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Old 19-03-2017   #91
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Re: Fiat 500D Engine 1962

Ehmmm I am of the opinion that removing them might give you more grief than it's worth Sean. What's behind them anyway, what's their purpose in life?
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Old 19-03-2017   #92
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Re: Fiat 500D Engine 1962

They are covers that block the ends of the galleries. The casing would have been drilled from this end and then they are capped off. I'm concerned that I may leave some swarf etc in the oil gallery. That won't help the engine much.
If I remove them I can make sure everything is clean before plugging them up again
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Old 19-03-2017   #93
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Re: Fiat 500D Engine 1962

Quote Originally Posted by Franko500 View Post
They are covers that block the ends of the galleries. The casing would have been drilled from this end and then they are capped off. I'm concerned that I may leave some swarf etc in the oil gallery. That won't help the engine much.
If I remove them I can make sure everything is clean before plugging them up again
Good point didn't think of that. Maybe it is good idea after all to take them off.
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Old 20-03-2017   #94
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Re: Fiat 500D Engine 1962

I would not remove any of the plugs in the case or crankshaft. You can flush the crank by filling from the front end of the crank.
There is no reason to remove the case plugs unless they are loose or leaking. In both the crank and engine case you would be creating more work than is necessary. Both can be flushed.
The only thing to use to blast the case is soda. Do not sandblast or bead blast. If even one piece of sand or bead is left behind it can really ruin your bearings.
After blasting with soda then thoroughly wash the case to get the soda out.

John
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Old 31-03-2017   #95
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Re: Fiat 500D Engine 1962

After getting my head back from the machine shop. It was time for a clean up. They had recut the valve seats, checked the guides were ok and gave the head a quick skim as it was not exactly flat. Ooh a couple of extra bhp
I was going to get it vapour blasted, but that was going to cost about 50 and they wanted all grease, paint and dirt removed first.
Now I like things clean but barely any of the head is on display.
The head was in really bad condition in terms of dirt & grime. Even after a good wash in petrol/gunk remover the head had burnt on stuff of which I was not sure if it was paint, oil or dirt. All I know is it wasn't coming off.
I tried everything to remove it.
I even resorted to sandblasting. First off I covered all apertures and the valve guides with heavy duty tape so as to minimise any glass bead getting in unwanted places. It was tough going but it cleaned it quite well but really struggled in between the fins.
So I decided to go for using caustic soda.
Now I know you aren't supposed to use this on aluminium, but it does work! I mixed a small amount with water and gently used it on the casing with a toothbrush. It started to dissolve the gunk, but it does cause some discolouration to the alloy surface. It basically goes a dull grey colour.
I washed it down with water. Checked it and then gave a few areas a scrape with a screwdriver to cut through the heavy stuff. Then repeated the process about 5 times. You can actually see the alloy surface fizzing away
Make sure you do this outside though as it does give off a harmful gas.
Anyway it removed 99% of the gunk and left the fins nice and clean which will help with the cooling.
I did read somewhere (maybe on this site) that it has been known to paint the heads matt black. Cant see why really.
After a thorough clean with water, detergent, petrol and a good blow out with the air line it was now looking clean - a little grey but nothing a coat of high temp aluminium paint wont resolve.
I had to remove one broken engine cowling bolt from the head, re-tap any bolt holes and run a die down the head studs for the carb and rocker shaft.
A final bit of decoking with a rotary wire brush and then a lick of paint.
I'm quite impressed with how it came out.
Now all I need is a couple of O-rings for the inlet valves and I can install the valves. I had 2 in bag of gaskets I had but they are too small.
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Old 31-03-2017   #96
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Re: Fiat 500D Engine 1962

I wish I could be arsed with that much effort. Just started the defilthing ready for the machine shop. The head is really complex when you get into it.
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Old 31-03-2017   #97
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Re: Fiat 500D Engine 1962

