Archive for 166 Touring

Hundreds of Hours of Labor

Carrozzeria Touring Berlinetta

Carrozzeria Touring Berlinetta

Ferrari Headlight detail

Ferrari Headlight detail

Touring Carrozzeria Body Dashboard

Touring Carrozzeria Body Dashboard

High Build Primer Ferrari

High Build Primer Ferrari

Here are a series of photos of the block sanding process on the Ferrari 166 Touring Berlinetta. The sheet metal is all sorted and gaps are perfect but the body needs hundreds of hours of serious elbow grease (sanding) to make sure it is all straight as an arrow. Syl isn’t scared of the “mud”, he completely fills in all of the door and hood gaps allowing him to block sand right across them so when the light hits the highly polished top coat you won’t see any waves or change in reflection.

Even though the grill we made fit the opening in bare aluminum, Syl spends hours making it perfect with skim coats of body filler and attacks the headlight rim contact areas with the same level of perfection. There isn’t any room for error when working with super fine trim that is used all over this car like the delicate headlight rings and the low profile windshield and rear glass surrounds. Imagine these surrounds,  start with a long  section of 1/4″ aluminum rod and whittle it down so only a quarter of it is used.  We re-made this trim because the delicate original material was destroyed when the car was disassembled.

Right now, the car is sealed up in high build primer with a blue tinted epoxy primer that seals the polyester filler from moisture and greasy finger prints. Now we have some more fitting here and there before it goes back to Syl’s shop to work out some more details such as the incredibly complex belt-line crown that goes from the headlight to the tail light..

We’ll probably have more hours in sanding and painting the dashboard that it would take to paint an entire late model car like a Mercedes or Honda. The dash on this car is a thing of beauty but it requires a perfectionist sicko to finish it because like the rest of the car, the trim that surrounds the gauges and switches are like string bikinis

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Another Jig for Stainless Steel Water Pipes

If I were making a production run of something, this isn’t how I would do it. Ferrari made thousands of “250″ series cars all with these goofy water pipes for the cooling system which vary drastically throughout the 10 year production run.  They are so complex and hard to duplicate that re-making them nearly impossible. This “J” shaped pipe has a compound curve with barbs that have to be welded on in exactly the right location even though they appear to be stitched on at random locations. If they are off one millimeter, they will hit the oil filter or run into the fan.

These pipes are for the Lusso/GTE series of 250, but I can make a number of other styles from 166 up through the 275 cars utilizing my incredible and growing stockpile of bends and flared ends. Right now I am making a short run of the water pipe that connects the thermostat housing to the engine on a 275 GTB/GTS Two-Cam engine.

Water pipe for Ferrari

Water pipe for Ferrari

Water pipe copied for Ferrari

Water pipe copied for Ferrari

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Cleaning and Ebaying

IMG_5760We cleaned out the attic over the holiday and discovered a number of items that we’ll be putting on eBay in the coming weeks. Currently listed are a Bosch Voltage Regulator (black box BOSCH) 6v 12v volt for returning your classic back to the original configuration – or just the look.

Ferrari Bonaldi Brake Booster for rebuild will only stop you in your tracks in it’s current condition – not working – but in very nice cosmetic shape.

A rare Ferrari 275 GTB and GTB/4 Egg-Crate Grille Brandoli reproduction isn’t easy to come by and is in good condition.

Marchall 660 Fog Lights for Ferrari 250, 225, 212, 166 will actually look at home on a variety of other cars including Porsche 356, Mercedes 300, etc.

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Fitting rear glass

166 rear glass

166 rear glass

Side glass plastic

Side glass plastic

Side glass profile detail

Side glass profile detail

Even though the original rear side glass for the 166 fit terribly, I used them as a rough outline to make new pieces from plexi-glass. It still took 4 hours of sanding per side to get it to fit tightly. These windows open at the rear for ventilation and the reason Touring made them from plastic is to allow them to bend outward without a hinge as the cam mechanism pushes it out. Crude. In the photo with the drawn outline you can see the original shape being so much smaller than what it needs to be in order to fit properly.

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Beautiful workmanship

Can you believe how much labor went into building this dash? I would guess that the bulk of the piece was hammered out to fit a profile but the stepped bores for the gauges were made from a two piece press die, simply and amazing number of hours to fabricate this piece.

