101 1300 rebuild part 8: back on track

I mentioned in my last post in this series that I broke a motor mount boss stud off, well, it turned out to be a pretty involved process to get it repaired.  When I mentioned the problem to ‘expert’ friends they all said ‘Oh, those studs never want to come out’ well, I broke it off installing  a new one, not removing the old, bent stripped stud.  I’ve broken studs off before on other rebuilds and was ready with the usual arsenal of tricks.

First I tried simply grabbing the remaining piece with Vise-grips, no good.  Then I drilled it out and used an easy out seen below, I couldn’t get a grip on it so I welded a nut to the easy out, the easy out broke at the weld.  I got a bigger easy out and tried to turn it, it was resistant despite a lot of force.  I heated the boss and tried again, this time the corner of the boss cracked.

easy-out-stageHere I am at the first attempt, the easy out wasn’t so easy and even with a nut welded to the end it wouldn’t turn.

heating-up-bossStep three was a bigger easy out with heat.  All I managed to do was crack the corner of the boss.

Once I cracked the boss I decided it was time to get expert assistance.  I Dremeled out as much of the stud as I could, disassembled a bunch of the engine and took it in the trunk of the Berlina to an appointment I made with Glenn to weld up the crack.  He Dremeled the rest of the stud out, welded up the crack, installed a Helicoil, accepted a check for $50 (labor and a thermostat cover) and helped me get it back in the trunk.  Expert assistance is under rated!

engine-transportHere I am back at the shop getting ready to unload the engine.  Fortunately there is an engine hoist in the shop so this is a one man job.  Berlina was on the bump stops  when I drove with the engine in the trunk.  In a perfect world I would give it new springs and shocks as I suspect they are worn out, but that would cut in to my Sprint/SS budget.

repair-doneHere I am, back where I was a week ago, getting ready to install the engine mount.  Note the finishing machine cut on the edge of the block when they cut the engine mount boss face smooth. 

starter-installedI had installed the flywheel without aligning the timing marks so I used the disassembly required by the transport as an excuse to remedy this so I took it back off and aligned it.  When reinstalling the clutch I noticed some alignment marks between the clutch and flywheel which I aligned.  As can be seen here, I need to paint the starter.

breather-repaired-and-installedThis is the 750/101  1300 breather.  Mine was cracked so I dropped it off and Dennis at NRG welded up the crack and smoothed it out.  $20 

What is left to do you ask?  Well, my Lucas distributor was deemed unfixable by Jaan so I need a new disributor, hopefully a Bosch unit will surface (anyone?).  The exhaust side engine mount still needs to be installed as do the rest of the oil pan bolts.  I need to get a big hose clamp to try and compress the Giubo and test fit it before I make it an under car operation.   I still need to paint the starter and alternator bracket.  Oh, and I need to decide if I am going to install a mechanical fuel pump and cap it off as a back up in case the Facet dies again when I am out in the wilds on a rally.  I am hoping to begin the install late this week.

Click here fo rthe next post in the engine build saga!


7 thoughts on “101 1300 rebuild part 8: back on track

  1. What about running electrical and mechanical pumps in series, with a switch to activate the electrical unit, eg if the car’s been sitting a long time and needs more pump action to get gas back into the carbs?

    • I discussed this idea with Glenn and may do it in the future. I have a couple of mechanical pumps laying around but don’t want to spend the time right now. I’d rather get started on the 1600 rebuild for my SS.

  2. Matt,
    Great work! I thought that I would let you know that I have been told that running an electrical and mechanical pump in series is very, very dangerous. If the diaphram in the mechanical pump fails, and you have an electrical pump running, the common result is that fuel will flow into the engine through the mechanical pump via the front cover. It is only a matter of time before the fuel ignites on something. Apparantly, more than one alfa has been burnt up in this way.

    • Hmmm, sounds plausable. What if I simply installed the mechanical pump but capped off the ends and installed one of those barbed splices in the right spot to have it replaced by the pump in the event of the Facet’s failure. It would also give the necessary hose clamps something to do.

      Thanks Jon,

  3. Yeah, that should work. I am thinking that the diaphram would be working all that time. It would wear, but not any faster than normal. Maybe keep a spare diaphram, too? Then again, after all this effort, it might be easier to keep a spare Facet with you. I dunno.

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