Another difference between the D and later models: the rocker cover & valve springs.
When I stripped the head it had single 26mm valve springs. I ended up using the twin 30.5mm springs from my L head. No problem there. A slight upgrade that nobody will see.
Then I came to fit the original D rocker cover. It wouldn't fit. It felt like it was hitting something. Now from the outside it looks almost identical except the filler neck is smaller in height and the cap fitting is different. I imagine this has been changed on the later ones to prevent oil leakage?
The vent pipe to the air filter is also smaller diameter.
So I checked against my original L cover.
As you can see in the inside there is a bracket that allows the oil to go in the top and restricts oil going back up to the filler neck. Very similar except the later one is fitted 180 degrees from the D model so instead of fitting between the inlet springs it sits over the rocker shaft.
Also the later one only has 38.5mm clearance between the valve springs. If I had fitted the D springs there would have been 44mm clearance. The bracket in the D was 40mm wide hence why it would not fit between the later springs. The later one was narrower and had a hole either side to allow oil through.
So out with the bracket, make 2 cuts, weld it up. A quick sand blast & thorough clean. I knocked a few dents out of the cover, and tidied up the seat of the rocker cover cap as it was a little dented. Run some weld over the surface and ground it back smooth so I would get a good seat for the cap.
Then welded the bracket back in the same way as the later one.
A coat of primer and hey presto it fits nicely.
A little more prep to do and it will be ready for painting with the rest of the parts.


Its amazing how much work goes into making things just right!
And yet it will be one of those things most people wouldn't give a second glance. But I will know!
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Old 01-04-2017   #98
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Re: Fiat 500D Engine 1962

Liking your work Sean. Wish I could weld, I will learn one day
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Old 01-04-2017   #99
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Re: Fiat 500D Engine 1962

Morning Sean;
Regarding 'Vapour Blasting' (aka 'Aqua-blasting), done properly, this is a very good way of cleaning parts. I have had various parts done on my engine, including a bell-housing that came up so well that my son thought I had found a new one! As far as I can see, the nearest 'vapour-blaster' to you are "TSR Vapour Blasting Services" in Sevenoaks--01732-462883 (info@tsrvapourblasting.co.uk). They seem to specialise in engine restoration (bike and car). Another one, a bit further away in Copthorne, are:- CBX Vapour Blasting Services (01403-701111-- steve@cbxvapourblasting.co.uk ).
Hope this is of help to you.
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Old 01-04-2017   #100
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Re: Fiat 500D Engine 1962

Thanks Tom,
I really did consider this after seeing some work completed by a company called Maxspeed Vapour Blasting which had a stand at the Excel Classic car show.
The downside to having the head done is that no one gets to see it.
I also read a number of posts on the internet that put me off as they say you need to protect the alloy after as it will go dull within a short space of time.
Usually I stick to the good old fashioned thorough clean and leave it in its natural finish.
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Old 03-09-2017   #101
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Re: Fiat 500D Engine 1962

Quote Originally Posted by Franko500 View Post
2. The engine breather goes down the back of the engine rather than into the air filter.

A bit of a revive of an old thread to say thanks for this amazing breakdown, I'm sure I'll be referring to it.

I came across it while looking for where in the world the crankcase breather hose goes. I know on the later models it goes into the air filter but until now I couldn't find the appropriate place. Now I know to look down the back of the engine!

Essentially mine had no breather hose, and the valve cover was spraying oil into the back of the bay! I assume this was an oversight from the former owner... anyway, another part onto the list
(side note: I take great great joy, having owned a few other old cars, in seeing how amazingly affordable it is to replace the bits and pieces on these cars!)
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Old 04-09-2017   #102
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Re: Fiat 500D Engine 1962

Quote Originally Posted by BambinoClassic View Post
A bit of a revive of an old thread to say thanks for this amazing breakdown, I'm sure I'll be referring to it.

I came across it while looking for where in the world the crankcase breather hose goes. I know on the later models it goes into the air filter but until now I couldn't find the appropriate place. Now I know to look down the back of the engine!

Essentially mine had no breather hose, and the valve cover was spraying oil into the back of the bay! I assume this was an oversight from the former owner... anyway, another part onto the list
(side note: I take great great joy, having owned a few other old cars, in seeing how amazingly affordable it is to replace the bits and pieces on these cars!)
Glad it helped.
Hopefully it wont be too long before my engine goes back together.
Just waiting some parts to be delivered . Hint, hint...
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Old 04-09-2017   #103
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Re: Fiat 500D Engine 1962

Quote Originally Posted by Franko500 View Post
Glad it helped.
Hopefully it wont be too long before my engine goes back together.
Just waiting some parts to be delivered . Hint, hint...
spend some quality time with Er indoors!!!
they are whisking their way to you as we speak...
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