Jake has now almost
completed his repairs of the Superleggera tubing at the
front of the chassis. Several sections of the old tubing
have been replaced with new 4130 chrome-moly steel.
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Plotting the location of the upper shock mount
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Forward picture frame has been removed
for repair
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This section has suffered damage from both
impact and corrosion
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New lower engine bay brace fabricated and
welded in place
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Forward picture frame has lost its symmetry
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Frame is now symmetrical, straight and sound
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Double walled chrome-moly tube now welded in
place for rear shock mounts
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The
following sequence of photos show the transaxle rebuild
underway and also Jake repairing and reinforcing the front
and rear shock mounts.
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Transaxle will be fully rebuilt
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Upper front shock absorber mounts will be
repaired and reinforced
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Removing the front right mount revealed minor
rust lurking behind
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All surface rust was ground away before being
sealed and coated in Wurth Body Wax
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Jake welded a piece of angle iron behind the
shock
mount panel to add strength
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Welding the reinforced panel in position
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Rear shock bar has been reconstructed using
new,
heavy walled chrome moly tubing
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Using infrared beam to ensure rear shock bar
is
perfectly straight and level
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Lots of
progress in the engine shop and the CJ Coachworks.
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Setting cam timing
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Restored oil pan and baffle
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The first new panels being fabricated
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To be continued!
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I am
delighted to report that Jake now has the Ferrari body
restoration underway.
Assembling
the short block and installing the rebuilt cylinder heads.
I am
pleased to report that we have now completed all of the
machine work for this project and rebuilt/assembled both
cylinder heads.
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Honing rod wrist pin bushings to size
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Hanging rebuilt rods on the pistons
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Torque plate honing the cylinders to final
size
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Pressure testing with custom head gaskets
trial fitted
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Balancing the flywheel and clutch
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Assembling the cylinder head and setting valve
lash
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Heads now full rebuilt and ready to install
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We have now received your custom
forged pistons. It's always fun to see the finished product
when so much work has gone into the design and production
behind the scenes.
Corey has
been busy designing and machining a piston mold from which
a new set of custom forged pistons will be made.
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Custom Ferrari V12 torque plate
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Heating block in oven to aid removal of seized
studs
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Squaring main caps prior to performing a much
needed align hone
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Setting up for align hone with cylinder heads
bolted in place beneath block (essential)
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Magnaflux checking rods
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Honing rod housings
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Setting up to hone new pin bushings
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Rods now fully rebuilt
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Preparing to trial fit main bearings
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Surfacing one of the cylinder heads
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Honing new valve guides
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Machining for new valve seals
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Measuring head cc
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Pressure testing the engine block
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Damaged oil
pan spends a little time with Jake in the CJ Coachworks...
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Weighing connecting rods after cleaning
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Ferrari rods of the era had the weight stamped
on them - in this case 514g
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Complex timing chain idler sprocket
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Water pump bearings and gear badly worn
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Timing gear idler assembly
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Damaged timing gear
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Scary looking banjo bolt
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Custom torque plate
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Crack in oil pan rail
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Badly installed thread repair for oil pan
drain plug
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Oil pan has several previous weld repairs |
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Several cracked/damaged fins will be welded
and reshaped
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Repaired pan looking virtually new once more
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We know from service records that
this engine had been rebuilt back in the 1980s and has been
driven very few miles since. Unfortunately, the quality of the rebuild leaves
much to be desired, and we therefore have a full rebuild
underway.
Inappropriate valve springs were used, resulting in coil
bind, the valve stem to guide clearances are huge (over
.004"), and piston skirt clearances range anywhere from
.004" to .009". One of the most telling signs that this car
did not receive the engine rebuild it deserved was the
presence of a knurled piston. Knurling pistons is an old
school practice designed to give extended life to worn
pistons. Knurling a piston skirt actually helps 'take up the
slack' in the case of loose skirt clearance, but the high
spots created by the knurling process wear very quickly, so
the remedy is very short lived. Despite the use of the knurled piston, the skirt
clearance in that particular cylinder was .009", or .005"
out of spec.
