My new project, finally got my integrale.

[KevJTD]

The tilter has been used for a few Suds but needs a bit of adapting to fit to the integrale.

Rear section wasn't too much out of where I needed it off the bat so just a couple of angles made up and welded to the originals which will then pick up the bumper mounts in the floor/chassis section in the boot.

[KevJTD]

The rear end support then was ready to slot into place.

[KevJTD]

To further reinforce things I cut some angle for inside the boot floor so the floor gets trapped between 2 pieces of angle, which I then joined with some 2" box section.

Just to ad the belt and braces approach I ran a piece of angle forward to the seat mounts. Not really necessary as all the other cars I've had on this tilter got far less bracing but I had stuff to hand so why not!

May have a go at the front end one tomorrow after work then the car will be ready for some underside work

[Johnboy]

Your be flying through it now chap

[Kegsti66]

Cracking on now mate, nice one.

[KevJTD]

Had a few hours this afternoon to myself so with the sun shining despite the low temps I set about getting the car up on the tilter.

Actually started off by getting the wiring loom out of the car after labelling up where stuff goes then giving it its' first hoover out!

With the car empty of all the stuff now I set about making the front connections for the tilter...

Simply just a case of getting the car onto the pivot points and hoping it didn't spin like a top!....

[KevJTD]

Apologies for the crappy pictures, only had my crappy camera on the 'phone...

I'll update to some better pictures now, featured below..





There is literally about 2" ground clearance for the roof when it does it's full circle.....





If we're not snowed in I'll get started on tidying the underside and probably redo some of the welds, in places it's not that good where I was laid upside down with my little welder, I'll grind them down and go over again with the big new welder.

Rear turrets look much easier to tackle now so with those done and some smaller repairs left to do I can finally start grinding off the old stuff and getting ready for prime/stoneguard etc.

Thinking I'll most likely hand paint the underside rather than spraying, Jims' place is somewhere I try and keep free from too much crap, he has some rare & hard to find Lancia parts stashed in the rear of the building, covering them in overspray isn't what I want to do! Once I have the underside all sealed and painted then the suspension will go back on ready for it to be transported to the unit later this year, hopefully sometime this summer...

[junior]

I chap taught me how to hand paint motorbike frames and though it took care and patience of which you seem to have lots I often got an exceedingly good finish.

So under a car I think your very sensible to hand paint. Good to see it progressing.

[KevJTD]

Yes, a reasonable finish can be achieved with hand painting but this will be easier than that as the stoneguard finish is very much "orange peely" so the thick paint makes it easy to cover, without getting big runs I hope!
Allows me also to drizzle some though seams too. I'll also inject plenty of protection materials into the crevices whilst it's upside down too, then again the right way up. That should hopefully keep the rust at bay for many years to come...

[rsfruitbat]

Awesome work Kev.

Rsfruitbat

[Johnboy]

Great seeing it on the tilter

[KevJTD]

Yes, great to see it up on the tilter JB, which reveals more work needing to be done, but at a much easier working level!

Took some better pictures this afternoon, my 'phone is really crap at pix so the camera gets the job, when I remember to take it!

Must admit that I only stayed for a few hours this afternoon, tidied and swept the floor as I'd not been able to get all the rubbish out plus made plans and chatted to Jim for a while....then decided about half 4 with the sun going down and it rapidly freezing again I'd call it a day.
Looking forward to getting on with it now, rear arches are still a fairly big job to finish off but at least I have great access now. Then in a month or two I can start getting ready to paint the underside. It'll feel nearer to making progress then

[Kegsti66]

Amazing work Kev.
I can not get over how much you get done, knowing you have a full time job as well.
Shell is really taking shape now and looking like a Lancia again.
It got me worried the first couple of times I spun the Giulietta on her side as I had never experienced using one before. I never turned it upside down

[KevJTD]

Does seem to have turned a corner now mate, forever seeming to make no progress as there was always more and more to do...
At least now it's on the tilter I can set about tidying up the bits underneath I'm not happy with and finishing off the inner rear arches then once some stoneguard and paint are on it'll be that bit closer again.
The tilter is a really useful bit of kit but agree a bit unnerving to use! The Suds that have been on it have all been probably a little lighter than the Delta but the balance is still good, you can turn the car with one hand to whatever position you need then lock it in position with the lock bolt I added.

