02956 Restoration

I have been helped so much over the last few years that I thought it was time to share my progress. I committed to get many of the hardware items completed over the Winter and I did fairly well. A few of the items tackled included the wiper system, half shafts, pedal box, heater blower motors, rear lid hinges, door strikers, rear axles and hood release. Of all of the projects, the wiper system was the most challenging due to the large number of parts. One of the gears was badly stripped and had to be be replaced. Otherwise, many many pictures were taken to keep track of everything. And, thanks to others that have posted previously as determining the original finishes was not always obvious. If anyone is interested in any one system, let me know and I can add more pictures.
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I am guessing that I have at least two more years to go on this project. This Summer I plan to finish most of the body work. Rust took its toll on the lower section of the Dino so there will be new rockers, inners and outers, one new door for the RH side, and rear quarters. I have some of the parts made; just need to weld in place.

There are a few more hardware items that I want to finish this month and I will post pictures of them as I get them done.

Jeff

 

I have tackled a tricky part; the handbrake assembly. I was missing the lower lever arm that connects to the hand brake cable. This part has two bits to it. The first is the lever arm and the second is the pivot. The lever arm was straight forward....sort of. I copied a number of pictures posted by several of FerrariChat members. I used my shop press to create the two angles required and machined the sides to agree with the pictures. The pivot required a little more thought as there is a spline that must be produced to engage the mating feature in the main handle. I used bondo in the hole and just as it started to harden, I pushed it out with a rod and ended up with an exact duplicate of the spline. I ground a single point cutter with a profile exactly to the bondo part and then used a dividing head on my mill to recreate the spline. After a couple tries, I got one to work perfectly. The threads on the end were very-fine metric and so I had to purchase a special die to cut the threads (M10 X 0.75 mm). The parts were welded together and assembled loose until I put it on the car. You will notice that the lower hole for the cable is not yet in. I will measure this once installed and drill for the pin. Fun project.

 

OK, here's some pictures to prove it.
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I have made some progress over the Summer but not near what I wanted....house projects too precedence. I am working on the right and left heater boxes and heater valves. I have one heat/air diverter that was damaged. Has anyone removed the flap assembly from one of these units? My plan was to remove the flap assy, then cut the sections apart, repair and then reweld. Any advice? See pics for current status.

Thanks
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Peter,
Easier than I expected. I will give this a go on the weekend.

All the best.

Jeff

 

It did not go well. The shaft appears to be solidly welded to the square shaft. So, I split the tube and extracted the shaft and plate as an assembly. Here's what I have....see pic.

I will remove the spot weld and remove the shaft as it will be much easier to do the plate and seal repairs.

Peter, did you drill out the spot welds or just pries the plates apart and slide the new seal in?

I will make new tubes from flat stainless or tube and reconstruct the system.
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Peter,
I will attack in the order you recommended. I will go with mild steel....I may be able to salvage all but the straight tube. Brackets are easy to make so I will reconstruct them. Zinc plating is relatively cheap and considering that this car will not likely see much rain in its lifetime, it will probably last forever.

Thanks for the assistance.

Regards,

Jeff

 

I am making progress slowly and surely. The damaged duct required more work than anticipated but the result was good. The shafts for both ducts were welded on both sides and in 2 places. I had to carefully grind each weld removing the least amount of material. Everything came apart easily after that. One shaft was saved and one was machined with new bushings. The rubber for the flaps was replaced with new material. The damaged duct was carefully cut away and a new section was made and welded in. The attached pictures show the result....and I blasted and painted both ducts and one of the heater boxes....the other one was painted some time ago. I also finished up the pedal box. I was missing the adjusting link for the brakes and was able to get pieces on-line to recreate it close to original.

2 of the trim pieces are out for straightening as they were dinged a bit. I was sorry to see that they are just mild steel with chrome plating.

Some of the body panels on my car had some rust or were easier to replace than repair. Alberto came to the rescue and I have several replacement steel parts...rear quarters, lh door skin and a couple inner panels. Thanks Alberto.

I should also mention that I also sent bumpers, license lamp housing and several other miscellaneous parts our for rechroming. It took 2 months but who's in a hurry!

Regards,

Jeff
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I have pretty much completed all of the heater bits and will assemble as soon as I get the hardware plated. I did find a vent that I cannot find on any of the parts drawings. See the pics below and hopefully someone will recognize it.
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Looks like I stumped the stars with the last post. I can't find any references showing the part so it looks like it will not be going on the car.
I tackled a number of smaller metal parts that I'm sure that some of you have dealt with in the past. I made new heater boxes; the ones that mount on the outside of the forward fiberglass inner panel. They came out pretty well so I worked on making a new back-up lamp housing. The original was rusted beyond repair, so I made a new one. See the pics for old vs new.
Being in the mood for sheet metal work, I have also made some new inner wheel covers where the originals were rusty. The fiberglass portions were cleaned and sand blasted. One will need some repair.
I will be starting on the repair panels for the main body shortly.

Regards,
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I don't think that it is threaded....maybe splined. This appears to be one of the derivative Fiat hand brakes that was never meant to be disassembled. Pin passes through from one end and cold headed on the other.
Has anyone ever taken one of these apart?

Regards,