Steve Maxwell “Max” works in the “second building” next door to our main shop and makes spectacular parts out of Carbon Fiber, Kevlar and other composite materials. This is a complete front clip to a Triumph Spitfire, one of many body panels he’s made molds for. He makes tons of body panels for Datsun 510 Race Cars as well as Formula Ford’s, Hyundai and Subaru  Rally Cars and the occasional Classic Italian parts for me. I’m always blown away with the quality of work that Max churns out and amazed at his attention to detail to make the parts very rugged while staying extremely light weight.

Later this week I’m going to show you photos of brake cooling ducts that he makes for a major Catalog that sells race car parts so stay posted for these incredibly light weight and rigid examples of “black art”.

Body parts for Triumph Carbon Fiber

GTC for Sale 330

Here is a Super nice 330 GTC that a customer of ours is interested in selling. We’ve gone through all of the mechanical components within the last two years such as the engine, transmission and numerous other details. This car is outstanding and is ready to light ‘em up for 2012!

This is a subject that I write about frequently because I just don’t understand why Ferrari Transmissions are bigger than the engine in front of it. We just had a transmission out of a 1955 Ford Pickup that was the size of a shoe box and a 5 speed ZF transmission out of a Maserati is tiny compared to the 5 speed out of this 330 GT 2+2. If I seem frustrated it’s because getting this Parthenon out of the car is a job that only Zeus can handle.

This transmission works well but the synchronizers are worn to to point of having a chrome plated polished look instead of the required rough cast finish but all the bearings and gears are perfect. We used to replace the operating sleeves on these transmissions but they take so long to “wear in” that I feel they are doing more damage than good especially considering how well they shift with the original parts re-installed.

5-speed 330 Transmisison

Re-finish Ferrari 330

It doesn’t look bad in this photo but the paint on this 330 GTC is displaying it’s age with small cracking, a few minor rust bubbles and areas where its flaking right off the sheet metal! I was looking carefully for signs of the original color which appears to have been blue from new. There is a hint of red paint around the front window but I can’t tell if the car was red at one time or if it was just some extra protective coating in an area that needs lots of rust protection. The car will likely be re-painted a dark blue.

330 GTC in for Paint

Stainless Steel Water Pipes 250, 330

Tubing for Ferrari engine

Since I have the jigs, stainless steel tubing and motivation, I decided to stock up on some commonly used water pipes for Ferrari 250′s. The top photo is a mixture of trashed original parts and my re-made parts that attach to the water pump and have a barb for the heater return and a threaded boss for the thermostat bypass. The pipe in the next photo is a custom job for a repilca 250 that was sent to me for duplication. This part doesn’t follow any of my jigs so I made a crude jig to complete this order. I’ve done 4 pipes recently for 1962 Ferrari 250′s, an early 1962 GTE, a ’62 250 PF Cab and two 1962 Short Wheelbase Berlinetta. Even though they should all be the same, all 4 of these are significantly different with barbs going in different directions and the main bend radius unique from one to the other. I’d like to know how these were made originally because there isn’t any consistency in  the style of construction or shape.

It’s only original once.

This Ferrari 330 GT 2+2  interior is original but the wear and tear is getting a bit out of hand with cracked and split leather and blown out webbing in the seat bottoms.  The drivers seat is so crushed down that I couldn’t even see over the dashboard! The owner was thinking of changing the color but wisely decided to keep the red leather (slightly darker, less pink) and red wool carpets. Even though the headliner is in good condition, we are going to replace that material since the foam in the pleats is falling out and the glue is coming undone here and there.

Red Leather seats upholstery for Ferrari

Leather for Ferrari 2+2

Re-upholster 330 Interior

Head gasket and oil leaks

Since the late 80′s or early 90′s we have been servicing the car that goes with this engine and it has always been one of the best running examples we know of. I remember riding in the truck with my father to get the car on a cold and foggy night, probably around this time of the year, no, it had to have been early November. It was a brutal trip through that pea soup thick fog as we went over some of the mountains in the Berkshires on route 22.

The current owner of the car drives the wheels off of it and we have overhauled a number of components like the brakes, transmission, and fuel pump but now it’s time to address the engine. It runs great, starts instantly and doesn’t smoke but there are so many oil leaks that we have to break it down to clean it off in order to remedy them. We were blown away because as well as it ran, the compression and leak down numbers were bad displaying 30% loss in some cylinders where there should be no more than 5-10%.

So, apart it goes – it’ll run through our “process” that includes getting the rear main bearing cap cut and grind the crankshaft for a conventional lip seal, new forged pistons and a needle bearing roller follower set among thousands of other things. The motor mounts are blown out and the water pipes will likely have holes in them and will need to be replaced so we will be busy this winter getting all these 250′s back together for the spring.

As much as I hate to mention it for superstitious reasons, we’ve had great success with Ferrari engine overhauls over the last half a dozen years. A few times a week other shops call me asking how to get head gaskets to seal and how to make water pumps turn without leaking or how to make mechanical fuel pumps to work as intended. Their shops are struggling to find the exact formula, and we seem to have it locked down lately. Nate has assembled so many of these engines, he seems to have a real formula on setting the clearances, knowing the tricks to seal them up and making sure every detail is nailed down too.

Clutch housing on 250 engine

Blue Sera BB

Ferrari 512BB Blue

The new Canon G10 is working out well as you can see from these photos. Admittedly, part of the reason they’re so sharp is because I shot them at the end of the day with that mystical diffused light coming through high clouds which eliminates the major dark and bright patches on the car. Bill gave me some tips on standing way back and using the zoom to fill the lens with the car which gives the image such better depth. This camera has been great. Keep an eye out for more amazing displays of photography in this blog!

More Group B Fun

While I am obsessing about the Audi Coupe, here’s a good article in Hemmings Motor News on the Cars of the Group B Rally series in the late 80′s. The RS200 Ford is my all time favorite and one of these days I will own one.

You can’t really look back at the Class of 1986 without taking a look at the Group B homologation specials that reached their zenith that year, the last for the highly advanced, extremely powerful and now legendary rally cars.

The original intention of the FIA-sanctioned Group B rally and sports car racing category, accepted for the 1983 rally season, was to replace Group 4′s homologation regulation of 400 units with half that number to encourage more manufacturers to join the fracas. With a need to produce just 200 cars, the acceptance of all-wheel drive, exotic materials and very low minimum weight restrictions, manufacturers pulled out all the stops and created street-going race cars, like the outrageous, flared-fender MG Metro 6R4… read more at Hemmings.