The bare main shaft - ready for reassembly of gearwheels, synchros and bearings.
Parts mailed express from classicalfa.
New and old gears and synchros ready to go back in.
Finished transmission shafts - input top left - output top right.
Meticulous reassembly with cautious application of gasket.
Checking the shift mechanism action - approved!
Et voila! Packed and ready to go into the car - cannot wait.
I left my car at Steffen's place on the return trip from the Rømø Motor Festival.
Nothing wrong with the shift mechanism (note the high-quality forks).
Separating input shaft from main shaft reveals 4th and 3rd gears.
Dog-teeth on 3rd shifting sleeve worn round - that doesn't help.
But the real problem is this: all-crooked nut and synchro-band inside synchronizer!
Synchro-band has kinked and somehow jammed under the nut - locking everything up!
Here the kink is visible on the left band.
This is how the nut should sit - not allowing anything to go under it.
Steffen found some old original stock (OOS?) in the basement - yes please!
Compare the perfect teeth on the new dog-ring on the left with the worn on the right.
Nice and pointy dog-teeth on the shift-sleeve also - excellent.
The reassembly begins - additional new parts ordered from classicalfa in the UK.
BTW, this is from my 2nd gear - only synchro we changed when the gearbox was originally refurbished (only 5 years ago - bad quality?) You can watch my videos; I know how to change gear! I believe there has been a period recently when it was almost inevitable to get bad quality parts sourced from China. Last time we ordered all parts from Myalfa; wouldn't they have good quality?
Camber is now -0.20' (-0.33 degree) and caster is +0.10' (+0.17 degree) ... both sides!
Toe-in is +2 mm.
Main jets are 118 with 100 air correction in F16 emulsion tubes.
Idle jets are 55F4.
Radiator cap has the correct pressure rating.
Before going to Steffen's, I installed the air/fuel ratio sensor.
And I went with Keld, who was headed the same way in his Zagato.
Angry Giulietta without front wheels but in good company.
Radiator removed and ready for repair at a specialist.
Temperature sensor drilled out for use as a heater fitting.
Race-spec-size cabin heater from Demon-tweeks.
Difficult disassembly - expecting to see a bent axle.
But all was straight - both sides!
Upper ball had a bit of play - but both sides were straight!
I had to go and see for myself - and could hitch a ride with Rejkjær.
Front view with suspended string.
Distance between the strings.
Rear view.
Same distance.
Left side view.
Tight string.
Right side.
Tight string.
Body centering.
Wheel alignment (no toe-in/out).
Wheel alignment (no you-in/out).
Wheel alignment (slight toe-out 0.2 cm ?!)
Wheel alignment (slight toe-out 0.3 cm)
Right side lower ball-joint distance.
Left side lower ball-joint distance.
Checking right upper triangle distance from tire.
Checking left upper triangle distance from tire.
Ready at the the workshop from early morning.
After a reference-drive the old carburetors are removed.
The new Weber DCOE40s came with all-wrong tubes and jets.
It pays to be thorough in this line of work.
We spent almost two days, because it was really difficult ...
We even re-checked the camshaft timing.
An in the end it all turned out very good!
During the two days a couple of exciting cars came in.
Like this GTA-abnormale with a dysfunctional 2-liter engine.
And in the end I could drive home in the angry red car.
On the journey home I used 19.17 liters of 100 octane petrol.
While driving 199 km - that is 10.4 km/liter.
Dent repair in boot-lid and rear left corner; now with new "airplane".
Glad to see that the underside is okay.
Planned for a long time; new rear interior side cards.
They will fit in neatly with the new parcel-shelf.
Talked for years about putting door check-straps in.
Stripping off paint in some places; applying new paint in others.
Painted and with the doors back in; getting there!
Since I lost a bezel in my autumn crash
I have been indecisive about how much refurb I should do
But this time it has to be properly attached.
I also sourced new lenses for the rear lights.
And while I was at it - the cracked number plate light (airplane) is also fixed.
Yes there will be racing this year!
Come and visit me at the Copenhagen Historic GP in august.
Right now in the garage, I am doing some body work.
And some remaining fiddling in the interior.
The engine at rest after some angry driving last fall.
While Steffen is working on 'the other engine' ...
There's another engine?! - yes, why not?
Carburetor innards - all shiny.
CROWD-funding now at a total of 455 EUR
Pick-up after using the Notruf phone number (2009).
Between Metzgesfeld and Kallenhard.
Not so proud passenger, but memorable drive!
At Rent-4-Ring with broken petrol pump.
Stranded at RSR Nürburg with failing alternator (2016).
Handing over car to Bongard for SOS International return to Denmark.