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Neil's Fiat/Bertone X1/9 
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QFP80 - Contributor

Joined: Thu Jan 12, 2012 12:54 pm
Posts: 58
Location: South Africa
After some philosophication and study I can see what I did wrong. The retainer has been staked to stop it from turning and I removed enough stake to get it to loosen but the thread is on the outside and as soon as it came into contact with the staked metal it jammed. A full size 19mm spanner was too much for it, it is not very strong, nice brittle cast ali as you observed.

But its not so bad! Turned out I did not need to remove it at all despite what the manual says. As soon as I released the damper I was able to pull the rack far enough to one side to insert the bush. I used a punch to rotate the retainer back to its original position and some metal epoxy to seal the broken bits. The retainer itself seems to be total unobtainium. One day I will it get out again and and get a replacement made.

Steering rack assembly now ready to go back in the car. That will be a mission and a half.


Thu Jan 30, 2014 8:33 pm
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AncientGeek wrote:
After a lot of beer and study while hung over I can see what I did wrong.

Good progress! :-)

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Thu Jan 30, 2014 9:06 pm
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QFP80 - Contributor

Joined: Thu Jan 12, 2012 12:54 pm
Posts: 58
Location: South Africa
I finally got into the old girl's pants. Not a pretty sight!
Attachment:
pipe1.jpg
pipe1.jpg [ 61.24 KiB | Viewed 2061 times ]

I started off trying to drill out the spot welds but soon said "golly this is not worth it" or words to that effect, and just cut the damn thing open. It was not worth saving anyway, I will make a replacement out of galvanized sheet metal.

I don't have access to any lift or pit, so all this was done with ramps and jack stands and working inches from my nose.

These spots are radiator stop-leak. Lots of muckies in the pipes, the rad will also have to come out and be professionally cleaned.
Attachment:
pipe3.jpg
pipe3.jpg [ 39.09 KiB | Viewed 2061 times ]

I managed to find a genuine original unused pipe from a local guy, the other one I will have to get made up. It has a series of complicated bends at both ends.


Sat May 24, 2014 7:47 pm
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QFP80 - Contributor

Joined: Thu Jan 12, 2012 12:54 pm
Posts: 58
Location: South Africa
A few ructions in my life so work has proceed slowly.

I drilled out most of the spot welds in the end, but left one side of the original belly pan.

I had a second pipe made up from stainless as nobody would make one in aluminium for me. the small heater pipe was made in alu.
Attachment:
File comment: The old and new pipes. the small one is the heater pipe.
old_vs_new_pipes.jpg
old_vs_new_pipes.jpg [ 1.43 MiB | Viewed 1902 times ]

The inside of the belly pan was cleaned up and sprayed with rust converter and hammerite. The right hand side you see here I made in alu and riveted on to the body. I attached the small heater pipe first.
Attachment:
File comment: Empty belly pan with the pipes removed
inside_pan2.jpg
inside_pan2.jpg [ 1.24 MiB | Viewed 1902 times ]


Attachments:
File comment: This is the inside of the old pipe. Mind boggling. I fear for the block.
rusty_pipe.jpg
rusty_pipe.jpg [ 1.02 MiB | Viewed 1902 times ]
Fri Feb 06, 2015 9:22 pm
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QFP80 - Contributor

Joined: Thu Jan 12, 2012 12:54 pm
Posts: 58
Location: South Africa
Interlude: the driver's floor was rusted right through. Thoroughly cleaned with wire wheel and rust remover, coated with rust converter, sanded, etched primed and painted with anti-rust paint before being glass fibred and covered with sound block.


Attachments:
fixed_floor.jpg
fixed_floor.jpg [ 1.5 MiB | Viewed 1902 times ]
holes-In_floor.jpg
holes-In_floor.jpg [ 1.03 MiB | Viewed 1902 times ]
Fri Feb 06, 2015 9:30 pm
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QFP80 - Contributor

Joined: Thu Jan 12, 2012 12:54 pm
Posts: 58
Location: South Africa
The pipes were then fitted and held in place temporarily with cable ties. I put some rivnuts on the inner pipe supports so when the bottom cover was riveted on I could bolt them tight to stop any rattles. I also glued some rubber to the inside of the bottom cover.
Attachment:
File comment: Pipes fitted
pipes_in.jpg
pipes_in.jpg [ 1.75 MiB | Viewed 1896 times ]

Attachment:
File comment: A view from the front with the cover riveted on
front_view_finished.jpg
front_view_finished.jpg [ 1.81 MiB | Viewed 1896 times ]

I then made supports for the front of the pipe near the radiator.
Attachment:
File comment: Home made front pipe support
front_pipe_bracket.jpg
front_pipe_bracket.jpg [ 1.26 MiB | Viewed 1896 times ]


Sat Feb 07, 2015 8:16 am
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QFP80 - Contributor

Joined: Thu Jan 12, 2012 12:54 pm
Posts: 58
Location: South Africa
Interlude: cleaning the radiator.


Attachments:
rad_sludge.jpg
rad_sludge.jpg [ 1.26 MiB | Viewed 1896 times ]
Sat Feb 07, 2015 8:19 am
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QFP80 - Contributor

Joined: Thu Jan 12, 2012 12:54 pm
Posts: 58
Location: South Africa
The finished product, car is back on the road although it will soon be taken off again to do a engine out serpentine belt conversion with a triggerwheel. And to to check the block of course. Plenty of work to do. I've also acquired a hotter cam.


Attachments:
File comment: A view from rear prior to sealing and painting. The cable on the left is the speedo cable (which Haynes claims is an accelerator cable)
rear_view_finished.jpg
rear_view_finished.jpg [ 1.5 MiB | Viewed 1894 times ]
File comment: The final product spayed with stone-chip. The gooey looking black stuff on the left is Devil's Diarrhea (bitumen based chassis black) to seal under the driver's floor.
belly_pan_stone_chip.jpg
belly_pan_stone_chip.jpg [ 1.68 MiB | Viewed 1894 times ]
Sat Feb 07, 2015 10:07 am
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Good work,keep it up! :-)

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Feb 08, 2015 5:50 am
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QFP80 - Contributor

Joined: Thu Jan 12, 2012 12:54 pm
Posts: 58
Location: South Africa
Well I've found a lot wrong with this car and lost heart a bit but I'm working on it again.

Fixing one always reveals 10 other things that need fixing.

For example, I replaced the headlight switch and added some relays. While there I noticed some dodgy wiring for the electric windows with an unfused connection direct from the battery. I opened up the left door where the window had never worked properly.

I found

1. The inner weatherstrip was missing.
2. The wiring was incorrectly routed and loose inside the door getting entangled in the mechanism
3. The glass was not original and too thick for the guides
4. the glass was not tempered auto safety glass. :o
5. The glass was mounted skew on the base plate.
6. The height adjuster screw was stuck solid (might have been welded from the inside) requiring drilling out and re-tapping.

All on one little door window.

I was unable to find a local replacement (international shipping costs are crazy) so had one made. Works great.


Mon Feb 29, 2016 9:55 am
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