Here is the BB engine, finished up and running on the stand with a link below to see it on youtube. No leaks! Needs a little more tuning but this is the second start up and it ran very well. Since this video was taken, we dialed in the carburetors and it sounds amazing.

There were a bunch of leads as to why this engine overheated but we aren’t sure exactly which problem led to its demise. The water pump looked nasty, maybe it failed and blew all the water out of the weep hole or maybe the head gasket failed. Once we finally got the case split, we found that the cylinder protrusion on the 7-12 bank was .007-.012″ where it should be about .003″ from the deck surface so the gasket may not have sealed around the water passages.

Since the engine was burning a little bit of oil when it ran and the 2nd gear synchro needed to be replaced, it reinforced the need to overhaul this drive train. We are thinking of enhancing the engine with slightly higher compression pistons and increasing the flow by matching the intake manifolds and testing and enhancing the intake and exhaust ports.

A problem with the Ferrari Boxer design arises when you wash the car or drive it in the rain and water pools around the main bearing studs causing a major corrosion issue between the case and the studs, “gluing” the halves together. We made steel blocks that use the main bearing nuts to push the halves apart as you un-thread them but it didn’t work at all. We ended up making hardwood wedges to drive in with a hammer and 3 portable hydraulic cylinders so after nearly a week of labor the job was finally done.

Have a look at the massive amount of corrosion on the studs!

Boxer engine

12 cylinder horizontally opposed

Case halves BB, BBI

It can be so demoralizing to work on old cars, even worse working on Ferraris! After overhauling the engine on the blue 330 2+2 and addressing a bunch of other issues, we drove the car and experienced a major vibration that is present under high speed. Whether the car is coasting in neutral or in gear, anytime you go above 50 mph the feeling is there. We suspected that the original Ferrari driveshaft with the rubber flex joint was the problem even though everything looked good so I sent it to be balanced and checked for run-out. The vibration was still there so I checked the transmission and rear axle flanges for run-out, both of which were perfect so after experiencing problems with numerous Ferrari driveshafts, I opted to make adapters to convert the shaft to a Spicer-Hardy U-Joint style. Nate installed the new shaft and guess what, still a vibration (although much less). Could it be a bent pinion shaft or bent main shaft in the transmission?

I assembled a Ferrari 250 engine and got to the cam timing today only to realize that the valve height was not set correctly, so all apart again!

A car deal blew up in my face as well, only because of a minor miss-communication no less.. I could really have used that deal to keep my quota up to maintain my dealer license. It is so hard to broker car deals and so rewarding to sell something that either we own or have at the shop. When the car is gone, there is so little control.

What else…. We have a low mileage 512BBI all apart for a major service which is becoming a major engine bay clean up, not such a big deal but how does a legitimate low miles car look so ratty? It won’t take much, a little paint here and there will tidy up things immensely.

Here is a photo of the BBI engine out and apart to replace the lower timing belt drive pulleys as well as a major service which includes valve lash and new cam belts.

Oh yeah, the brake shoes that we sent to be re-lined for the Monza are way to thick and the newly re-sleeved drums don’t fit over them! Ahhh!

BBI belt service

We dynoed this blue 512BB last summer, and I cannot remember the exact figures. But, I do remember the incredible torque curve and how it made the maximum HP and torque at 5000RPM then plateaued out. I think it made just under 300HP at the rear wheels. We are going to be overhauling and enhancing this engine soon and it will be cool to put it back on the dyno to see the new numbers.

Here’s a link to a similar 512BB on the dyno this winter – this time in red. http://www.ferraricraft.com/2010/01/video-1984-ferrari-512-bbi-at-the-dyno/

We took the red 1984 Berlinetta Boxer to the dyno this week. The video has great sound, but turn it down if you’re at work.

People have accused me of being too technical on this blog, they think that I should make it more appealing by showing great photos of the cars and making it more slick but this is my effort and the technical stuff it what interests me. I was going to work with a marketing guy to get us a nice image, capitalize on the sex appeal of these cars but it just does not work for me and I do not have the time to stage scenarios and have posed photos. What I am documenting is the day to day of what happens at the shop and why working on machines whether it be tractors, air conditioning units or classic cars, this is what I am interested in and hope that my readers can appreciate it.

Here is a slightly staged photo of a spectacular casting that like so many castings by Ferrari is both beautiful and a marvel of engineering. The forethought that went into making this to work as a transmission casting, differential housing, oil sump  as well as the surface to carry the engine is remarkable. It also carries internal porting for the scavenge and pressure side of the dry-sump oiling system for the engine. Since the transmission has its own oil pump, there is porting for pressurized oil system to lubricate the gears and bearings.  Ferrari spent so much time engineering this sort of part while selling so few cars that it seems that they should have been even more expensive to purchase when new.

I hope you can enjoy these photo. By the way, this part is huge, you could fit about 5 cats inside it.

Transaxle housing for Ferrari 512BB

Transaxle Casting Ferrari

A few posts ago I reported on a 1984 Ferrari 512 Berlinetta Boxer that had a knocking sound in second gear. It sounded to me like a bad cluster or a bearing with some debris caught in the race. When I jokingly called my main man Geof at Partsource (http://www.ferrariparts.com/)  asking him what he could sell me to fix the problem without disassembling the transmission, he told me that I was the 3rd person in the last month asking for the second gear cluster!

He wanted me to get him the acid etched part numbers on the gears to determine if they were shaved or ground gears but I said, “who cares if they are shaved or ground, I want a matched set of ground”.  Leave it to Ferrari to have even thought shaved gears would hold up to the torque that these parts need to withstand. By the way, if the odometer and the condition of this car is correct, there are less than 10,000 miles on this transmission! Great stuff! I could not find any acid etch numbers to confirm that the gears were shaved but I am sure that they were and not the higher quality ground gears.

As you can see in the photos, the smaller gear has many pits from metal fatigue, not from abuse or lack of lubrication, just poor quality materials and process. What a bummer.   Geof just located gears from a Testarossa transmission that cost a prohibitave amount of money but at least this transmission will not be apart for months and months while we wait for gears to be re-made!

Ferrari Boxer transmission repair