This piece had so many layers of primer, filler and paint that it has taken about 8 hours to strip it down to bare aluminum and will take another 20 hours to re-finish it in the dark blue color that it was originally. There are more man hours in this dash than goes into assembling a new Pontiac!

166 Touring dash panel

166 Touring dash panel

Touring berlinetta

Touring berlinetta

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One of my Favorite Conversions Solutions Revisions

We rarely have to repair rear axles and usually just clean and inspect the bearings and install new oil seals. Be it a Jaguar, Chevrolet or Alfa Romeo, it is rare that we see a ring and pinion that is damaged or bearings that are worn out. I hate to disturb the factory relationship between the ring and pinion gears so if the bearings check out ok, I keep the thing together.

Additionally, most car companies have figured out how to make the final drive robust and problem free because they are aware of the forces involved with the ring and pinion bevel gears – except for Ferrari. They used a deep groove ball bearing and sliding inner race roller bearing that cannot handle the axial loads on the pinion shaft. Other companies used tapered roller bearings that can handle a tremendous amount of this fore-and-aft thrust while spinning with ease but the Ferrari style comes apart and destroys the gears.

My solution is to replace the sliding inner race roller bearing and the deep groove ball bearing with a pair of tapered roller bearings. This photo is a 250 GT Lusso center section with the “chicklet” style limited slip differential. On some axles I’ve install tapered roller bearings to support the differential but on the later axles there isn’t much room to install this type of bearing and I have found the original ball bearing set up to be adequate. I have done this conversion to many cars that have gone many thousands of miles with no issues.

Final drive Ferrari

Final drive Ferrari

GT Ferrari 250 Axle Center section

GT Ferrari 250 Axle Center section

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Ferrari 330 GT 2+2 transmission

Still looking for someone to explain to us why Ferrari went from the compact light weight and wonderful shifting transmissions in the early 166/195/212/225 cars to enormous and heavy cast iron transmissions on the later 250/330/365′s. Here are photos of the 330 2+2 5-speed and a 166 5 speed. There is about 100 lbs difference in weight and a considerable size difference. Did Ferrari use some truck or tractor transmission for these later cars?

The blue 330 GT 2+2 that came in earlier this year ended up needing an engine overhaul but I was fortunate to be able to drive the car prior to breaking it down. The transmission shifted perfectly but on acceleration/deceleration the shift lever moved back and forth significantly. As some may remember, this same thing happened to a 330 GTC transmission a few years ago and it turned out to be a loose ring nut on the main shaft.

I was certain that we had the same issue on this 330 2+2 and when I took off the top cover, it was instantly obvious that the ring nuts at the back of the main shaft holding the gear cluster on were totally backed off. They are doubled up to jamb together to prevent loosening plus there is a locking tab for extra protection on backing off… but still, someone managed to mess this up. Thankfully no damage was done to the internals.

Huge Ferrari transmission

Huge Ferrari transmission

Early Ferrari 5 speed aluminum transmission

Early Ferrari 5 speed aluminum transmission

loose ring nuts on a Ferrari transmission

loose ring nuts on a Ferrari transmission

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The Shop – March 2010

Bill took a few pictures from around the shop today that show both the range and the beauty of some of the cars that we are working on. Sometimes I fear that there is too much “range” and not enough beauty! Bill takes outstanding photos that look super pro. Have I written a post on Bill yet? Bill, can you write a post on yourself, introduce yourself?

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Upstairs: the Osca, Whitehead Special, and a silver Ferrari

Downstairs: The rare green 330 GTC and a deep inventory of stored classics, projects, and restorations.

Downstairs: The rare green 330 GTC and a deep inventory of stored classics, projects, and restorations.

Ferrari 750 Monza at Restoration and Performance Motorcars in Vermont

Ferrari 750 Monza at Restoration and Performance Motorcars in Vermont

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More Stainless Steel water pipes

We have made jigs for re-producing the often rusted and leaking water pipes for Ferrari 250′s. These are not  perfect reproductions but now that we have the tooling we can easily make an exact copy if anyone is interested. We are using Stainless Steel so they won’t rust away like the originals.

Ferrari tubing

Ferrari tubing

250 water pipe

250 water pipe

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100mm Carello Tail lights

These are 80mm Carello Tail lights, where can I get the identical ones but 100mm in diameter? These were on a Vignale Ferrari 225 Berlinetta at Cavallino and I need the 100mm ones for the 166 Berlinetta that we are restoring.

Tail light

Tail light

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