My Lancia Delta Integrale 8V restoration project

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samo
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My Lancia Delta Integrale 8V restoration project

Post by samo » Mon Dec 06, 2010 11:51 am

Hello everbody,

Here I will try to present my restauration project. It is still not finished but at this stage I am assembling the engine so I have a few questions every week. I will post pictures as time permits.

Please bear with me if I miss type something, English is my second language!
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It was love at first sight. And YES the colour was as bad as it looks.
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samo
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Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Mon Dec 06, 2010 2:06 pm

After a few months of dancing around the car with a screwdriver I took out the real tools and begun dismanteling the car.
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rear inner wheelarches looked like this
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My sill's looked like the bad side of Titanic
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samo
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Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Mon Dec 06, 2010 6:38 pm

Since this story is too long to try to post it all here I will now just show you a few pictures...
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First wisit to the body shop!
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After getting the car back from the body shop I spent a few hours finishing the details like cleaning the wheel arches...
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And I found this underneath!
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samo
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Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Mon Dec 06, 2010 6:44 pm

After that I promissed myself that I will do all that's neccessary to get the car to bare metal to avoid any surprises.
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I spent one whole summer under the car with a burner, scraper and I removed all the underseal.
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All the sealant on all the joints has been removed (grey areas on this picture).
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I have had the car sandblasted. This is the 2-pack primer.
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1NRO
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Re: My Lancia Delta Integrale 8V restoration project

Post by 1NRO » Tue Dec 07, 2010 8:45 am

A proper job, well done you. I know the work you've been through, it is worth it.

Nik
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Guy Croft
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Re: My Lancia Delta Integrale 8V restoration project

Post by Guy Croft » Tue Dec 07, 2010 10:46 am

MODEL POST!

I do admire these bare-metal restorations, I did one once on a Mini Cooper so I know too how much work it is and that was a very small car.

The Integrale must count (in my view) as one of the more 'worthy' restorations given the extraordinary provenance of these incredible cars (what was it - 9 times World Champion??) and it's fantastic to see these in-depth projects here. But - I can't believe how they rusted/rotted.

Well done indeed. I'm especially impressed with the way you have photographed and captioned your work..

G

samo
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Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Tue Dec 07, 2010 11:37 am

Thank you.

I have a lot more pictures but it's time consumming to upload them. So if anyone is interested on seeing the complete story it's published here http://forum.Alfa-klub.com/viewtopic.php?t=18646

You won't understand much as it is in Slovene but the pictures tell the story. I hope the link doesnt violate the site protocols? It's not a commercial site, no popups ...

So after 3 years of non stop work, metal repairs, cleaning the car, scraping off the sealant, 2 trips to the body shop and a sand-blasting session the car was ready for painting. Since I stareted this project seriously I have had the car professionaly sprayed because I didn't want to bodge it myself.

I belive integrales (together with HF4WD and EVO1) had won 6 manufacturest WRC's. And elthou they retired from racing in 91 (or 92) they still hold the record for most wins which is incredible. I allways say that the only thing faster than an integrale is the rust on the integrale. Sadly Italians decided in the 80's to make cars from recycled "white tin"- that's recycled white appliances. So 80's and 90's integrales (and other Italian cars) are in fact 60's and 70's washing machines and refrigirators.
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The lower screen surrounds were lead loaded. Integrales flex at this point and fillers crack.
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Half finished process.
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Next the stone chip protection was applied. A special thin protection was used. Note the clever "roasting" jig.
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This is the primer filler (spray on filler !?) Looks good in flat black :)
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1NRO
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Re: My Lancia Delta Integrale 8V restoration project

Post by 1NRO » Tue Dec 07, 2010 7:19 pm

I've just been right through that link and can only confirm what I've already said, a proper job, better than Lancia made.

As for that roller, my dreams are made of stuff like that :-)
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samo
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Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Wed Dec 08, 2010 8:32 am

@1NRO-thank you. I hope you enjoyed the pictures.

