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Old 23-04-2011   #16
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Re: 695 Engine Project

Got the engine in today. The only issues were minor.

The studs that hold the rear engine mount are shorter on the 650 crankcase so I changed them for the longer ones from my 500 engine. Fitted perfectly.

The other issue is the cabin warm air supply. Because the starter motor is now mounted at 3o'clock instead of vertically, the first metal pipe will have to have a dent put in it to clear the front end of the starter. I had one like this on my Niki wreck but I gave it away with a whole lot of other parts.

The number plate is a personalised Queensland plate. When the Topolino was superseded the new small cars were called Nuova 500 so I figured that this is a Nuova 695. As close as I could get with 3 letters and 3 numbers was NVA 695. A fitting tribute. Also, in Queensland, the black and white plates were in use in the 1960s and NVA would have been used about 1967. So it's also correct for the period.

I've got a little bit of wiring to do tomorrow and then I'll fire it up and maybe go for a drive Lets hope it goes as well as it looks

The twin pipes look (and sound) great. The reflection in the stainless bumper is the drivers seat. I've got them both out to finish wiring the ignition switch.

Chris
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Old 06-05-2011   #17
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Re: 695 Engine Project

I am following your build and liking it all!! Nice work and systematically done! I have never rebuilt an an entire engine and might find it intimidating, but may well try after seeing your fine results.

Do you have any idea of final horsepower/torque gains? What is used to circulate the air from the engine(looks like large tube of some kind)? Why did you use the carb as shown rather than a Weber sidedraft?

Keep it coming!
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Old 07-05-2011   #18
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Re: 695 Engine Project

Thanks doc - I appreciate the sentiment.

If you have some mechanical knowledge, I'd encourage you to undertake a similar rebuild on your motor. These engines are quite simple yet well built and are not difficult to repair. They are also lightweight so you don't need expensive engine stands or lifting devices. When I built this engine I used the opportunity to take lots of photos, both as a record and in order to help (and possibly encourage) others like yourself who are thinking of doing something similar.

I'm not sure of the final power increase and will have the car dyno tested when complete and road registered. I guess that it may rise to about 30 to 35 bhp at the flywheel. That will be more than enough for me.

Air circulation is standard. From the rear vents, air is drawn in by the large belt driven impeller and distributed across the head and flanged cylinders. Oil cooling is by virtue of a large, ribbed, alloy sump.

The carburettor is a Dell'Orto FZD 32/28. It is an 'inclined' single throat sidedraft (if there is such a thing) and is favoured by tuners of these little motors. As far as I know, it was always a bespoke addition and was never fitted as a standard carby to any engine. I've heard of them being fitted to MotoGuzzi bikes and in pairs to Mini Coopers. Nowadays, they are unfortunately quite rare - I sourced mine from Sicily and it came with a second one for spare parts. Gasket kits and jets are still avaliable with some components shared by the more common (and really good) Dell'Orto DHLA carbies. I went this route because I'd been reliably told that the IMB Webers aren't great carbies and have particular problems with fuel foaming and flooding - made worse if you live in a relatively warm climate. The FZD has a much deeper fuel bowl and a better internal delivery system for the air-fuel mix. It also has an accelerator pump, which is a major advantage over the IMB. My engine starts without using the choke and idles very nicely. I haven't revved it much yet as it is still bedding in and everything will be a little bit too tight for red-lining

At some stage I'll fit the Abarth instrument set (Tacho, Speedo, Fuel gauge and Oil temperature/pressure) and the transformation will be complete. I've absolutely no intention of any deception, it will always be a replica, but even so, it'll be a hoot to drive.

I'll post a few more photos sometime soon.

Regards,
Chris
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Old 09-08-2011   #19
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Re: 695 Engine Project

Bump - for Hamish in NZ
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Old 15-08-2011   #20
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Re: 695 Engine Project

you should of bored the engine out more im running a the 126 motor thats been bored out to an 850 with webers dc40e and some high comp pistons .. the thing flys! I just broke in the motor and i hit 160 eassyy!.. designed to hit 180 lol ... just ran out of road(n)
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Old 15-08-2011   #21
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Re: 695 Engine Project

Cripes - anything over 120kph in one of these would terrify the life out of me .....

