:13


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Ganz
post 19th March 2017 21:20
Post #146 | Print


1.6 8v
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Local Time: 25th May 2017 17:20
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Member No.: 10,640
Driving: 145 Cloverleaf 2.0L ts
From: uk



Update on the project.

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Balance belt tensioner

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VDO gauges with carbon fibre mount

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Location of bulkhead hole for VDO gauges. I used a 6.5mm drill and carefully drilled into the rubber grommet of the main wiring loom.

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Used a wood screw to open up the hole.

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Fed the wire through.

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Wire inside the engine bay


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dante giacosa
post 28th March 2017 13:46
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1.4 16v
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the quality of work on this is fantastic...
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Ganz
post 29th March 2017 23:32
Post #148 | Print


1.6 8v
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Local Time: 25th May 2017 17:20
From: East Mids
Member No.: 10,640
Driving: 145 Cloverleaf 2.0L ts
From: uk



QUOTE(dante giacosa @ 28th March 2017 14:46) *
the quality of work on this is fantastic...


Thanks mate! If I see a rusty bolt I start twitching lol! Just putting it together with love and care. Wish I could take the engine out and give it the full treatment but I'd be working on it for another couple of years if I did that.


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Ganz
post 1st May 2017 23:17
Post #149 | Print


1.6 8v
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Member No.: 10,640
Driving: 145 Cloverleaf 2.0L ts
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April's work.

I had to get the balance belt pulley off the crank. Tried a variety of pulleys..

Attached Image


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The one on the left is a cheap Chinese 3 leg gear puller.. waste of time didn't budge a mm. My own gear puller the same. The big b**ger on the right which I brought from the NEC Practical Classics for 8 made easy work of it.

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Brought some heat shield. Makes the engine bay look a lot smarter.

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Got the corner of my original cam cover welded up. This usually cracks because people over tighten the bolt.


Put the Halfords buffer kit to use.
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I put the buffing bar in the vice and rolled the drill end over it.

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I buffed off some of the red but I quite like the weathered look.

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I don't suppose anyone knows what this bracket goes??

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The variator would not budge!! Even with this breaker bar.

VDO wiring:
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I spliced into one of the the ignition blocks. The Blue wire is the key-operated side lights. I spliced a blue wire from it for the gauge illuminations. the red wire is a key-operated wire for power to the gauges.

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I put my oil temperature sensor into one of the plugs on the oil filter housing.

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Made sure I covered up the sensor wires with a new wiring sleeve

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I'll post the rest of the wiring tomorrow


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Ganz
post 10th May 2017 23:28
Post #150 | Print


1.6 8v
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Local Time: 25th May 2017 17:20
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Member No.: 10,640
Driving: 145 Cloverleaf 2.0L ts
From: uk



Just wanted to mention the resistance of the variator rant.gif The variator would not budge a mm. My make shift tool wouldn't shift it. I

Attached Image

brought the Alfa variator tool and with a breaker bar but still it wouldn't budge.


In the end I had to take it to my local *Alfa garage. An impact gun was used but to no avail. Then we clamped the camshaft in a vice. One person holding the cam in the vice and using a bigger impact gun, the type you use to get centre axle nuts off but to no avail!! My bruv-in law said he had not seen one that tight before and usually they come off easily with an impact gun. In the end I was instructed to hold a MAP torch (you can just see the red handle of the MAP gun) on it for 5 minutes (800 degrees of heat, you can see the variator 'smoking' in the pic) until the oil inside the variator caught fire. Second go with the massive F*** off impact gun and off it came biggrin.gif

*Intaservices in Leics

Attached Image


This post has been edited by Ganz: 10th May 2017 23:33


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Ganz
post 22nd May 2017 22:41
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1.6 8v
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Joined: 2nd November 2012
Local Time: 25th May 2017 17:20
From: East Mids
Member No.: 10,640
Driving: 145 Cloverleaf 2.0L ts
From: uk



Finally I get to post the VDO gauge photos.

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I took the live feed from the ignition block. Red and blue wire is the live feed for the gauges and the blue and white wire is from the sidelights so the gauges are only illuminated when you turn the sidelights/lights on.

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This is where my ground wire connects to.

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The green and black wire is for the oil temp gauge sensor and the blue and grey wire is for the oil pressure sensor

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This is where i feed the two sensor wires through the bulkhead. Also used some wiring dressing to protect the wires.

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Fed into the centre console like this.

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This is my make-shift wiring diagram lol!

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I used a couple of inline fuse holders for the live feeds and sidelight feeds

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Used some silicone tape for the wiring. The two sensor wires from the engine bay (oil temp and oil pressure)


The following are pics to illustrate my setup
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Attaching the gauges was really tricky

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Trying to figure how to connect the gauges and then install the gauges with the facia.

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Finally they're in!

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I had purchased some green illumination bulbs for the gauges but it appears some shine brighter than the others.

I had always wanted to do this mod smile.gif

This post has been edited by Ganz: 22nd May 2017 22:47


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