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Disassembling the cylinder heads
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All the valve seats had different widths
and heights
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No to valve jobs were the same!
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This line clearly visible on the bottom coil
is
evidence of coil bind
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Pressure testing cylinder heads
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This cylinder had .009" skirt clearance!
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Knurled piston is cost saving old school
practice
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Stem to guide clearances were huge
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Valve stems measured inconsistently
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Engine tear
down underway in the CJ machine shop.
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Strong fuel smell in oil pan
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First head removed
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Amazingly slimline V12 block
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Signs of fuel wash and scuffing on pistons
and cylinder bores
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I was very
pleased to come across the very first Ferrari 330 GTC
prototype on display in Las Vegas last week. Chassis
number 6431 was originally built on a 275 GTS chassis and
was apparently regularly used by Enzo Ferrari himself. The
car has dozens of detail features not seen on any other
330 GTC.
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Koni have done a stellar job rebuilding
your original shocks
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The prototype Ferrari 330GTC
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We have now
received the restored fuse board and superb quality wiring
harness that was made for us in Italy. It really is a very
impressive piece of kit.
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The original fuse panels have been restored
and completely rewired
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Every terminal has been carefully labeled
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Front suspension
rebuild underway - and some beautifully restored Borrani
wire wheels...
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Suspension and brakes will be completely
rebuilt
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Separating the springs and shocks
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Road springs will be replaced, Koni shocks
will be rebuilt at the Koni factory
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The Borrani factory in Milan have done
a fantastic job with your wheels! |
Back from being
media blasted to back to bare metal, a few minor rust issues
are exposed, and also evidence of some sub-standard 1960's
Italian bodywork.
Preparing the
Ferrari for blasting back to bare metal..
Removing the
fiberglass dash and floor pan in order to gain full access
to the chassis..
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Fiberglass dash/firewall is first to be
removed
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Panel has slight damage around transmission
mound that will be repaired
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Framework of the dash exposed
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Hundreds of rivets hold the floor pan and
front
and rear bulkheads in place
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Panel beneath rear window is aluminium
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Removing rear window panel/upper rear bulkhead
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Rear panel now removed
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Main floor pan now lifted away
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Removing pans was essential to gain full
access
to the chassis
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Many rivets were broken or corroded
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Chassis will be blasted back to bare metal,
repaired
and refinished to new condition
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Unusual view from beneath the car with the
floor pans removed
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Time to remove
the engine and gearbox...
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Lowering the 5 speed gearbox to the ground
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With the gearbox out of the way, removal of
the engine is a simple matter
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Chris Scarborough carefully extracting the
compact
V12 from the engine bay
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Engine is angled in order to clear the
firewall
on the way out
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Almost clear...
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With the engine on the ground, the mechanical
tear down is almost complete
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Tear down
continued, a glittering new Borrani wheel, and unspent
shotgun cartridges hidden beneath the gas tanks...
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Front suspension now removed
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Removing rear suspension
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Note thick bondo lurking behind front bumper
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Left rear strut mount
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Right rear strut mount slightly damaged and
pushed
upward, causing car to ride low in right rear
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Strange assortment lurking beneath gas tanks
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Unspent shotgun cartridges, Italian newspaper
clipping, glue, lipsalve and screwdriver
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Glittering new RW 4039 Borrani spare wheel
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Tear down,
continued...
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The only significant rust so far..
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Drain hole in left bumper tube requires minor
rust repair
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Next task is to remove the rear suspension
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I am pleased to
report that this important restoration is now officially
underway!
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First task is to remove all the glass and
interior
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Some photos are for reference purposes only
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Jake and Carlos double teaming the front
windscreen removal
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One last
inspection by the proud owner before we get this project
underway!
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One last opportunity for the proud owner to
see the
car whole before the restoration gets underway
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I
am delighted to report that your car is safely inside the
Team CJ workshops and we will have this exciting
restoration underway very shortly!