The Portuguese Aurelia .........the Phoenix has arisen......

[Spider2]

I have a pretty good idea of the MPG of the Appia, both cruising and around town. I keep a log of the fuel uplift and usage so regardless of the fuel gauge I reckon I know the quantity in the tank to within 5% or 2 litres. Flying aircraft with either dodgy fuel gauges or none at all has given me good training. You may be interested to know that big aircraft like Boeings and Airbuses do not need serviceable fuel gauges to fly. There was a famous incident in Canada 25 years ago when a Boeing 767 of Air Canada ran out of fuel and glided to a safe(ish) landing. The company had recently changed their units of fuel from pounds to Kilograms and the crew asked the re-fuelers to pump in 20,000. The re-fuelers assumed 20,000 lbs but the Captain wanted and needed 20,000Kgs. Without fuel gauges an accident was bound to happen. We call it RIRO. Rubbish In Rubbish OUT. Google the "Gimli Gilder". Makes fascinating reading. Also this incident is an episode of Air Accident Investigations. The rules about flying without fuel gauges was not changed after this incident.

[Parisien]

I am afraid my experience with my B12 sender unit was not so positive. It had stopped working (actually jammed at 1/3 tank and I did not realise till I ran out of fuel...). I freed it off and electrically it was working and the float had not died, but the mechanics has suffered sever corrosion. I did put it back in the tank but when it stuck again showing 1/3 full when I had filled the tank Idecided that fuel gauge was quite important on a thirsty car like the Aurelia so I bought a remanufactured sender from Cavallito and it has worked ever since...

Hi Simon, thank you for the float offer, I was advised by another member that the cork was originally coated in shellac and that the 5/10% addition of ethanol to petrol will dissolve this, suggested a brass float from an older SU carburettor, or am sure a modern plastic float would do?

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[Spider2]

I used lacquer on my cork float and hopefully by using Esso 99 which, reputably, is 0% ethanol it will last as long as Lancia originally managed (about 60 years). I have had to tweak it a couple of times to get it to work reliably (straightening the wire and getting the balance between buoyancy and weightiness correct). Also needed to adjust the low level sender contact a couple of times but now all seems to work OK and the red low level light comes on at, I think, about 6 or 7 liters.  All in all a very interesting and rewarding project, but If I had charged myself the man hours, even at minimum wage, I could have bought a new one from Cavalitto many times over.

[Parisien]

Things have settled down for my mechanic plus the months effective delay as Cavillito was closed has passed. so work now continues.

There were one or two issues with new loom, which will be sorted shortly. The carburetor ( which my mechanics dad would have worked on if he had been well) had been passed to another carburetor guy ( along with a full kit), and taking into account Chris Gawnes experience and advice with working on same.

A further consignment of parts due tomorrow to allow refurbishment of steering linkages etc. At same time front brakes have been dismantled for rebuilding, again taking much advice from several members about relining and setting up. New cylinders to be fitted,  shoe bearings ok, as is spring.

Front bearings also being swopped out and seals.

Steering box, cleaned out, new needle bearings inserted, refilled with  EP140 oil , steering column connected

Work is ongoing for both door lock and boot lock.

Work ongoing prepping petrol tank, also applied crackle finish to airbox, think I need to cure it too.

New outer door handles obtained, remainder door furniture to be rechromed, plus other smaller parts, (timescale 10-12 weeks)

Radiator to be refurbished in coming weeks.

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[Parisien]

Noting curious markings on shoes, reckon the linings  had "slipped" or become part detached, hence advice on riveting and bonding, dually noted

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[Parisien]

Brakes, first time seeing light in 50-60 years

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[Parisien]

He also remarked that for some reason one side was better maintained than the other, why one wonders.

Cylinder looking sorry for itself

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[Parisien]

As in grease found!

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[Parisien]

Many small jobs remain to be completed.

One of which is to refurbish the boot lock/ handle combo, specifically the lock barrel as it didn't have a key, plus as you can see it needs rechromed.

The little locating bar tagged onto a "V" shaped little spring was released, this then allowed the barrel to be tapped through from the inside.

But then spent an hour releasing the glass inside due to a type of putty keeping it in place, then cleaning it!

New barrel with key to be installed at a later date.

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[lancialulu]

Be careful when rechroming as it adds more metal than back in the day and things like locks are hard to refit.

[Parisien]

Unsure of metallurgy of said lock, it's hard to know how it will take the rechroming full stop. I'll certainly mention it, assuming they can "tailor" their process, or bypass/lessen one or more of the layering of the various coats

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[Parisien]

More progress, steering arms ball joints fitted plus new cups. Bush fitted too. Now more more tight and fluid on moving.

Brake drums were within tolerance, so ground to the relevant "rough" finish. Both front bearings and seal replaced, backplate in good condition, cleaned and painted.

Brake shoes will be back next week

Petrol tank, lower half , bituminous paint finish scrapped off, found two earlier braised repairs, but metal in remarkable condition after 70 years, primed and will be recoated in bituminous paint by Friday.

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[Parisien]

A few more pics

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[Parisien]

Back plate, cylinders, bearings, seal in situ

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[Parisien]

Some more

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