Fingers crossed next week the weather will be back to something like comfortable so I can get going again.

Imp will be getting more attention over the coming Saturdays, 155 has taken a back seat for now....as well as Tim's Sud lurking in the background which will most likely get started soon there's always something to do

[KevJTD]

Finally found time to go to my local bearing supplier last week to get the thankfully only bearing that needed replacing in the gearbox. He's usually superb and can get anything.....this time though despite the bearing in his hand and contacting SKF directly he couldn't supply one as it's made under license to Lancia
Handily though there is a few specialists that can get the integrale stuff so although it was expensive I do now have one, complete with the neccesary groove in the outer casing to locate the circlip, which if it didn't have would have been easier to find!

Took the opportunity to get a few other bits from them, O ring for between the diff and transfer case, 8 driveshaft boots (downside to a 4WD car!), an input shaft seal and sleeve, a full set of caliper seal kits plus a couple of other small seals. Not cheap at £221 for the lot but the bearing was near £100 on its' own!
At least stuff is available though, I know the search for Sud stuff can be nigh on impossible so happy that at least I have been able to get the parts in the first place.

I'll start to put the 'box back together soon...

[Kegsti66]

Who needs Easter eggs, eh mate ?
Looks like your Christmas came early.

[KevJTD]

Much more useful mate, eh

[KevJTD]

A busy day but yet again without too much progress on the poor old integrale, I'm starting to run out of excuses now!

I'd taken a bunch of parts down to the blaster/powder coaters in the village a few weeks back, he rang last night to say they were ready for collection so after finishing a morning at work I collected them.

By the time I'd collected them, unloaded at home then had something to eat it was about 3PM....do I go to Jims' to do a bit or write the day off?

[KevJTD]

As I DO need to keep pressing on then set about something was the only answer.

The rear strut towers are just about the last bit to tackle, well on the underside bits anyway

The rusted section that also sits inside the car was cut out, the rest is still thankfully very solid as being 2mm steel it has a bit more resistance to rust.

New repair section made up from some fresh 2mm sheet, just about as thick as can be easily folded.

Welded in place from underneath..

And from above, bit tricky to grind back in the tight space!

[KevJTD]

Just then a section to join from the strut tower to the inner C pillar wall

Hopefully I can start to get things going again soon....

[KevJTD]

Didn't get down to Jims' this last week to do anything although I really must make an effort now the weather is better to do some in the evenings after work....

Have got the gear casings all cleaned up though so with the new bearing fitted I set about the dreaded task of putting it back together. I say dreaded as it is some time since I took it apart, was gonna say it must be 6 months ago but looking back it was April last year!!

Took precaution of buying a genuine workshop manual some time back, expensive but very comprehensive and worth the money at times like this

Innards all back together which went better than I thought it might, all those detent springs and plungers seemed tricky when it came apart but logical once you follow it along.

End casing seemed very tricky to get apart, more so to get back on until you realise exactly how to line stuff up. Trial fitted for now as I neglected to get suitable sealant for the gasketless joint...

[Kegsti66]

I love the look of all those cogs and shafts Kev, but that would scare the life out of me
Cracking pace.

[Sud 145]

500 piece jig-saw done before lunch. Well done.

[KevJTD]

A few folks have asked me how the gearbox works as it is sometimes a scary thing to take apart, so here's a few pictures to show what happens inside once you start stirring the gear lever

First off I talked about detent plungers. These are either little ball bearings or in the case of the selector shafts little bullet shaped plungers that are designed to prevent more than one shaft moving at one time, the aim of course to stop you getting more than one gear at a time! The central shaft has a smaller one that goes all the way through the shaft so that if one outer one moves then it pushes the plunger through and locks the opposite side one.
The small plunger is laid next to it's hole through the shaft, this shaft control 3RD & 4TH gear.

