Some TLC for my QV | Page 12 | FerrariChat
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Some TLC for my QV

Discussion in 'Mondial' started by afterburner, Mar 25, 2015.

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  1. afterburner

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    #276 afterburner, May 24, 2021
    Front section clean-up and repairs. Note the two humps for clearance of the radiator fan motors and the inclined surfaces fading of the side/rear of the car. This is an exit air guide guiding the air sidewise away from the centre section, which has blocked exit on the bonnet.
    This deviates the air away from the centreline section of the car and over the front wing, helping reduce front end lift.
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    Battery-cover side repairs
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    Some holes needed to be filled and cracks repaired
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    Parts painted
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  2. afterburner

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    #277 afterburner, May 24, 2021
  3. ronfrohock

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    #278 ronfrohock, May 24, 2021
  4. afterburner

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    #279 afterburner, May 24, 2021
    Thanks Ron!
     
  5. afterburner

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    #280 afterburner, May 24, 2021
    Fuel filler neck gasket as removed
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    Cleaned up and silicon paste treated
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    Gas pedal cover as removed
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    part number on a vacuum forming:
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    cracks around the mounting holes

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    Repairs
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    repaired
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    and repainted - as new!
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  6. afterburner

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    #281 afterburner, May 24, 2021
  7. afterburner

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    #282 afterburner, May 24, 2021
    HVAC restoration - the elephant in the room > heater leaking, fresh air flap inop... and what else once it's opened up? Here how it looked removed:
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    The fan motor looks tired - and see the rust...
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    Heater core has badly leaked. My guess is that some cheapskate used water instead of proper coolant...bust tubes:
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    drain plate inside the housing has corroded away
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  8. afterburner

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    #283 afterburner, May 25, 2021
  9. afterburner

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    #284 afterburner, May 25, 2021
  10. afterburner

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    #285 afterburner, May 25, 2021
  11. afterburner

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    #286 afterburner, May 25, 2021
    The exit flap is in metal - the foam gone
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    cleaned up and foam cut
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    done
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    Replacement heater core as removed - lots of bent/blocked fins, pressure tests ok
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    There is a foam sealer strip on the top front edge:
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    Cleaned up and masked:
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    repainted end plates with zinc paint and all fins straightened and cleaned out, new rubber gasket

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  12. afterburner

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    #287 afterburner, May 25, 2021
    Evaporator with end sections bead blasted, pressure tested, but tons of bent fins:
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    Expansion valve
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    inlet pressure hose tags

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    Tags removed
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    flattened and ready to be refitted onto the new hose - invisible originality! Image Unavailable, Please Login
    Evaporator masked
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  13. afterburner

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    #288 afterburner, May 25, 2021
  14. afterburner

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    #289 afterburner, May 25, 2021
  15. afterburner

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    #290 afterburner, May 25, 2021
    Core pack fitted to housing base
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    Fan assembly - new motor, old drums and rubber dampers. Rivets had be drilled open and need replacement with bolts.

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    there's a grommet at the cable passage:
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    new motor's cable were shorter than original - lengthened and original colors used at the plug side so it turns the right way round...
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    Fan assembly completed
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    and fitted to the base

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  16. afterburner

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    #291 afterburner, May 25, 2021
    There is an inconvenient wiring setup for the evaporator temp sensor, which goes directly from the relay set through the top housing:

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    This means you need to have those relays dangling with the top housing. Very impractical for assembly and potential trouble shooting.
    I added a plug (yes, another potential source of trouble) but really convenient for reassembling the HVAC and refitting it to the car:

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    Now, the relay set can be fitted once the rest is in place - no ripping cables out while fitting the HVAC. Sensor testing while it's convenient:

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    Checks out fine. Bleed air sensor:
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    So reassembly continues with the exit air section; parts ready:

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    completed, with previously restored power transistor and checked vacuum actuator

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  17. afterburner

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    #292 afterburner, May 25, 2021
    Top section with intake flaps is next. Those flaps have surrounding gaskets which were broken:
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    Cleaned up and new gaskets made
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    Parts ready, with brackets repainted and vacuum actuators checked
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    Assembled top section
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    Note the little centre stop that prevents the fresh air flap from completely closing - it will always allow a minimal external air enter the car even when AC is selected (internal air circulation)
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    Hypoxia prevention???
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  18. afterburner

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    #293 afterburner, May 25, 2021
    Final assembly of the unit's top and bottom sections include a bead of Seal'n'Peel on all touching interfaces, which do have a groove and tongue section, to prevent air leaks and rattles:

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    That includes the external footwell outlets - and don't forget to connect and route the vacuum hoses. Easy now, a pain later:

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    Evaporator sensor gets sealed in too
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    I built a water tap vacuum pump to test the flaps via the centre console control box before installing it into the car
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    It all worked perfectly.

    That's what your control box should show electrically:

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  19. afterburner

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    #294 afterburner, May 25, 2021
  20. afterburner

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    #295 afterburner, May 25, 2021
    2cam likes this.
  21. 2cam

    2cam Formula Junior

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    #296 2cam, May 25, 2021
    I'm continually impressed by your commitment to the project and ability! VERY cool!

    2cam
     
  22. afterburner

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    #297 afterburner, May 25, 2021
    Thanks Mike! More to come :cool: till the car is back on the road.
     
  23. afterburner

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    #298 afterburner, May 26, 2021
    Main wiring loom restoration - front fire wall to centre tunnel - engine bay - trunk. As removed:

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    Some detail shots:
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    Rock-hard sheaths, oil, tape ....
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    All cleared sections secured with cable ties to keep the junctions correctly located
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    engine bay connectors...

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    all removed

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    cleaning
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    before/after
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    re-color coding after cleaning
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  24. stoked_7

    stoked_7 Karting
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    #299 stoked_7, May 26, 2021
    Fantastic work, can't wait until you have this back on the road.

    What paint are you using for the black interior plastics like the pedal cover you repainted?
     
  25. afterburner

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    #300 afterburner, May 26, 2021
    Ignition multi-plugs cleaning and re-insulation on damaged zones
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    retaped and ready

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    Next lower engine bay wiring loom cleaned - main power supply bypass visible:
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    retaped
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    Upper engine bay loom as removed
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    Some damage detail - often caused by hardened sheathing and dried out rubber boots
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