So after 3 years of hard work and a few thousand hours spent on the chassis the car was finally painted and I was astounded by the work that was done. I did go for the best (and most expencive) expert I could find that has experience with oldtimers. He was also the only one who said that before taking on sutch a project he wants to see the car if it is prepaired up to his standards. When he arrived he told me that he's sick and tired of people ringing him for a quote for a paintjob but they forget to mention that half of the car is missing. And halfway trough his explonation he made a quick check of the body repairs, enquired me about my intentions with this car, history of the car, my history, checked that i am a proper car fanatic and a genuine oldtimer lover (I belive he considered me too young to be serious)... but then he bent over and looked underneath the car. He stopped talking and crawled under the car and then spent 30 minutes there in silence. And then he said that he rarlely see's someone clean the car so well.
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Colour is the original NERO METALIC
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samo
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Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Wed Dec 08, 2010 9:08 am

Some more pics of the painted car. This was a turning point in the project as I knew that I finished tearing things apart and I shall start the assembyl (or so i tought).
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samo
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Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Fri Dec 10, 2010 8:06 am

After getting the car back from the paint shop the assembly begun!
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First the electrical instalation has been returned to it's place and then I had to make new isolation padding because the original has disintegrated.
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I bought a brand new carpet to get the "factory" fresh look. The dashboard and center console have been installed.
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Various bits are beeing returned to their original places. All the brackets, nuts and bolts have been zync-plated again.
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tricky
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Re: My Lancia Delta Integrale 8V restoration project

Post by tricky » Sat Dec 11, 2010 6:37 pm

Wow that really looks something, the highest of respects to you sir.
Twice as many valves

samo
Posts: 224
Joined: Mon Dec 06, 2010 6:52 am

Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Sat Dec 11, 2010 7:25 pm

Thank you!

This is my first project of this sort and I belive the last, since I have been threatend with decapitation by my wife :) Since this is primarly an engine building site I have only posted a few pictures of the chassis build.
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Rear differential before the renewal.
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Disassembeld, washed, checked, measured components.
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New rotary seals, o-rings and diff carrier sandblasted and powder coated. Note the long 225mm M10 fine thread screws 10.9 hardnes for rear arms. I had these custom made because they can not be bought anywhere!
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samo
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Re: My Lancia Delta Integrale 8V restoration project

Post by samo » Sat Dec 11, 2010 10:08 pm

I am building the engine to be driver friendly with as much torque as possible, because I belive the dyno queens with huge graphs are only good for bar showin off. So I am not expecting huge power. The car will not be raced as I shall try to take care of it and keep it in as original state as possible.

Engine configuration:

-block & crank on 1st regrind
-king bi-metal bearings
-woessner forged pistons
-Garrett T385
-inlet manifold with 16V integrale throttle body
-spesso headgasket (one-piece with integrated fire rings)
-12,9 non stretch head bolts
-F/L 2.0 i.e. NA intake camshaft
-dyno&remap

The crank with the 1st regrind is an experiment of sorts. I know that they shoul not be regrind ever but I have had the crank tested for surface hardness by a reputable engine shop and they graded it as "above average" in hardness (don't remeber the numbers unfortunatley). I have also seen a similar setup engine with 3rd regrind and Fiat Tipo TD bearing which refuzes to die despite beeing abused on a race track. All the components have been measured, checked, re-checked, cleaned in gasoline, degreased, power washed with hot water, air line dried... I am trying my best to make a clean built. Crank has had the plugs removed. All the block oil lines cleaned and I even had the balance shaft center bearings replaced with new items. Aslo conrods small end bushings have been replaced and the oil pump renewed. So there should be good oil pressure and no contamination. I followed the strict guidelines for cleaning the bores with ATF, piston rings gaped properly...

So I shall wait and see how it goes. Anyways if you have any ideas on how to make good torque witouth chasing high BHP i am opened to suggestions.
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Piston gaping to 0,3 mm.
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Crankshaft preparation.
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Crank instalation for final end float measurements (0,1mm). Crank can be turned by hand witouth problems. If rotated by hand it continues to rotate approx. half turn by itself (that is crank only!)
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Piston & conrod pairing.
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tricky
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Re: My Lancia Delta Integrale 8V restoration project

Post by tricky » Sun Dec 12, 2010 6:52 pm

The crankcase certainly looks clean enough, as for high torque usual tuning tequniques apply.

Which con rods are they samo ? they don't look as if they have the stampings of the Fiat / Lancia origianals.
Twice as many valves

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