Yes once I have got this engine and box in and running, the spare engine and box I have will have a full strip, vapor blast, tune and reassemble on it ready for when the car its it's full resto...……


After i've finished my beetle that is

Thank you Peter for implying that my dementia has still to start! I have started to write things down already rather than trust to memory. On a more serious note, i have found that when doing one of these projects it is best to get a couple of 'ring-bound' files and to start collecting/collating all the information that you garner into various sections---engine, carbs, electrics, transmission etc. This makes it so much easier to find the info that you need at a future time. Having said that, it can also lead you to a bollocking from 'er indoors who is convinced that you have far to many books and files---I have 38 books on Abarth & Fiat in my reference library--as well as the files!

By the way of an update. I had to put another order in for parts last night as the bearings in the Alternator where shot and during the frantic strip down I made the school boy error of not removing the brushes before pressing the shaft out (D'oh)…..


I also noted that the fuel pump spaces was cracked and slightly squashed so for the money involved it wasn't worth not getting another.


Hopefully the first order will arrive today so I can start the rebuild.


All the block, crank, cam etc are cleaned, the head has had all the valves re-lapped in and just needs a final clean and reassembly, pistons and barrels need a final clean (barrels deglazing) and the new rings fitting, carb I've not even stripped yet but got a full rebuild kit on it's way, sump and tinware is just getting a blast over with a knot wheel in the grinder, degreased and a coat of black...….


I'll post some pics of the rebuild as it goes for those interested....don't get too excited its just a throw together


Picking the car up from storage at the mother in laws tomorrow night so I can start the strip on that and swap over the drive shafts....


A week tomorrow It will be getting hitched up to the motor home and dragged to Newquay on holiday...…...time is ticking.....

The Whitakers said:

Assuming it's just a straight swap on the drive shafts regardless of diameter?

Click to expand...

Did we give you this link?

https://www.fiatforum.com/500-class...-axles-driveshafts-help-needed.html?p=4359917

fiat500 said:

Did we give you this link?

https://www.fiatforum.com/500-class...-axles-driveshafts-help-needed.html?p=4359917

Click to expand...

You didn’t but I have seen it from the recent thread about drive shaft thank you.

Transplant happening this weekend

Ok so I dropped the existing lump out today and swapped over the shorter 500 driveshafts, luckily they were the 24/25 mm type......so after a not so fun day elbows deep in gearbox oil nearly everything is back together and ready for trial fitment today. I’m hesitant weather to fit it yet as I haven’t got my new bearings for the alternator so it would be fitted without it and the alternator and that section of tin fitted afterwards.......thoughts on that gents please?

Also from your vast experience which is better the 500 dizzy cap setup or the 126 twin spark coil?

I have taken pics which I will post I’ve just not had the time. 10 hours grafting yesterday in the sun kind of broke me yesterday....

Unless you have 4 foot arms with about 3 joints in each, I would NOT recommend that you try and fit the alternator and housing after the engine is in the car. Among other things, unless you get the shims in the right order/position, the fan could make contact with the housing. Also, the nuts at both ends (alternator one end, fan at t'other) of the alternator shaft have to be TIGHT. I would suggest that you fit the gearbox, have that all bolted up, have the engine all ready to have the alternator to be fitted, and then fit the engine with the alternator in situ. Due to a problem I had with the ignition light on my new (Abarth style) instrument cluster I had to fit my spare alternator (turned out it was the fact that I had fitted a LED ignition light and not a 'bulb' ignition light)---I had the engine out, the alternators swapped and the engine back in in one long working day---and I am not in the first flush of my youth!

OOps, sorry, forgot to answer your 2nd. As both systems still need 'spark timing control' from the distributor, I don't think it makes much difference. I have been advised that you can still use a 'Hall effect' ignition module in the distributor with the 'flat hat' cover when using the 'waste-spark' coil.

Thanks Hobbler...ok so I’ve refitted the gearbox...

The engine is complete bar the alternator which I’m waiting bits....

I’ve removed the warm air pipe from the tin ware to the car, I’ll worry about that later.....

