Berlinetta build and restoration

[scott h]

Re: Berlinetta build and restoration

I have been busy refining the dashboard layout and this is finally one that I am happy with.

20170219_192618-1632x1224.jpg

This will be used as a template for the final dash made from a burr walnut blank purchased from Europa.

As a footnote this is the first post done completely on my phone as I have become increasingly frustrated with my laptop since I changed to windows 10, what a disaster! So I hope this worked ok.

[scott h]

Re: Berlinetta build and restoration

Center console. As I said before I want to have adjustable vents with flap valves to divert between them and the footwell. So I had a go to see what I could do.

Here is the front showing the vents with the control for the flaps in the middle.

1576.jpg

Here is the rear, showing how the rod is connected to the flaps by welding wire. The feed from the heater comes in at the top and can be directed rearward to the vents or forward to the footwell.

1581.jpg

This was intended as a mock up but it turned out better than expected and could well end up on the car for good. I think after it is covered with maybe black vinyl or something, it will look ok.

[scott h]

Re: Berlinetta build and restoration

Thanks Angus. I know very little about woodwork and nothing about veneering. I am very much aware that a poor dashboard can have a huge effect on the overall appearance of the car. Your professional advice is very welcome.

[angusgrooby]

Re: Berlinetta build and restoration

Hi Scott, be carefull if you go down the veneering route as you can get the grain pattern on the ply transfer though to the veneer also veneer both sides of the ply in the same timber because if you don't it can warp badly. I think Mike Gardner did a sandwich of ply then thin sheet of aluminum and then veneer but you would have to ask him.
I use capital crispin for my veneer they will let you buy just one sheet of your desired veneer Google there web site as they have pictures of all different types / cuts of veneer and may give you some inspiration.
I have seen the dash blanks you describe and they do look effective but being a cabinet maker you really can not beat the real thing.
Have you thought about going down the solid timber route for your dash as long as you leave enough room for the timber to expand and contract you will be fine and maybe slot your fixings at the bottom to allow for it to move.
You could also use moisture resistant mdf to veneer on as angouther option.
Hope my ramblings have helped Angus

[scott h]

Re: Berlinetta build and restoration

I've been getting on with the wiring and now because so many of the switches and other electrical components are on the dashboard it is time to tackle that.

This is the original dashboard.

1561.jpg

This time I want to add a radio and a clock. I also think that burr walnut will look better. I cut a dashboard shape from some old plywood and tried out some ideas for layout.

1566.jpg

The radio is a retro style but has bluetooth for hands free phone calls, it can also use bluetooth to connect to music devices. I also want a center console below the main dash to house two adjustable vents, with a control to vary between them and ducting to the footwell. The screen will have a constant feed from the heater, and for maximum demist the plan is to direct the main air flow away from the footwell to the vents then close the vents. This will mean the only route for the air from the heater is to the screen. It sounds simple when you say it but time will tell if it's possible!

1571.jpg

Here you see one of the vents and the flap valve to select between the vent and footwell. Also here is the temp control for the heater which operates a flow control in one of the heater hoses. You can also see one of the push button billet aluminium switches which at the moment will be in a vertical row behind the steering wheel. The heater fan and the headlight switches are rotary and a mate says he will machine knobs for them to match the push switches.

I am trying to decide what to use to make the dashboard, whether to use ply then cover with veneer, or a ready veneered dashboard blank from Europa Spares.

[scott h]

Re: Berlinetta build and restoration

Thanks guys. Setbacks are always a pain but when you eventually find a solution it's a boost to morale.

[Mike]

Re: Berlinetta build and restoration

Success! The engine started right away for the first time with the proper wiring in place. .

Scott, well done.
Its always such a thrill to hear an engine fire up for the first time - you must be really chuffed

Mike

[cameronfurnival]

Re: Berlinetta build and restoration

well done Scott!

[scott h]

Re: Berlinetta build and restoration

If at first you don't succeed, try try again. The new injection pump arrived last Thursday so I couldn't wait to fit it and get the engine running. But it still refused to start! Tonight was the first chance to get back in the garage since then as I had the weekend at the classic car show at Birmingham.

The new pump worked if it was connected directly to the battery but not when it was connected properly. There was no power getting to the pump, where before with the old pump there was power. This is when it is handy to have a stock of components such as relays and ECUs that have been checked to work ok, by previously fitting them when the engine was running. Alas still no joy. Then literally a light bulb moment, I noticed that the ECU warning light was not lighting when the ignition was switched on. It should come on then go out when the engine starts, indicating that the ECU was not getting power. A small wire that is connected to ignition live had come adrift. Success! The engine started right away for the first time with the proper wiring in place. It's still a mystery what happened to the old pump , which I checked again but still dead. At least I can sleep tonight and I think I may solder the wire that came adrift to make double sure it stays put.

[peterboat]

Re: Berlinetta build and restoration

Should have read further! Your electrics are better than my Hunters my fuse box is in mid air very poor

[scott h]

Re: Berlinetta build and restoration

Yes a low pressure pump continually tops up a swirl pot in the engine bay, with an overflow return to the tank. The injection pump takes fuel from the swirl pot and the fuel rail has a return to the swirl pot. So a low pressure circuit and a separate high pressure circuit. What I did with the fuel system starts on page 13 of this build diary.

[peterboat]

Re: Berlinetta build and restoration

I take it you have a low pressure lift pump running to the high pressure pump?
I just have a high pressure pump at the tank which failed at 33k due to lack of filter I fitted a new pump with inline filter before it and the old bulkhead filter before the fuel rail is still in place [I had forgotten about it] it seems to work ok so if it isnt broke dont fix it are my thoughts.
The old FSE facet pump I cut in half it was full of crap and totally seized up hence why I fitted a filter

[scott h]

Re: Berlinetta build and restoration

The facet pump at the tank has a filter built in to the inlet. It was recommended to have a filter before the injection pump and a high pressure filter after it before the fuel rail.

I took the pump off last night but it is completely dead. It is also sealed and no way of opening it up. Looking into the inlet you can see a gauze filter which looks clean. I ordered a new pump.

[peterboat]

Re: Berlinetta build and restoration

Thats a lot of filters most modern cars manage with just the one and do over a 100k without problems. Just one before the high pressure pump at the tank is enough to protect the whole system

[scott h]

Re: Berlinetta build and restoration

Yes there is a filter union on the lift pump at the tank. Then a second filter between the swirl pot and the injection pump. Then a third filter between the injection pump and the fuel rail.