1500ti restoration. Ex racer

[junior]

Hi. Thanks for the encouragement chaps, much appreciated.

Now trying to get the heater in. Its the right one from John at justsuds and so is the plastic piece that ducts the air to the screen but I just cannot get it in to place.

Heater goes in fine without it, but when the piece is in place above it I cannot get it in. Any thoughts please ?

The duct is hard up against the dash and locked in correctly on to the heater. The angle changes a bit depending which way you put the duct in but neither allow it much better than can be seen above. Hope that makes sense.
Had the dash out to ensure its not catching that end and the wipers linkage has been taken out as well.

[Sud 145]

If you mean you can't locate the four mounting bolts try what I did. Put the four nuts back on and hacksaw the bolts in half-wind the nuts back off to remove any burrs. You will still have plenty of thread left.

[Kegsti66]

It was a while that I fitted mine, but can you not pass the trunking part through the bulkhead from inside the car, having fitted the heater box first?
Have you already fitted the dash ?

[junior]

I think your right it goes in from the inside. I tried that but with the roll cage and all it was tricky and I gave up.

I now think I should have tried harder so will take the dash out again. Hey ho.

Halved the front bolts as well. Makes life easier, thank you.

[KevJTD]

that trunking piece between the heater box and dash does indeed sit inside the car, slots in before the dash goes in
the heater box is tight enough without the extra 1" in movement you're losing by having it in the bulkhead space ..

[junior]

Thank for the second opinion, always helps one to do a job with confidence. Esp having tried to do it wrong several times.

Just started on my brake pipes having been taught how to do it on a Morris 8 at the week end.

Fitted two flexible pipes and there used to be a bent piece of metal with a hole in it the pipe passed through and then the next nut clamped it down to hold them in position. Anyone got two they are happy to part with or know where I can find them. I suppose one would call them clips ?



Also I need to have the two brake pipes from the remote reservoir feed into the brake master cylinder.
The clutch one has a small bent pipe sticking up, but I need two for the brakes. Any thoughts gentlemen ?

[KevJTD]

the clutch one feeds off the brake reservoir.
it purposely feeds from around the minimum level so that if your clutch springs a leak it doesn't empty all the fluid from your brakes

[KevJTD]

these are the clips you need...

http://www.ebay.co.uk/itm/4-X-VW-AUDI-F ... SwrhlXT1r6

[junior]

Bought ! Many thanks.

Now how about the plastic inserts to the master cylinders ? Anyone ?

[Kegsti66]

As Kev says, a feed from the brake reservoir feeds the clutch then the clutch slave if fed out of the end with the thick black plastic pipe.
Pictures are a bit rough. If they are no good I will try and get better ones for you of the finished car. This was when I was stripping it out.

[junior]

Just clicked on what to do and why. Will post a photo later to explain it.

Very handy photo's as mine was not that complete. Thanks.

[junior]

I was going to replicate how the car was originally, but following your photo's it got me thinking and I realised the reason the brake fluid reservoir was against the bulkhead was because of the heat from the exhaust and so a fire hazard.


As the exhaust no longer follows that route there is not reason to go to that effort. I had not realised that was the reason I thought there was some other cause or advantage, such as it being more secure in the event of an accident.
If anyone feels my logic if flawed please feel free to speculate as well.

The heater is in. The dash is back in. The brake pipes are most of the way there, and who ever told me to get a good brake flaring tool was dead right. It made the job very easy.
I may never use it again, but so nice to use I don't feel like giving it back.

[Kegsti66]

I see what you mean now James.
Personally, I would now put it back to standard, with the reservoir on top of the servo. Less chance of leaks without all the joints. I presume you will also blank off the holes where the old exhaust went through as you now have a "normal" set up.

[Spacenut]

That's a pretty bonkers exhaust route, but I can see why the heater was removed as the exhaust would have heated the cabin pretty well!

I remember the heat-soak from the Janspeed system on my Firenza used to evaporate the water in the passenger footwell quite effectively!

[junior]

Yes the leaks did a lot of damage originally so I do not want to repeat that in this area of the car.

