Tuesday, 5 January 2010

Engine from Hell, balancer shafts and other bits and pieces.....

The car came in just needing 'A few bits of finishing off' following an engine rebuild by some expert (Note: Not Lancia specialist). On a brief road test it didn't drive too well and when on the lift in the workshop an anonymous knocking started.... After draining off the nice glittery metallic oil, the first thing to come off was the sump pan to reveal lots of tiny pieces of metal which weren't attached to anything, I noted that the sump pan had a dent in it with a nice imprint of the oil pick up gauze on the inside.



Possible cause of oil starvation? Yes I think so.


On removing the bearing caps all the shell bearings were completely shot. After conferring with the owner It was agreed that I remove and strip down the engine to assess it and more delights were revealed: Scored bores, pistons, crank journals and oil pump, various bits missing from the external of the engine such as strengthening plates, spacer bobbins, bolt heads snapped off: Photobucket Silicone sealer oozing out from the mating surfaces of various components, second hand gaskets, cambelt practically hanging off:



Some old piece of water pipe from another car with the wrong angle on it was hardly going to let the cooling water flow very well.



One of the blanking bungs for the gearbox was badly mangled and rolling up and down the dashboard, why this had been removed we'll never be entirely sure, to fill the gearbox with oil maybe? Either way it never made it back to where it previously lived as a bit of rag had been stuffed in there instead.

Best of all, one lobe from each of the cams partially missing. Only just worn like this? Nope, the corresponding shim was about as thick as my house doorstep so the builder must or should have known. Photobucket Apart from having a few stripped threads the head looked ok, although some muppet had replaced the Sodium filled valves with Stainless steel ones more suited to a naturally aspirated engine. Apart from the basic block and head the engine had been reduced to scrap.
The block had been painted quite nicely though.

After much more conferring, a spec was agreed on and the task of rebuilding it properly began. Basically it was to be running stock power for now, but with uprated components built into the block so it could be safely modified by 'bolt ons' at a later date when funds allowed.

New steel rods and forged pistons were specced, a checked good used crank had its journals polished, core plugs knocked out and was left in the dip & strip tank for a few hours before being high pressure washed and dried off. It was mated to a new steel flywheel, paddle clutch with high pressure plate and sent off for balancing along with the pistons and rods. I have found the OE cranks to be quite well balanced from the factory and only needing a bit of a tickle here and there on the counterweights to make them perfect, they do however need all the other components bolting to them and balancing properly by someone who has the right equipment and knows how to use it. The steel flywheels we sell are already balanced, but clutch pressure plates rarely are and need a fair amount of attention. Photobucket Whilst that was being done the block was being decked, bored and honed. I specify that the boring and honing is done with a deck plate, main bearing caps in place and torqued down to the correct settings. For the little extra time and effort involved you might aswell try and get things as perfect as possible. When all the components were back with us and thoroughly cleaned a dry build was done and all clearances set and checked. It is folly to simply assume that everything has been done properly, isn't worn or will be ok. This calls for a good collection of tools such as bore clock, micrometers, dial gauge, feeler gauges and Plastigauge. Photobucket Photobucket Pistons are hand finished by us, ARP bolts used on the new rods. The block also had the balancer shafts removed and all associated oilways etc blocked off with our own kit, much has been discussed about this modification, my thoughts are this:

Balancer shafts

People talk about "2nd order alternating inertial forces" quoting it from the Lancia manual or some online text without knowing exactly what it means, the best explanation I have ever come across is here:

http://en.wikipedia.org/wiki/Balance_shaft

To simplify what they are saying is that in a four cylinder engine the pistons aren't in exactly the opposite places at the same time in the four stroke cycle so can't cancel out the forces caused by each other. There will always be some vibration, but the engine is mounted on floppy rubber bushes so will you feel it? Not really.
As outlined in the aforementioned article, the two litre capacity is borderline size for needing balancer shafts. So the advantage of BS on an otherwise unmodified engine is just singularly to reduce some vibration of a not completely properly balanced production engine and no more.

What about the advantages of removal? Well the centre bearing shells are no longer available and when worn will leak oil reducing the overall oil pressure, removing, blocking these and the other associated oilways off will see a big improvement in oil pressure and reliability.
There is an increase in engine power and response. Servicing is easy and cheaper due to less belts and bearings. Reliability goes up due to increased oil pressure and less moving parts to fail.

Interestingly the balancer shafts changed weight over the years, the last ones used in the Fiat Coupe were different compared to of the early ones in the 8v, this was done by machining more or less out of shaft along its length which must have altered its balance too, I do wonder why...

Knocking out old bearing shells: Photobucket Pulling in new bungs with appropriate tool: Photobucket The block was completed with a new oil and water pump The head was stripped, inspected and cleaned as per the block, valves lapped and re-shimmed with some good used cams. There wasn't any point in going overboard with the head as it was going to be replaced with something a bit more fruity in the future. Pretty soon it was finished and ready to go in: Photobucket Photobucket Once in, fitted and turned over until we had some oil pressure showing it fired up first time. More 1970s garden-shed tuning then came to light, It was running really rich, the fuel pressure regulator had been tampered with and the pressure was sky high, the boost gauge was also showing 1.2 bar when it should be 1 bar on overboost with the stock chip it had in it, once sorted it ran like a dream, lovely and smooth - vibration? Forget it, do the job properly and you can sling your balancer shafts in the bin.

The guys smile when they came to pick it up made it worthwhile, they plan on running it in then just getting some use out of it on the road and doing some sprints. More modification will follow when needed, but just for now they were happy to get the car back with a good reliable strong bottom end.

Friday, 1 January 2010

Happy New Year.....

......... To all readers.

