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Old 5th October 2010, 23:42   #166
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Sorry folks, Was busy with a different kind of restoration, house painting and a failed wi-fi

After the tinker left abroad, its becoming a tough job to find another competitive one to finish the rest of the pending work on the car.

In the mean time, the Head is gone in for ONE FINAL time to a reputed lathe, IF this does not work. We are left with only one last Hope.

GET A NEW REPLACEMENT HEAD.

Presently, work done on the car.

1) New floor pans added
2) Body line achieved
3) Door shut lines achieved
4) Bonnet shaped
5) Bumpers tinkered
6) Fenders aligned and tinkered
7) Door locks and handles repaired and set
8) Headlights installed and checked
9) All the brake lines replaced
10)Brake shoes re-lined
11) Brake Master cylinder kits replaced
12) All Wheel cylinders replaced
13) Brakes bleeded and working fine
14) Tail light setting done

Pending work

1) Suspension spring blade resetting (Work started)
2) Spring blade bushes replacement (Search is ON)
3) Body tapping ( No Tinker)
4) Door Glasses ( Not ready)
5) Spare tyre cover ( Need to design as per original)
6) Painting (Found a good paint shop)
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Old 8th October 2010, 13:35   #167
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The spring blade setting is almost done.

Got them to the car, checked the height, its a bit high by an inch, making the wheel arch show a big gap, it goes again to the re-setting guy.
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Old 12th October 2010, 20:49   #168
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Work Done:

1) Work on Suspension - DONE
2) Head - DONE

Pending:

1) Source the Suspension bushes - search is ON, but nothing suiting.
2) Engine Head, is supposedly been worked on and have been confirmed its 100% leakproof. Only tomorrow afternoon will tell. LITMUS TEST
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Old 13th October 2010, 16:23   #169
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Raghav - 2 things I noticed in a TV show called 'wheeler dealers' on Discovery Turbo. I saw how a (1) compression testing is done (2) head is checked for its health.

(1) is pretty straight forward, you should do that simple test after refitting the head even before cranking with fuel.

(2) is more of a DIY, unofficial test. That mechanic filled the head with petrol in pic.2 and 3 above. I think he fit the spark plugs in place, and poured petrol into the 4 valve heads. If any valve is not tight, i think the petrol leaked and showed its bad health.

Sorry if I sounded nonsense, but I saw it on TV and looked straight forward.

PS - Do you know of any mech doing the compression testing with the gauge (looks like tyre pressure gauge), and not start the engine straight away?
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Old 13th October 2010, 16:52   #170
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Quote:
Originally Posted by svsantosh View Post
(2) is more of a DIY, unofficial test. That mechanic filled the head with petrol in pic.2 and 3 above. I think he fit the spark plugs in place, and poured petrol into the 4 valve heads. If any valve is not tight, i think the petrol leaked and showed its bad health.

Sorry if I sounded nonsense, but I saw it on TV and looked straight forward.

PS - Do you know of any mech doing the compression testing with the gauge (looks like tyre pressure gauge), and not start the engine straight away?
Thats to do a leak test for the valve seating. In our case the gring and facing of valve and seats has already been done. So no issue there.

The leak is more to do with other surfaces on the head.

The biggest problem is the combo of aluminium head and cast iron block. Different materials, softer one always is sacrificial in nature.

As for compression testing, a lot of people use them, I too have one. It is a very good tool to diagnoise issues related to compression on an engine. And I have seldome seen people using the same after repairing the engine. As the compression form the new components will be near to specifications.

@ Pawan: sorry to hijack and post. I could not meet you last sunday too. This Friday / saturday is all mine to devote on my CAR .
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Old 14th October 2010, 19:02   #171
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We are all set to fire the engine with the re-worked head.

This time, making sure, we dont face any major hurdles. Each and every aspect is being checked rather than a enthusiastic approach.

Tomorrow , will be the face-off. Pray to god to get it right this time.
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Old 17th October 2010, 13:55   #172
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Default Testing , Testing.........!

9:30 am : The head was re-checked with a pressure plate

RESULTS: Came out clean, no leakage.

11:00am : Head was fitted on to the Engine block. water poured into the water body, and we wait to see any significant leakages.

RESULT : Over 2 hours of water into the engine block, NO LEAKAGES

RESULT : The next 1 hour , we find little bit of moisture in one of the Exhaust manifold


Very minor, but we are not the one's to let that be. Removed the head again, checking it all over again. I took a break for lunch and came back.

Keep watching this space.............!
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Old 22nd October 2010, 20:28   #173
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Thumbs up Head On............

All izzz well..........!

But only for the time being.

We added water into the engine block (Without the radiator but), The Engine fires up well, the carb is acting funny by not idling, but anyways, 5 mins the engine was running on high revv. and NO PROBLEM.

We will now go in for a full blown test tomorrow. Do up the complete engine setup with the radiator, have a separate cooling fan and let the engine to run for a good 2 hours. This will decide the fate of the reworked HEAD.

