Flaminia engine rebuild

[lancianut666]

Some more pics. The paint is still wet in the last few pics as it was a bit chilly in the unit. Better news with the master cylinder as after drying it out from it's dip in the ultrasonic bath I lubed it up with some engine oil and the rear chamber was pumping the oil back out, the banjo is lacking it's banjo bolt (anyone got one?) so the front chamber was not doing much but at least it is all moving so I will risk an overhaul kit possibly after looking at the bores. The servo gizmo looks a bit scary so I am toying with the idea of  connecting up the front and back brakes but miss the servo out for now. I am sure I have read in the workshop manual to do a service on the back brakes you have to remove the transaxle...I hope I have got that bit wrong but they are inboard disc brakes.
Clarkey

[Richard Fridd]

  I have accessed my rear disc brake callipers without removing the transaxle

              Richard

[simonandjuliet]

The quality of some of the castings is amazing, the one for the accelerator cable is lovely !!

Lots of detail - love it ....

[lancianut666]

Easy to see where all the money went on these cars...why not just make a bracket in mild steel? why not have a lovely casting with a machined shaft with a grease nipple and a ball joint connection to the pedal? OK the casting then.

[frankxhv773t]

The hatch in the boot floor helps with the rear brakes but you're still in double jointed midget territory. I've removed a drive shaft to move a car with seized back brakes before now because that was easier than getting access to free them off.

Silver or light grey suits a Flaminia very well but I think two tone black over grey/silver always looks classy.

[lancianut666]

Hi all
Had a bit more rattle can painting completed using some paint I had bought for the Appia and when seeing it on a test piece on the Appia decided against it but is quite acceptable on the engine bay of the Flaminia as it lightens up the engine bay better than black, the paint is for a S1 Fulvia Grigio Vinovo. I have also managed to dismantle the master cylinder so I can check the bores and decide on an overhaul kit or an overhaul kit and a new master cylinder body. The master cylinder dismantled quite easily but the banjo fixing that has an 'O' ring seal in it is not co-operating so we will see what a bit of heat applied to the steel fitting achieves tomorrow. All the internal bits have been ultrasonicked and have cleaned up so we will continue with that tomorrow.
Clarkey

[lancianut666]

Hi all
A bit more done today with the rattle can so when the primer is dry (it is taking ages) I will put a coat of gloss on the bulkhead. Still deciding on black or the grey I used on the inner wings, I think the bonnet lock gizmos were originally black so might go with the grey and give the bonnet locks a touch up in black. The engine buffers have arrived at 160 Euros so slightly cheaper than uk suppliers I have just given the bottom caps a coat of primer but it is very slow to dry so will have to wait till tomorrow. Had a look at the brake fluid reservoir and the original is very corroded/damaged on the mating surface where it meets the plastic tank but the bore looks quite good. The thread on the tank securing ring was very rough but with a bit of persuasion ( the stilson) we have got the thread hand screwable so that is good. I will have a look again at the sealing surface as it is very rough but if you ignore bleeding the brakes most of the time it can just be a reservoir so the fluid pressure will not be too extreme but we still need a banjo bolt, I will try my go to nut and bolt man to see what he has later in the week.

[lancianut666]

Some more pictures...
Oh and I need an engine mount plate as only three came with the car. The bonnet catch is quite complicated and one of the catches had seized but managed to free it off but really I need to dismantle it and clean all the dust and grot out of it.
Clarkey

[lancianut666]

Hi all.
Well today started off really well despite the atrocious weather. My first job was to get the fluid reservoir banjo fitting out of the master cylinder so I could give the bore the once over. So armed with all the extension bars I have I came up with the idea that by bolting the master cylinder back in the car I would have a better chance as the car sans the engine must be 22 and a 1/2 CWT and I an 11 stone weakling would not be able to move it so the banjo fitting would be forced to surrender. Alas no the socket would not fit straight on and we had to employ one those useless universal joint things but this left the socket not quite on the fitting so after a tentative heave on it we adjourned to the vice and by standing on the bench and pulling straight up out it came. I have sourced a new banjo bolt but no luck with a replacement dynamo so anyone got a spare dynamo for a Flaminia? Some more rattle can work sees the bulkhead with a nice coat of grey and the bonnet lock catches and the coil bracket in a nice gloss black. As the engine rubbers are to hand I tried out all four to check they would screw into the brackets on the engine so far so good. Finally I gave the master cylinder a good clean out and check of the bore...looks good with a bit of corrosion or gunk roughly where the rear O ring goes, it has been stood for 40+ years.
Clarkey

[lancianut666]

Some more pics.

[lancianut666]

and a few more...Simon was admiring the castings for the throttle linkage, check out these bonnet catches.

[frankxhv773t]

Never use one part when fifteen will do, the Lancia way.

[lancianut666]

Hi all
Bit more done today as I have manged to get the heater hoses on at the bulkhead as it will be tricky getting to them with the engine in. I also had a practice run through with the brake fluid reservoir as I am concerned with the seal between the plastic tank and the metal body, I have a 2nd hand reservoir on the way so will see what that one is like. The throttle bracket is on so a good day.
Clarkey

[lancianut666]

Hi all
Update on progress so far. As the heater tap membrane was here I set my mate Terry on to cleaning up the old tap and fitting the new membrane. We tested it by blowing in one of the out lets and making sure when the tap was shut no air was getting back through the cylinder head connection. Today was master cylinder day so all the old seals were removed and the piston assemblies stripped down cleaned, new seals fitted and reassemble and pushed back into the cleaned out master cylinder lubed up with some Dot4 brake fluid. A couple of tricky parts in the reassembly concerned the strength of the large springs and the need to replace the 2 pins holding the piston assemblies together. The springs were overcome by using a trim panel remover to hold the spring down over the connecting pin so the seal carrier can be connected. This means the two pins (they are tiny) have to be pushed back in as you are holding the spring down. I had a thought as I was struggling with this ( two flights into a low earth orbit were undertaken by said springs) could the the rod end fit past one pin and then as it was secure push the other spring...it would so the front? one was done and with a bit more fiddling the back one was done so they were popped into the master cylinder and the lock bolt screwed in and a result!

[lancianut666]

Some brake pics...