Spasso's '84 Euro 635, #8183039

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Spasso
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Location: The Jet City, USA

Paint

Post by Spasso »

Still a bit bent but located correctly.
Attachments
Bad Pylon- Painted Side (Small).JPG
Bad Pylon- Painted Side (Small).JPG (123.18 KiB) Viewed 13042 times
Bad Pylon- Painted Aft (Small).JPG
Bad Pylon- Painted Aft (Small).JPG (137.96 KiB) Viewed 13042 times
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Spasso
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Location: The Jet City, USA

Race Skid

Post by Spasso »

5/16 thick plate steel.
Attachments
Race Skid.JPG
Race Skid.JPG (1.19 MiB) Viewed 13042 times
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Spasso
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Install The Skid

Post by Spasso »

Nut plates go inside the two front pylons.
- Support skid with the jack screw and start the two forward bolts.
** NOTE: The 3/8's bolts supplied come with lock washers but the slots are too big and you need to back up the lock washers with larger flat washers.
- The two aft nut plates have heavy wire welded to them so you can insert them inside the rear cross member.
- Start the two aft bolts and adjust the skid plate as needed.
**NOTE: The instructions say to cut of the remainder of the nut plate wires when finished.
I left them on and pushed them up into the cross member for later use when the skid has to come back off.
I left a little loop hanging out so I could fish the nut plates later.
Attachments
Installed Skid- Bottom (Small).JPG
Installed Skid- Bottom (Small).JPG (87.36 KiB) Viewed 13042 times
Installed Skid- Front (Small).JPG
Installed Skid- Front (Small).JPG (84.76 KiB) Viewed 13042 times
Installed Skid- Oil Plug (Small).JPG
Installed Skid- Oil Plug (Small).JPG (66.08 KiB) Viewed 13042 times
Installed Skid and Wire (Small).JPG
Installed Skid and Wire (Small).JPG (116.59 KiB) Viewed 13042 times
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Spasso
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CLEARANCE TO THE PAN AND ROAD

Post by Spasso »

The clearance between the front of the oil pan and the inside of the skid is 1.00 inch.
The skid continues forward and downwards slightly before kicking up to the pylon mounts. (See picture below)
This actually DECREASES clearance because the kick-up in the skid is forward of the axle center line.

I went to back the car off the lift and the forward kick-up of the skid plate hit the aft end of the lift ramp.
I also bottomed the skid plate when I came off of a speed bump a little too fast.
It didn't hurt the car (or oil pan) but it does make quite a racket.

** Keep in mind that my car is lowered more than most.
On a car with standard springs or even some H & R springs (1.5" drop?) I don't think bottoming would be as much of a problem.
This is something you'll have to figure out for yourself.

This skid could be reconfigured and re-drilled if you can find somebody with a big enough brake to bend it.
For now I'll stick with what I have. I'll just have to be a little more careful.
Attachments
Skid Plate- Side View 1 (Small).JPG
Skid Plate- Side View 1 (Small).JPG (124.11 KiB) Viewed 13042 times
Installed Skid- Front Angle (Small).JPG
Installed Skid- Front Angle (Small).JPG (87.78 KiB) Viewed 13042 times
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dwcains
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Re: Spasso's '84 Euro 635, #8183039

Post by dwcains »

That's some serious blacksmithing work - nice.
Dean
Lutz, FL

'85 635 CSi Euro #9402254
'87 Spider Veloce
'92 Spider Veloce
'08 350Z

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Spasso
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Re: Spasso's '84 Euro 635, #8183039

Post by Spasso »

dwcains wrote:That's some serious blacksmithing work - nice.
Thanks.
The metal was so stretched out that there was no way to get it all straight.

Drove it to work today to get some miles on the break-in oil.
I'll change that out this weekend after I get 100 or so miles on it.

The gearing is really tall, high gear, 65 MPH = 1800 RPM.
It would be nice if I could get that with the 5-speed manual.
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Spasso
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First Oil Change

Post by Spasso »

Finally got a chance to change the break-in oil.
A total of 131 miles.
Very clean coming out, no nuts or bolts, metal shavings or anything in the pan..
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Spasso
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Skid Plate Mod

Post by Spasso »

After driving this thing for the first hundred miles I found that the configuration of the skid plate just didn't work with how low this car sat.
I don't imagine it would be that great on a real race car because it hit EVERYTHING.
Pine cones, small rodents, cigarette butts, joints in the pavement and anytime the suspension was compressed even slightly.

The bend (kick-up) in the skid was too far forward and too low.
While I was doing the oil change I decided that the plate was not going back on until I got my clearance back.
I decided to flatten the original kick-up and make a new one about 4.5 inches aft, about even with the front of the pan.

Using the floor, some extruded steel channel to support the skid at key points and my Oxy/Acetylene torch, I used the ramp on my four post lift and the weight of the car to act as a brake to flatten the original kick-up.
This is 5/16 plate steel and it did not want to bend, even with heat. After most of the bend was taken out I placed what was left on a steel bench top and finished the job with more heat and my trusty 4 lb hammer.
It isn't perfect but after all, it is a skid plate.