Meanwhile, the suspension spring blade bushes that was giving me headaches, Found them finally , Thanks to Arun1100 and Funkykar for leading me to the right shop.
Attached Thumbnails
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Old 25th October 2010, 20:45   #174
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Unhappy Suspened over the Suspension issue

No matter what part it is, each and every component of an old car is sure to throw some unpleasant surprises each time.

I started work on the Brakes 2 months ago, and felt , other minor mechanicals will be as easy a swim as the brakes worked out.

Last 3 weeks ago, i dismantled the suspension, the spring blade resetting took time, but the blade bushes are a nightmare. I was helped by the FCB guys Funkykar and Arun1100 , though the bushes looked like they will be an easy match, BUT NO.

The diameter of the blades are 26mm , but the bushes dia was 28mm, so this meant lot of time and work at the lathe. I waited for my mechanic to do the same ,but his busy schedule only meant a delay, Off i take them and head to the lathe, made some time off from office.

First thing was to turn the bushes and shave off those extra 2mm dia OFF them. 1 Hour at the turning machine, and all the suspension bushes were ready to go in.

Next thing was pressing them into the blades with the help of a hydraulic press, its such a dangerous job, but the lathe guys were very helpful and they finished the complete job just under 2 hours.

Finally a job well done

Off i drop it at the workshop for them to be fitted onto the car tomorrow morning.
Attached Thumbnails
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Old 25th October 2010, 20:48   #175
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Phew!! Lots of hard work going in there!

Whats the update on body work?
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Old 25th October 2010, 22:02   #176
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Originally Posted by funkykar View Post
Phew!! Lots of hard work going in there!

Whats the update on body work?
Thank you.

Well the Bodywork is a long story

Anyways, the story goes like this.

The tinker felt the grass on the other side is green and wanted to migrate, he completed the aligning and most of major tinkering work on the car. He left and he came back due to incompatibility, but after coming back he's half interested in doing any work. Maybe he's depressed.

But anyways, i tried various other tinkers, but none of them can work on the car as per my requirement.

Will update tomorrow about the other work happening on the body.

Last edited by PAVAN KADAM : 25th October 2010 at 22:03.
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Old 26th October 2010, 16:18   #177
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Talking Time and PAVAN KADAM waits for None

Sneaked a chance when AirbusDriver (Joy) the car owner not being in town, and finally gave the mouse my Favourite color

On a serious note, This is the etching primer that is being sprayed, We saw several rust spots on the car over a period of time, and this was due to be done right now, hence, got the painter to start work by spraying a coat.

There are 3 advantages of doing this.

1) The rust spots will be seen easily and can be treated, after this rusting will be history
2) Few places i had got the tinker to do body tapping, now we will exactly know the uneven surface.
3) Had to satisfy myself seeing this car in Color Yellow (Joking)

The insides are getting scrubbed, by end of day, even the insides of the car will be sprayed.
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Old 26th October 2010, 16:38   #178
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Dear Pavan - those are Padmini leaf spriong bushes. It is necessary to assemble them with the rectangular cut at a certain angle to get ride height / characterisics correct. In the 1100, Approximately, this angle is around 85 degrees from the top of the top blade and 45 degrees to the top of the body support (everybody assembles them incorrectly for some silly reason, after which the car does not work properly). Please post details of the topolino's spring mounting orientation. I will guide you so that in the end you get the result that you want.

Best regards,

Behram Dhabhar
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Old 26th October 2010, 18:31   #179
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Originally Posted by DHABHAR.BEHRAM View Post
Dear Pavan - those are Padmini leaf spriong bushes. It is necessary to assemble them with the rectangular cut at a certain angle to get ride height / characterisics correct. In the 1100, Approximately, this angle is around 85 degrees from the top of the top blade and 45 degrees to the top of the body support (everybody assembles them incorrectly for some silly reason, after which the car does not work properly). Please post details of the topolino's spring mounting orientation. I will guide you so that in the end you get the result that you want.

Best regards,

Behram Dhabhar
Correctly said sir, Indeed they are from the premier padmini, but the diameter is shaved off by 1.25mm to fit the topolino.

I had got them pressed in a wrong angle, and had to go back to the lathe to re-align the bolt angle, But this time i got it perfectly pressed.

I have also asked the lathe guy to fabricate brass bushes with an attached grease nipples for longevity, as guided by another T-BHP'ian.

The Standox etching primer turned out to be too expensive as compared with those generally used., But my friend needed the Best of the materials used, so had no other go.

The pics as per your request are here.

Tomorrow we are planning to plonk the engine into the car for futher test-trials, hope the mechanic completes his other pending work.
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Old 26th October 2010, 18:43   #180
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Hello Pavan. Hope the Padmini bushes work perfectly. If not, please feel free to ask me.

I am keenly looking at the painting procedure too. I will advice you as and when needed.

Regards.
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