The day my "onboro ALFA" would revive

I cleaned the disassembled brake master cylinder gradually in my spare time. Cleaning of the master cylinder piston Before: After: It was not dramatically cleaned…I had to make effort a little more! I also cleaned the master cylinder with a wire brush. The inside was also cleaned.  It seemed that this could be reused. ☺︎ It would take a while to start this type of work , but once it is started , it's fun to do such work while listening to the radio at night. ( My original blog was written on 10th Jun 2009 )

I started the overhaul of the brake master cylinder after the clutch slave cylinder. This day ’ s work was removal and disassembly of the brake master cylinder. My “ onboro ALFA ” is early type ( Mk. I ) 1750GTV RHD.  The brake master cylinder is made by BONARDI and it is installed on the frame under the floor together with the clutch master cylinder ( this is made by BENDITALIA ) . Regarding the removal , there was a little try and error. ( 1 ) Remove the pipes Then , I tried to separate the linkage rod connecting to the brake pedal.  However , the fixing nut was so hard that I changed the process. ( 2 ) Remove the bolts fixing the brake master cylinder on the frame. ( These bolts were also fixing the clutch master cylinder penetrating the frame. ) ( 3 ) & ( 4 ) Separate the linkage rod from the brake pedal , and remove the brake master cylinder together with the linkage rod. ( The linkage rod and the pedal were fixed by a split pin. ) ...

This day was a Father ’ s day in 2009.  My wife and kids had their tasks , therefore I was alone at home and enjoying the repair of my car in a garage. When I finished my work in a garage , I found a parcel was arriving to me. I opened it and found… Wow!  It ’ s great!!! It was a father's day gift from my eldest daughter living in Nagoya. A handmade tinplate sign designed by my eldest daughter!!! ( She was studying at the University to be a designer. ) It was the most surprising and happiest gift I ever had in my life. I was a really happy father ’ s day for me. ☺︎☺︎☺︎☺︎☺︎ ( My original blog was written on 21st Jun 2009 )

I started the assembly of the clutch slave cylinder. At first rubber parts were renewed using the repair lit I ordered before.  2 rubber piston seals and the rubber boot for the push rod could be easily replaced , however , it was a little difficult to set the fixing ring to the small end of the rubber boot.  The assembly of the slave cylinder was started after the replacement of the rubber parts. The fixing wire ring for the large end of the rubber boot looked not strong enough for me , therefore , I decided to use the hose band instead of the wire ring.  I had a stock of the free-size hose band.  I used it. Okay , it looks better! ☺︎ Slave cylinder assembled Of course I prepared the new hose. Next was the installation of the restored clutch slave cylinder.  I thought it could be finished quickly , however , it took more time than I expected because I assembled it in wrong order at first. Wrong order: I fi...

Last time when I did the maintenance of WEBER , I found fuel leakage from the fuel hose connected to WEBER. I recognized that the gaskets of the fuel union had to be replaced. I bought a gasket sheet with 0.8mm thickness at a motorcycle part store.  I guess it is cheaper if I order it at automobile part wholesaler.  But I bought it at motorcycle part store because I wanted to get it quickly.  I found there are lots of parts , which can be utilized for a historic car repair , in a motorcycle part store. ☺︎ I copied the gasket shape on the gasket sheet and cut out them with a cutter , but to cut out the rounded shape was little difficult.   It took more time than I expected.  I should buy a circle cutter in next time. The appearance was not very good , but it should be no problem functionally.  And it would be invisible after the installation. After the installation I activated the electrical fuel pump and confirme...

Recently my onboroALFA had a difficulty in engine start. The phenomenon started before the restoration of the fuel tank I did almost 1 year ago.  Regarding the engine start of Giulia , normally push the gas pedal several times to operate the acceleration pump , then the engine should be started.  It didn ’ t work.  But the engine could be started with choke.  After the engine start , there was no problem.  So , I guessed the acceleration pump had some problem and cleaned it.  But the problem was not solved.  That was the situation. I overhauled the WEBER carburetors , but 2 years had passed already since then.  I thought probably the gasoline deteriorated , or some foreign matters may be clogged in the fuel line. However , when I was looking at the WEBER manual , I found some points , which could cause the bad engine start. There might be problem in these parts shown in the following picture and it could be cleaned wi...

I got the new weapon to clean the inside of the clutch slave cylinder.  The honing tool for the master cylinder ( attached to the drill ) I bought at the tool store.  Cost was about 1 , 000 JPY.  It looked like a ray gun ☺︎ Fix the slave cylinder in a vise. Drop the engine oil to the inside of the slave cylinder , insert the honing blades in the slave cylinder and power on the drill.  Then , the honing blades were spread by the centrifugal force and polish the inside of the slave cylinder equally.   The inside of the slave cylinder became like this. The other parts were also cleaned. ( My original blog was written on 20th Apr. 2009 )