Back to the floor, the torch and the ramp on my lift, I made a new kick up but with more of a gradual bend than a sharp fold like the original.
I had to change the forward slots to a 'T' shape to pick up the holes.
I also had to flatten the forward flange so it would sit correctly on the forward pylons.
I sanded it out with the DA and sprayed some fresh paint on it.

Now the lowest point of the skid is even with the forward axle line and I still have almost an inch of clearance at the front of the pan..
Attachments
Top View (Small).JPG
Top View (Small).JPG (104.51 KiB) Viewed 12980 times
Top View (Small) (2).JPG
Top View (Small) (2).JPG (97.88 KiB) Viewed 12980 times
New Curvature 1.JPG
New Curvature 1.JPG (63.14 KiB) Viewed 12980 times
New Curvature 2.JPG
New Curvature 2.JPG (70.66 KiB) Viewed 12980 times
Last edited by Spasso on Mon Aug 01, 2016 3:59 am, edited 3 times in total.
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Spasso
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Profile Comparison

Post by Spasso »

Old Profile, top picture.
New profile, bottom picture.
NOTE: The shot was from the forward side of the tire so the new kick-up looks like it is under the middle of the pan. It is actually closer to the front of the pan.
Attachments
Skid Plate- Side View 1 (Small).JPG
Skid Plate- Side View 1 (Small).JPG (124.11 KiB) Viewed 12980 times
Side 2 (Small) (2).JPG
Side 2 (Small) (2).JPG (110.67 KiB) Viewed 12980 times
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Spasso
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Final Installation of Revised Skid Plate

Post by Spasso »

...
Attachments
Exposed Pan (Small).JPG
Exposed Pan (Small).JPG (83.78 KiB) Viewed 12980 times
Covered Pan (Small).JPG
Covered Pan (Small).JPG (98.86 KiB) Viewed 12980 times
Installed Quarter View (Small).JPG
Installed Quarter View (Small).JPG (81.16 KiB) Viewed 12980 times
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Spasso
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Location: The Jet City, USA

More driving

Post by Spasso »

I drove 80 miles today and didn't hit one thing with the skid plate.
I think it will work now, and knowing how hard it was to bend, I think the pan will be well protected.
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dwcains
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Re: Spasso's '84 Euro 635, #8183039

Post by dwcains »

A sunp guard is somethingI should probably consider, too, a my car is lowered on BavAuto sport springs and HD Bilsteins. I wouldn't drive one my Alfa's without one, as they've also got vulnerable alloy oil pans:

Image

Of course, the Italian version of any car part is always more comlex and elegant.
Dean
Lutz, FL

'85 635 CSi Euro #9402254
'87 Spider Veloce
'92 Spider Veloce
'08 350Z

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jps635
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Re: Spasso's '84 Euro 635, #8183039

Post by jps635 »

You've done a great job with your engine build, tremendous attention to detail. Am following a similar course and will be referencing this. On the head gasket again, your engine is a B34 euro - correct?
'85 635csi JPS (RA2-66)
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Spasso
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Location: The Jet City, USA

Re: Spasso's '84 Euro 635, #8183039

Post by Spasso »

dwcains wrote:A sunp guard is somethingI should probably consider, too, a my car is lowered on BavAuto sport springs and HD Bilsteins. I wouldn't drive one my Alfa's without one, as they've also got vulnerable alloy oil pans:



Of course, the Italian version of any car part is always more complex and elegant.
Beautiful undercarriage Dean.
I too have an Italian that slumbers while I work on this German stuff.
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Spasso
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Re: Spasso's '84 Euro 635, #8183039

Post by Spasso »

jps635 wrote:You've done a great job with your engine build, tremendous attention to detail. Am following a similar course and will be referencing this. On the head gasket again, your engine is a B34 euro - correct?
Thanks. I owe the quality of the engine build to my brother. Like him, I couldn't see putting this engine back together without replacing all parts that we did.
Ideally new pistons would have been nice but the condition and dimensions of the cylinder bores and pistons was so good we stuck with what we had.

* The engine is a EURO M30-B34 according to the build date of 11/84. * The head gasket fit perfectly.

I drove it today 100 miles in 80+ heat, stop and go plus highway miles, ran it through the gears a lot.
The gauge climbed "almost" to center but most of the time stayed at 1/3 up.

I will be starting to drive it to work daily which will put 3 to 400 miles a week on it.

The head will be re-torqued at 1200 miles and valve clearances checked.
During that time I will refinish the cam cover. I spaced it out during the build and doesn't look all that great.
Top coat with the same Duplicolor High Heat silver used on the oil pan plus the Duplicolor clear as mentioned earlier in the thread.
Last edited by Spasso on Wed Aug 03, 2016 2:28 am, edited 2 times in total.
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Spasso
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Snake Oil

Post by Spasso »

I mentioned that the automatic in this car was showing signs of age, mostly with a sketchy/delayed shift between 1st and 2nd.
I'm not one for snake oil treatments but I've used this stuff in the past and it has helped on occasion.
I drained a couple of quarts of fluid out and replaced with 2 quarts of Lucas "Transmission Fix".

