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Rebuild of 400I Chassis 40877

Discussion in '365 GT4 2+2/400/412' started by Al Campbell, Dec 15, 2013.

  1. bundas

    bundas F1 Veteran
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    Dec 31, 2005
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    mitchell barnes
    a masterpiece. surely you will not drive it on the road. is your living room large enough to have this as a work of art
     
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  3. islerodreaming

    islerodreaming Formula Junior

    Aug 11, 2007
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    Al lives in the perfect place for this car - the roads are wide and straight (in some cases for kilometer after kilometer), surface good. Only downside is the heat in summer - mid 40's avg! But for that run to the shops with the wife (1500klms to Adelaide) it would be brilliant!!

    John
     
  4. simsko

    simsko F1 Rookie

    Feb 5, 2012
    3,619
    Great to see the progress
     
  5. Al Campbell

    Al Campbell Formula Junior
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    Nov 22, 2013
    483
    Australia
    Thanks everyone for your comments.

    It will get driven - the missus said it is not allowed in the house!

    As John said it is the perfect place for a car like this especially with our open speed limit North of town. Our other 400i (30847) is getting a bit of use but I can't wait for the cooler weather again to get it out more often.
    Having the other 400i on the road means I can do a full restoration on this one not just get it back on the road which was the original plan. I am also going to return it to it's original colour - Nero Tropicale. It will be a slow build as I save up for parts & do as much of the work myself as I can. So far it has been an enjoyable process (except for my bank account) & I'm making new friends around the world chasing up parts. There has been a long list of parts I've been sourcing but have managed to find most of them now.

    Cheers Al
     
  6. alastairhouston

    alastairhouston Formula Junior

    Apr 19, 2009
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  8. Al Campbell

    Al Campbell Formula Junior
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    Nov 22, 2013
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    #81 Al Campbell, Mar 12, 2015
    Last edited by a moderator: Sep 7, 2017
    Thanks Alastair.

    I have a long way to go yet but if I keep breaking it down to manageable projects it will get there.

    The rear shocks & load levellers have now arrived. :)

    Cheers Al
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  9. GT Jones

    GT Jones Formula Junior
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    Any spring rate markings or part numbers on the black coils?
     
  10. Schumi

    Schumi Formula Junior
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    Jun 5, 2002
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    Daren
    Are those new items? If so, where sourced and are they as original equipment?
    If not new, did you have your old ones rebuilt? If so, by who?
    Thanks
     
  11. Al Campbell

    Al Campbell Formula Junior
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    Nov 22, 2013
    483
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    New.
    Shock #105059 from awitalian & load leveller is a coil over replacement #100807R from T.Rutlands. I have not seen any numbers on the spring.
     
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  13. GT Jones

    GT Jones Formula Junior
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    Arrrgh Rutlands!!! I've been searching for that spring rate forever. All coil springs have the rate printed on them UNLESS the distributor wants it to be blank. Nobody seems to know the rate...
     
  14. Ak Jim

    Ak Jim F1 Veteran
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    Dec 23, 2007
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    Can the springs be tested to determine their rate?
     
  15. GT Jones

    GT Jones Formula Junior
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    #87 GT Jones, Mar 14, 2015
    Last edited by a moderator: Sep 7, 2017
    Absolutely, but spring rate measuring equipment is pretty hard to fine. Road race shops may have one, also circle track guys use them. I found only one place in the greater boston area that had one; KTR in Ayer, MA.
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  16. GT Jones

    GT Jones Formula Junior
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    I now have the coil over kit to replace the Koni load levelers and they use a hyperco spring 1812B0150 which is a 150# spring.
     
  17. GT Jones

    GT Jones Formula Junior
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    #89 GT Jones, Dec 26, 2015
    Last edited by a moderator: Sep 7, 2017
  18. samsaprunoff

    samsaprunoff F1 Rookie
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    Good day Christian,

    Excellent, thanks for the info!

    Can you provide any more details on the coil over kit you mention?

    Cheers,

    Sam
     
  19. Jim575

    Jim575 Karting

    Sep 26, 2011
    89
    Sydney Australia
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    Hi Al
    Would love to see more progress photos of your car if you have any?
    Jim
     
  20. Schumi

    Schumi Formula Junior
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    Daren
    I wonder if that spring could be used to replace the stock unit and keep the original self-leveling shock? I would like to find an OEM replacement rear shock if anyone knows where it can be purchased.
     
  21. GT Jones

    GT Jones Formula Junior
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    #93 GT Jones, Dec 29, 2015
    Last edited by a moderator: Sep 7, 2017
    Daren, the stock springs have a huge diameter. I dont have one handy but it may be 3 or 3 1/2". The 'standard' is 2 1/2" and you can find a variety of lengths & rates in that size. The trick will be to fabricate a spring perch to suit the smaller size. I found a threaded collar to slip over the Koni shock body and managed to fit 2 1/2" springs to replace my stock springs.
    Rutlands sells the coil over kit and there are a few other sources online that might offer cheaper/quicker shipping. The kit pictured has a threaded shock body to adjust ride height. I'm still sorting spring rates so I cant suggest what might be a good rate to use if you change the forward set of springs.
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  22. Al Campbell

    Al Campbell Formula Junior
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    Nov 22, 2013
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    Just a quick update on 40877. After sitting idle in the shed for quite some time I have now returned to this project. Having another 400i on the road meant this project wasn't as high a priority but I will try & keep it moving this time. Today the engine came out - will need a bit of work as the timing chain has no adjustment left.

    Cheers,
    Al
     

    Attached Files:

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  23. samsaprunoff

    samsaprunoff F1 Rookie
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    Good day Al,

    It looks like you are well under way! Best of luck with your progress and please keep posting pictures along the way! I am hoping to get back to my car later this year... and I will be removing the engine as well.

    Cheers,

    Sam
     
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  24. Al Campbell

    Al Campbell Formula Junior
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    Nov 22, 2013
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  25. Al Campbell

    Al Campbell Formula Junior
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    Nov 22, 2013
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  26. Al Campbell

    Al Campbell Formula Junior
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    Nov 22, 2013
    483
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    The engine is coming apart.
    Next step is to make up a plate to pull the heads off (as per cardboard template).

    I also made up an injector puller this morning from an old wheel nut, a bit of round stock, a 1/4 bolt & a couple of wingnuts.
    It works great. :)

    An interesting side note I discovered that the timing chain is exactly the same as the 2.9V6 Cosworth BOA 24valve engine I have apart at the moment and they both drive 4 camshafts with 6 valves on each.
    It's also interesting that the v6 Cosworth engines chain is about 300mm longer than the 400's.

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  27. Al Campbell

    Al Campbell Formula Junior
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    Nov 22, 2013
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    Head puller plate manufactured & heads have now been removed. :)

    The head puller plate was made from 10mm thick steel plate. I was after a plate 620x220mm but a 620x200mm plate was much cheaper so I ended up welding a piece of angle iron along the edge to give it enough width. This plate made the head removal a very easy task even with a bit of corrosion on some of the head studs.

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  28. simon klein

    simon klein F1 World Champ
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    Feb 25, 2009
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    Good job Al,you could probably rent that puller out.
     
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