I’ve run a cable from the dash to the starter motor, where the ignition is in the middle of the dash I’m mounting a push start button. My ignition is on the column. It’s a nice chrome unit do shouldn’t look too out of place...

Gone for the twin spark unit so swapped that over too and removed the conventional coil...

I’m knackered.....I’m well out of shape to work at this pace......

I’ll post some pics tomorrow....

Thanks for all the responses and advice, wine is my friend tonight....

Ok a few pics of the gearbox and final drive during strip, clean and rebuild..

Not the prettiest engine I've rebuilt but in a week of strip, clean, order parts and get back together it'll do...…

Hopefully the delivery of parts for the Alternator will arrive today so it can be rebuilt and the engine completed....


Carb had a rebuild and was fitted to the engine last night.....


I have mentioned what I have done as a temporary with the starter although when I have more time I will complete a set up to use the pull handle like the standard set up. this will comprise of a simple pull switch, spring and cable located under the access hatch at the rear of the tunnel in the car.....


The car intake duct, as this now fouls the starter.... it's been binned for now due to time constraints....I do have a plan in mind but i'll document that after I've been away.....


Need to sort the leccy out due to the dynamo to Alternator swap.....


Not leaving much time for a shake down am I?! however when I rebuilt my beetle that took 14 years (I fell out with it for quite a while) it's shakedown was getting drove to Belgium....that had all the suspension and brakes modified and uprated too...…..I made sure I had plenty of breakdown cover and tools...….

It lives!!!.......well sort of...

Couldn’t get the starter to engage, tried another starter....better but not right.....sat having a head scratch and another brew......so when the blatantly obvious slapped me round the face I bolted the engine main earth on and guess what......jeez.....

So it runs but didn’t let it run for too long as there is no alternator belt on yet so no cooling......

Tomorrow’s job is to swap out the starters again for the one I’ve cleaned up and do the alternator wiring.....one thing I’ve noted is that the exhaust from the back of the engine is fouling the bodywork so I’m assuming the 126 zaust is different to the 500? I may leave it on and notch the body as it will be better for reconfigure of the car hot air intake....

I’ll take some more pics tomorrow.....

Its quite common when swapping to 650 engine and exhaust for it to hit the rear cross member. You can get a spacer that sorts it out. Have a look at this thread.

https://www.fiatforum.com/500-classic/459876-guess-what-i-am-doing-tomorrow-2.html

The Whitakers said:

.one thing I’ve noted is that the exhaust from the back of the engine is fouling the bodywork so I’m assuming the 126 zaust is different to the 500? I may leave it on and notch the body as it will be better for reconfigure of the car hot air intake....

Click to expand...

The shape of the rear exhaust pipe is different and I had the problem that I think you refer to.

https://www.fiatforum.com/500-classic/438713-650-engine-rebuild-6.html?p=4253287

fiat500 said:

The shape of the rear exhaust pipe is different and I had the problem that I think you refer to.

https://www.fiatforum.com/500-classic/438713-650-engine-rebuild-6.html?p=4253287

Click to expand...

Yes the forth pic in your post is what I refer to....


I will double check the other points also, thank you....

Ok so it's in and running. Early indications show that it has totally transformed the driving experience of the car!....the extra power and the sychro box is fantastic...….


I still have a few jobs to do like the alternator wiring to tidy as I used the dynamo regulator as a junction point, the warm air duct etc....just small stuff really....


It's been quite a battle in 10 days to collect, strip, rebuild, remove, swap, refit and get running including 4 separate orders to parts suppliers.....


I do have to thank everyone for their persistence and input through my rambling posts on here, it wouldn't have happened so quick without you all....


So I'm going to drag it to Cornwall on Friday night for a week of nipping and bobbing so I'll report back on how it performed....


When I return I will post up valid points of things encountered during the swap which hopefully will give a little guidance and understanding to other.....


Thanks again Gents..


Rob

Guys really struggling for signal where I am, the car has had a long run and is hot but not over heating but it’s developed a misfire.....what’s the tappet gap on an A1 engine as I set them to standard 495cc setting!?