"The best that can be said for 2009 is that it could have been worse"
Joseph Stiglitz


Indeed, let's hope for a better year in 2010, it's my opinion that the economy has bottomed out and this year will see some slow recovery.
On some other more positive notes after finding time to do some more 'Blogging' this last week I am getting better at loading pics and presenting this Blog in a much more readable manner.
We have some more great products on the way this year so keep following here as they will be introduced with an explanation of all the whys, wheres and whatfors.





Thursday, 31 December 2009

In defence of the Specialist M'lud

If you own an integrale then you have in your possession a piece of complex automotive history, please treat it with the respect it deserves!

So many cars come through those workshop doors in such shoddy condition it is a crying shame, bits missing, parts put on back to front, oil leaking out of every silicone bodged orifice. Quite often the cost of the work involved to bring these cars back to a roadworthy condition is more than the car is worth and it is so sad that much of my job is spent finishing someone elses job off because they got so far in and realised they were out of their depth or just made such a hash of things that they caused more damage than than they did good.

If you can't afford to look after an integrale then don't buy one and they are expensive cars to run.
Think with your head and not your pocket.

I sometimes get asked to fit other peoples supplied products, the answer is usually 'No thanks':

1. When you go out for a meal do you take your own food with you and ask them to cook it? How do you think we stay in business?
2. If the car later develops a fault which could be linked with or solely blamed of this part where does the fault lie? The part? the fitting? Then the arguments start....

There are a few well respected integrale Specialists dotted around the country, please use and support them as they charge what they do because they have the parts and the knowledge to keep your car in top condition. In these times of ever declining spare parts, knowledge and common sense believe me, it ain't no easy task.

free counters

Sunday, 27 December 2009

Centre Lathe

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When I first started earning a crust at the age of 16 I was trained to use machines, both in the workshop and at college, I've always enjoyed working with them and still have all my own fingers...
Back in Summer I decided it was time we invested in a centre lathe, there were a few reasons for this.

The integrale is of course not a new car anymore and so many come in with bits and pieces missing, on a new engine build this was never going to do was it:

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With many parts NLA or taking a long time to get hold of you have to take matters into your own hands in order to survive and get the job done:

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The same car came in with one of the map sensor nipples snapped off and someone had tried glueing it back on, but the glue had run into the sensor and blocked the hole so when plugged into the scanner there was no reading. The car was needed and map sensors are expensive so the solution was quick, easy and permanent:


















A clutch centering tool was also one of the first things I made after not really getting on with the universal ones you can buy:

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To be able to make your own precision parts as and when you need them without having the problems involved with sub contracting them out is very satisfying, the lathe is a such a versatile tool it's difficult to imagine work life without it..

Some other bits:











Cheating a bit here, but it did the job:









I don't think we'll be winning any awards, but it gets the job done and properly.

Saturday, 26 December 2009

Auxiliary belt tensioners

At last a replacement for those badly specced cast iron things which snap so easily...


















Made from Zinc plated billet steel these won't ever break!

Click on the banner at the top of the Blog to gain access to the site for prices.


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Track of the month: http://www.youtube.com/watch?v=steC-8NSVIw

Poignant lyrics.

Project Evo Chapter one.

A bit of a slow burner this one, I'm hoping to get it finished before we stop using petrol to power cars as I have some radical new parts to use on it.
The idea behind it is simple, It will be a no compromise track car, be as light, powerful and handle as well as possible.

I started off with a straight, but rather rusty shell. It was cheap enough and I figured by the time I had hacked it about to strengthen it, lighten it, make things fit better and added light weight panels it would have been sacrilegious to start with a decent one, they've all got rust on them anyhow!


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Sandblasting in progress:

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The neighbours were well impressed.
It came out nice and clean though with an excellent surface for the primer to cling to. I masked off the seams so they could be welded afterwards:

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The rusty sunroof equipped roof panel has been taken off and we made a carbon fibre replacement, lots lighter and also stronger, it will eventually be equipped with all the composite panels we do.

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As you can see in the pics above I started on it at home, just doing a bit on free weekends. I bought some A frames and turned them into a spit so I could spin the shell around to gain access to every part, if you are working comfortably and safely you are going to spend more time getting the job done just right. The spit is now at the workshop for use on customer cars.

Deltaparts.co.uk


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I handmade all the strengthening plates to the front end:

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I knew that Metalworking course at college would come in handy one day!


Right now it is having the cage fitted and welded in, seam welding and the strengthening plates welding on. Every item was degreased and etch primed before being welded. Etch primer is the one and only thing which you should use on bare metal, it won't scratch off very easily at all as it attaches itself chemically to the metal. It's also good near the welded areas as it doesn't come loose, burn and flake off, it just goes orange.

The engine bay was braced and the suspension arms bolted on to prevent any possibility of warpage from the welding.

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Favourite track last month but one(!) http://www.youtube.com/watch?v=lLJf9qJHR3E
Not usually a fan of folk, but this hits the spot. Just 4 guys and some basic instruments, make the most of it 'cos the follow up is rubbish.

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About Me

My photo
Welcome to the Deltaparts Blog, here you will find, well, anything which is on my mind I guess, but mainly things to do with the Lancia Delta integrale and in particular anything to do with my business, Deltaparts. It will be a bit irregular as it's not every day (or even week) that something worth mentioning happens. I would like to try and make it interesting - at least to some people anyhow, but also hopefully accessible and readable for the average 'man on the street' so I won't bore you with loads of large words, bombastic overblown sentences or technical jargon. I will describe on here how lots of the parts that we sell came about as there isn't room on the website ( www.deltaparts.co.uk ) to explain. I hope you enjoy reading it as I do writing it, when something becomes a chore you know it's time to stop doing it....