The shifts have tightened up and under hard acceleration it kicks pretty good.
The results were so good that I don't think I'll have to visit the 5-speed conversion until next year.
Weeee'lll seeee.
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Spasso
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500 miles

Post by Spasso »

Currently have a little more than 500 miles on the engine so far.
I pulled the valve cover last weekend for refinishing and to re-torque the head.
I got very slight movement out of three bolts between cylinders 3 and 4 and 4 and 5.
Valve clearances remain steady at .012 cold so far.
Everything is nice and clean and the cam appears to be wearing in nicely.
Attachments
500 miles (Medium).JPG
500 miles (Medium).JPG (205.33 KiB) Viewed 12876 times
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Spasso
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Valve Cover Refurb

Post by Spasso »

Valve cover refurb.
Duplicolor DE 1615 High heat Aluminum
Duplicolor DE 1636 High Heat Clear
Attachments
Valve Cover Prep (Medium).JPG
Valve Cover Prep (Medium).JPG (218.97 KiB) Viewed 12875 times
Valve Cover 3 (Medium).JPG
Valve Cover 3 (Medium).JPG (182.9 KiB) Viewed 12875 times
Last edited by Spasso on Wed Aug 10, 2016 10:01 pm, edited 1 time in total.
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Spasso
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Blower Cowl Repaint

Post by Spasso »

One of my pet peeves is seeing the heater blower cover on various cars with both ends weathered and rusty.
Stripped and painted with high gloss black.
I should have used satin black but didn't have enough to do the job.
The gloss will weather better.
Attachments
Blower Cowl 1 (Medium).JPG
Blower Cowl 1 (Medium).JPG (192.91 KiB) Viewed 12874 times
Last edited by Spasso on Wed Aug 10, 2016 6:08 pm, edited 2 times in total.
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Spasso
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Coolant Tank

Post by Spasso »

The coolant level sensor wasn't working and I had my suspicions that the pressure cap was venting early so I replaced both plus a new expansion tank.
Attachments
Coolant Tank, Sensor, Cap (Medium).JPG
Coolant Tank, Sensor, Cap (Medium).JPG (177.85 KiB) Viewed 12876 times
Last edited by Spasso on Wed Aug 10, 2016 6:11 pm, edited 2 times in total.
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Spasso
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Air Filter Housing

Post by Spasso »

Another thing I see often is the top of the air filter housing dished in from people leaning on it.
I dollied out all the dents from the inside the best I could and painted with satin black.
Attachments
Filter Housing (Medium).JPG
Filter Housing (Medium).JPG (207.77 KiB) Viewed 12875 times
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Spasso
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Engine Bay So Far

Post by Spasso »

Engine Bay So Far
Attachments
Engine Bay (Medium).JPG
Engine Bay (Medium).JPG (214.12 KiB) Viewed 12874 times
GRNSHRK
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Lookin' good Spasso!!!

Post by GRNSHRK »

I went the powder coating route on the blower cover, this was done at "least" 20 years ago #-o

True, this car isn't exactly sitting outside, in the rain, and all that, but I do wonder how long paint will actually last :-k

I do need to do my air box cover as well :-"
Attachments
IMG_1010-sm.jpg
IMG_1010-sm.jpg (101.47 KiB) Viewed 12867 times
:mrgreen:
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Spasso
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Re: Lookin' good Spasso!!!

Post by Spasso »

GRNSHRK wrote:I went the powder coating route on the blower cover, this was done at "least" 20 years ago #-o

True, this car isn't exactly sitting outside, in the rain, and all that, but I do wonder how long paint will actually last :-k

I do need to do my air box cover as well :-"
Thanks!
Powder coating would be ideal for that blower cover.
Refinishing mine was kind of an after-thought at the end of the day Sunday and I thought, "What the hell, lets at least get some paint on it". I even found a strip of grey high density foam and glued onto the aft edge before re-installing.
This car is parked inside very night so it should last a good while.
When it's time to re-do I'll go with satin or semi-flat.

As far as the air box goes, I placed mine top-down on a bed sheet, folded into a big soft pad, and tapped the stiffener on the inside with my rubber dead blow until the top flattened out...and then hit it again a couple more times.
I finished up a couple of the smaller ones with the end of ball peen.
It still has a bunch of smaller dings in it I'll get to later.
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zinnocoupe
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Re: Spasso's '84 Euro 635, #8183039

Post by zinnocoupe »

I just read your whole project start to finish! Nice work on the engine and everything else. So much detail here, I'm going have to reread a lot of the head details. I'm going have a lot to live up to on my build. I wish I had a brother :D Awesome
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1979 Euro 635ci no longer a basketcase, just a running rust bucket!
1977 530i Partially restored and running now!
1987 635csi 60K KM Garage Queen
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