The big holes cut out I may just sheet over with aluminium and use the old holes round them to pop rivet them in place so it retains that era's feel to it. Also in the future if some one wants to use the race engine to go back to its full turbo, exhaust through the cap then I have not taken anything from it. They will need big pockets though !

Spacenut, the exhaust would have been pretty loud I reckon as well. Shame as I do love the idea of an exhaust coning out the side. Mind you looking at the new regs being discussed for old cars it s getting a bit worrying. Need it on the road before they change the rules.

[junior]

Finally got the brake and fuel pipes in underneath. Struggled for ages till a mate came to help today, then all went well. Much better to have one person holding the pipe in place whist another bends it to fit the next stage.
Also you get the restoration creep where by one bit fits well so the next has to look as good, and so you almost end up going back to the first because its now not as good as the last one.

Fitted a return for the fuel system, just need to `t' it into the return pipe, so cannot recall who suggested that idea but thanks.

Best bit I have learnt is ` Always put in the most awkward to bend pipe FIRST !'

I think we could collect all these thoughts together for the next person who restores a Sud or any other car. Then they could not spot it and go through the whole process again.

[junior]

All coming together around the back wheels, but slowly as small problems seen to take forever. Esp on the cold days.

This has ended up a busy spot with all the pipes and just hoping all will be fine come MOT time.

Still not fully happy with the hand brake set up so may have to revisit that. Especially as everything else has been done twice!



Reservoir now fitted on top of servo. Have some flexible brake pipe left over, so if anyone needs a short length for between brake servo and clutch I will happily post it as I had to buy a metre of it.

This pipe on the servo goes to the carb manifold I believe, but exactly where ? Thanks for your comments as ever.

[Kegsti66]

These show where it comes through the bulkhead, but obviously this is a single carb. Twins must have a similar set up on one of the manifolds.
Hope that is a start.

[KevJTD]

servo pipe goes onto drivers side manifold

[junior]

Ah ha, I see now and your pictures are excellent, thank you. A dead straight run then unlike every other pipe on the car !

What is the little plastic (?) bit in the middle of the pipe ?

Studying your picture has made me aware of another problem I may have with a coolant pipe so very pleased as have not painted the expansion tank yet

and it will need altering. Thanks again chaps.

[Kegsti66]

Glad it helped James.
Sorry but I can not help with the plastic thing, I just fitted it. I think it may be some sort of one way valve

[junior]

Ah, I wonder how much it is needed then, or if it just makes for better feel on the brakes.

A one way valve does make sense. in my anyhow !

[KevJTD]

one way valve is vital for keeping vacuum in the servo
so make sure you get it on the right way around! think it says "to carb" on the outer rim or an arrow pointing to carb, something like that

[junior]

Brilliant, many thanks.

[junior]

Struggling to get hoses to fit on the radiator as so close to the belts, are they normally this close or is my radiator sitting lower.

Top end to the thermostat is fine. It is a much later rad than is correct for this car.

Got the fan set up well, but then this dictates where the rad is held at the top and so the position of this lower hose.

[junior]

As you can see its an earlier an on a later radiator. This was changed from the WV one as I think they had used it with out a fan and fitting one to it would have been very awkward.

Also it was a good opportunity to make it more Alfa

Lots of little jobs just now, but feel the day when it fires up after 36yrs approaching. Hope it is going to be easy as my motor bikes were far less complex.

An indication of this was my mate looking under it going , `the MOT chap will not like that' pause `Or that'.

Still what he does not like can be rectified, if my mate has not already spotted them all

[alfadave]

Have a look at ebay ad
311199515418

Alfa 33 radiator....sits on two studs underneath
I bought one for my S2 sud, and it fits ok, and the hoses don't foul.

Dave

[alfadave]

Or, alternatively
ebay ad
111536695732

but the same item I think

[Kegsti66]

Just been looking back at your thread James, and you have a lot of bodywork chopped out.
As alfadave says, the rad usually sits on two lugs underneath. Yours looks quite different to the one I have. But I do recall that I had to use a spare top hose on the bottom as the hose shaped like a question mark came in at the wrong angle with the new radiator.
Sorry I can not add any more to solving the problem.

[alfadave]

Could juniors rad be from a late 33?
My sud rad is 250mm high

Looking on ebay the late 33 rad is taller, and has different bottom fixings