Chris
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Old 30-08-2011   #22
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Re: 695 Engine Project

good work
i have a fiat 500 l with a 650cc engine fitted with some tunning too

650cc
35/75 camshaft
28 - 35,7 valves
lowered 2mm
4kg flywheel
record monza replica exhaust

it reachs 115km/h and i'm still testing it.
I'm using a 28 imb weber but i'm not happy with that. i'm thinking in install a weber 32dmtr or maybe a 32dcof or even a dellorto like yours, i'm just out of money for now

Good work in your car
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Old 02-09-2011   #23
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Re: 695 Engine Project

Thanks for the compliment.

Have you looked at the Weber 30DIC. It's a twin throat downdraft carburettor which, with some modification, will fit, though I've not done it myself. I've attached a photo - it looks like a tight fit with not much room for an air filter ....

My engine ended up as -

695cc
3.5L alloy sump
35mm inlet valves
29mm exhaust valves
43/77 camshaft
Twin pipe sports exhaust
Standard crank with all reciprocating parts balanced
Dellorto 32/28 FZD with inlet tract bored to suit
123 ignition

with the rest of the car -

4 speed standard 650 gearbox
Standard differential

Front disc brakes
Rear 650 drum brakes

12" 4x98 pattern steel wheels shod with 145/70 radials - if I can afford some nice alloys, I'll fit them.

Suspension lowered about 25mm all around.

Body painted Ferrari racing red after a complete stripdown.

I've fitted a tacho cable driven from the distributor and will soon convert the instrumentation to suit.

The engine starts easily and idles smoothly. I've yet to have it tested on a dyno, but it certainly has more torque and power than the standard 650. The exhaust has a real bark and my wife has nicknamed the car 'Angry Boy' even though he still looks very happy and brings a smile to everyone who sees him.

The car is now badged as an Abarth replica and I'm very happy with it.

Chris
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Old 16-09-2011   #24
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Re: 695 Engine Project

wow, the build is looking great. thanks for all the help you been providing on this forum.
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Old 16-09-2011   #25
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Re: 695 Engine Project

Thanks - only too happy to help where I can.

Chris
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Old 25-10-2011   #26
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Re: 695 Engine Project

I've decided to purchase a new Polish 650 motor and syncro transmission. I should have them in about a month and plan to replace the 500cc motor and crashbox in my 69 500L. The new motor includes the starter but I understand the starter on the 650 is the solenoid type as opposed to the pull type on the 500. I've heard that the easiest thing to do is add a pushbutton for starting but was hoping to keep the lever as the means of starting the car. Any thoughts or ideas would be appreciated. If the pushbutton is the only way to go any thoughts on wiring that up would be appreciated as well. I also haven't found much info on hooking up the heating ducts other than having to bend one a bit to make room for the starter motor. I'm trying to get all the info I need for the swap in the month I'm waiting for the engine to arrive. The engine is supposedly complete (gearbox, clutch, starter, driveshafts, ignition, fuel pump, carb, alternator, etc.). Thanks in advance.
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Old 25-10-2011   #27
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Re: 695 Engine Project

When I put a BMW 700 engine in a 500 many years ago it had a combined starter and dynamo, which necessitated a button for the starter - I just ran a wire up the tunnel that contains the gearchange rod (and brings the hot air from the heater) and put the button beside the base of the hand brake lever. The BMW engine made an incredible noise so it was quite amusing to see people's reaction when - for no apparent reason as the button was practically invisible - the engine suddenly roared into life.

Good luck with the project.
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Old 25-10-2011   #28
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Re: 695 Engine Project

You can just use an ignition switch with a "start" position. I have a Fiat 125 ignition switch in my '69 500F with solenoid starter and Polish 650cc motor. It is pretty easy to run a wire down the left hand side with the main wiring loom and hook into the starter solenoid. The 125 / 127 ignition switch fits straight into the dashboard and looks just the same as the original. I used a late 126 heater duct which just screws in place and has a recess to clear the starter solenoid. All pretty straightforward really- plenty of people here who can help if you get stuck...
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Old 25-10-2011   #29
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Re: 695 Engine Project

Ditto on the starter switch only I used an aftermarket item.

You will also have to wire up the alternator.

Chris
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Old 02-11-2011   #30
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Re: 695 Engine Project

Thanks for the quick responses and useful info. I'm going to look for a 125 ignition switch. I usually get my stuff from Mrfiat.com but they don't carry it. Do you know of any place I can get one? I may tinker with rigging up the pull lever to a button that would activate the solenoid but I would like to have the ignition switch on hand in case that doesn't pan out. I think I read a post somewhere about someone doing this but now that I'm doing the upgrade I have been unable to find that post or any info. Also, is the electrical control box still necessary with the 650 motor and if so does it get wired to the new motor the same way?
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