1969 Fiat 124 SpiderAS 1800 conversion

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Spider 1969
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Re: 1969 Fiat 124 SpiderAS 1800 conversion

Post by Spider 1969 » May 8th, 2019, 8:13 pm

3 & 4 Relocating the firewall and brake pedal:

The postion where the steering shaft passes through the firewall needed to be relocated approximately 50 mm and 45 degrees down and right from the original postion. See below photo.

Also the brake pedal needed to be modified to clear the steering shaft.
Attachments
RNP_Firewall-001.jpg
photo 90 degrees rotated. Old one blanked off
RNP_Firewall-001.jpg (114.04 KiB) Viewed 432 times
RNP_PEDAlS-001.jpg
RNP_PEDAlS-001.jpg (83.48 KiB) Viewed 432 times
Last edited by Spider 1969 on May 9th, 2019, 7:43 pm, edited 2 times in total.
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Spider 1969
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Re: 1969 Fiat 124 SpiderAS 1800 conversion

Post by Spider 1969 » May 8th, 2019, 8:26 pm

5 Modifying the steering rack location:

Last weekend after installing the suspension and steering components I wanted to pre align the hubs. I turned the steering wheel from full left to full right and count d3,5 turns. Then turned it back to 1,75 turns to the straight ahead postion (in theory). I the found out that the inner steering joint on the right is located 20 mm further out board than the one on the left. See below photo. Conclusion is that the steering rack is not centered and that this kind of misalignment of the inner steering joints will lead to bump steer.

I will remove the suspension and cross member to be able to relocate the left steering rack bracket 10 mm to the left and rectify the missalignment.
Attachments
Rack_and_Pinion_Misallignment-001.JPG
Rack_and_Pinion_Misallignment-001.JPG (120.15 KiB) Viewed 431 times
Last edited by Spider 1969 on May 21st, 2019, 8:11 pm, edited 1 time in total.
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Spider 1969
Posts: 147
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Re: 1969 Fiat 124 SpiderAS 1800 conversion

Post by Spider 1969 » May 18th, 2019, 7:17 pm

5 Modifying the steering rack location continued:

I removed the cross member and removed the left side bracket as this one fixates the location of the steering rack. I the tack welded it 10 mm to the left from previous position and did some measurements that confirmed that the rack is centered. After final welding and paint it was simple bolting everything up again.
Attachments
Allignment-001.jpg
Left bracket removed
Allignment-001.jpg (111.33 KiB) Viewed 391 times
Allignment-002.jpg
Bracket tack welded
Allignment-002.jpg (117.24 KiB) Viewed 391 times
Allignment-003.jpg
Ready to be bolted to the car
Allignment-003.jpg (100.64 KiB) Viewed 391 times
Allignment-004.jpg
Everything back under and aligned
Allignment-004.jpg (84.61 KiB) Viewed 391 times
Allignment-005.jpg
Allignment-005.jpg (98.09 KiB) Viewed 391 times
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Spider 1969
Posts: 147
Joined: September 22nd, 2013, 7:21 pm
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Re: 1969 Fiat 124 SpiderAS 1800 conversion

Post by Spider 1969 » May 18th, 2019, 7:26 pm

6 Modification of the gear box cross member

As the sump was fouling the steering rack I had to shim the engine mounts to clear the sump. As a result the gearbox output flange was not parallel to the differential flange any more. (a difference of 0.4 degrees). I cut the gearbox cross member and welded the central part that contains the rubber mount in a higher position. After mock up, painting and bolting back again protractor measurements confirmed the right position. The prop shaft central bearing also was shimmed to compensate for the increased height until the front prop shaft was 90 degrees relative to the gearbox output flange.
Attachments
Gear_Box_Allignment-001.jpg
Gear_Box_Allignment-001.jpg (88.73 KiB) Viewed 390 times
Gear_Box_Allignment-002.jpg
Gear_Box_Allignment-002.jpg (92.82 KiB) Viewed 390 times
Gear_Box_Allignment-003.jpg
Gear_Box_Allignment-003.jpg (108.23 KiB) Viewed 390 times
Gear_Box_Allignment-004.jpg
Gearbox output flange
Gear_Box_Allignment-004.jpg (89.83 KiB) Viewed 390 times
Gear_Box_Allignment-006.jpg
Differential flange
Gear_Box_Allignment-006.jpg (99.61 KiB) Viewed 390 times
Front_Prop_Shaft-001.jpg
Front_Prop_Shaft-001.jpg (64.73 KiB) Viewed 300 times
Last edited by Spider 1969 on May 26th, 2019, 12:08 am, edited 1 time in total.
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Guy Croft
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Re: 1969 Fiat 124 SpiderAS 1800 conversion

Post by Guy Croft » May 20th, 2019, 1:47 pm

FANTASTIC COMMENTARY, DETAIL, INFORMATION AND PHOTOS!

GC
Guy Croft, owner

Spider 1969
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Re: 1969 Fiat 124 SpiderAS 1800 conversion

Post by Spider 1969 » May 26th, 2019, 12:21 am

7: Modifying the throttle linkage

Due to discarding the original steering box it was necessary to fabricate an alternative throttle linkage. The original throttle linkage spindle had been located with the rear bushingin a bracket at the steering box and with the front bushing in a bracket on the IDF manifold (sorry no photo available).
So I made a bracket to accommodate both bushings on the inlet manifold. Also I to located this spindle 8 mm lower and 5 mm more towards the engine which as needed due to the increased engine mount height.

Now it is finally time to start doing what this modifications were needed for: Installing a new GC approved header and fabricating a 2,25" stainless steel exhaust system!

(Don't know why the photos are rotated; sorry for that!)
Attachments
Linkage-001.jpg
Linkage-001.jpg (86.8 KiB) Viewed 298 times
Linkage-002.jpg
Linkage-002.jpg (98.46 KiB) Viewed 298 times
Linkage-003.jpg
Linkage-003.jpg (154.32 KiB) Viewed 298 times
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Spider 1969
Posts: 147
Joined: September 22nd, 2013, 7:21 pm
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Re: 1969 Fiat 124 SpiderAS 1800 conversion

Post by Spider 1969 » July 7th, 2019, 9:32 pm

Finally: exhaust time. Installed the GC design and GC approved MCJ Abarth header. Very happy that it actually fits because I had to install the rack and pinion steering to make it possible. Attached a home made exhaust to it consisting of 55 mm stainless steel pipe, bends and one muffler to it. Used two V-band couplings to facilitate fast and easy exhaust removal/installment when needed. Can't wait to hear its sound! Just some routine maintenance like a cam belt change, oil change etc. and it will be ready for start up and a shake out drive. After that: straight to an alignment shop.
Attachments
Header-001.jpg
MCJ Abarth header as designed and approved by GC
Header-001.jpg (98.3 KiB) Viewed 162 times
FIAT_EXHAUST-002.jpg
FIAT_EXHAUST-002.jpg (153.14 KiB) Viewed 162 times
FIAT_EXHAUST-003.jpg
FIAT_EXHAUST-003.jpg (98.47 KiB) Viewed 162 times
FIAT_EXHAUST-004.jpg
Oxygen sensor for the AFR gauge and custom made gearbox to exhaust bracket
FIAT_EXHAUST-004.jpg (94.59 KiB) Viewed 162 times
FIAT_EXHAUST-005.jpg
57 mm tail pipe to finish it up
FIAT_EXHAUST-005.jpg (82.68 KiB) Viewed 162 times
FIAT_EXHAUST-006.jpg
FIAT_EXHAUST-006.jpg (108.76 KiB) Viewed 162 times
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