You can just about make out the larger 2 plungers that live in the gearbox casing, don't lose them inside!!

This shows it better, 2 selector shafts in and a gear selected which pushes the plunger out which would lock the shaft that fits into this hole.

So with all the shafts in place and selector forks aligned and locked this is what you have. The shaft on the left controls 1ST & 2ND gear which are nearest the bottom as we look at it, the middle shaft does 3RD & 4TH, the right shaft does 5TH gear (yet to be fitted at the top of the shaft as it sits outside the main casing) and reverse gear, which you can't see as it's around the back.
The cut-outs are all aligned up near the bottom next to the casing ready to accept the change linkage attached to the outer casing. You can see that as the lever moves across the gate it will connect to either of the 3 selector arms.

[KevJTD]

Reverse gear engaged, if only to prove I fitted it!

And 1st gear, sure you see now how it all works selector wise.

So that's the selection sorted, but what actually happens to engage a gear?
As someone once pointed out to me, it looks like all gears are in already as the helical gears are running together!
They are in fact free floating on one shaft (well usually they are, this one has a mixture just to be different) and fixed on another so the shaft on one side is free to rotate inside the gears. The other shaft has all the gears fixed to it.

When you engage a gear there are several things that move to mesh the shaft to the gears, which is what you want to transmit the drive through whichever gear you are selecting.
How does it do it?
Well, here's the 5TH gear which I've yet to refit.

This is the synchro hub that as you can see is splined to fit onto the shaft so it turns at the same speed, remember it just the gears themselves that are free spinning. Important that bit to understand what's happening.

When you ask for 5TH the hub moves the selector ring, or baulk ring as they are known, onto the tapered portion of the gear itself, this grips the gear and makes it spin at the same speed as the hub and therefore the shaft.

It usually sits like this ready to grip the gear but with oil it readily spins on it with minimal fuss. Amazing really that they don't wear out every few thousand miles!

That is the piece that's prone to wearing on 2ND gear for Suds, hence the phrase beating the synchro which means you aren't giving the baulk ring time to match the speeds, but mainly because it's worn on the taper so is marginal on being able to do its' job.

Hope that helps to understand a bit more the mechanical goings on that are happening when the lever is feeling like stirring porridge!

[Sud 145]

Brilliant Kev....now give us a pictorial of "Electrickery"

[KevJTD]

As you well know mate, electricity completely baffles me

Can just about get by with old school stuff, this modern electronic stuff is the stuff of wizards

[Spacenut]

Thanks for that detailed explanation Kev. I think my brain just exploded

100% agree about modern electrickery, old skool is best. I've lost count of the number of abandoned moderns I have passed on the road, all suffering from electrical faults no doubt.

Gives me great hope that a Terminator-style dystopia could never come to pass. After all, what would Arnie do if his camshaft position sensor failed?

[junior]

Great that Kev. Thanks for the effort you put into it.

My introduction to gearboxes was having a 1930's Harley, hand change, that had the problem that 1st gear was very high geared. Till I realised the 4th gear was very low.

The selector box or shaft had been put back the wrong way round. Cannot recall which, but clearly remember taking it apart on the kitchen floor. Very easy mend to my surprise.

[KevJTD]

Cheers guys, the old mechanical stuff where you actually have a chance at stripping down are so much better than modern cars with all there fault codes and fibre optic wiring.

Today though, back to the welder for one of the last tasks albeit quite a tricky one, making and welding in the rear inner wheel arches.

With faces going here there and everywhere it would be massively difficult to make in one piece or even in a few pieces so the easiest way is to make up decent sized sections and weld it up as you go.

The section that fits under the arch lip needed the curvature of the outer arch and be a snug fit. The bead roller came out again to assist in this section.

Eventually everything got boxed in and ground down, hopefully out of the way of wheels and suspension!

Drenched it in etch so it ran everywhere, seam sealer will go onto the welds eventually.