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Some TLC for my QV

Discussion in 'Mondial' started by afterburner, Mar 25, 2015.

  1. afterburner

    afterburner Formula 3
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    #51 afterburner, May 22, 2017
    Last edited by a moderator: Sep 7, 2017
    The headliner was trimmed by clearly defined section, one by one, paying attention to not spray any glue on the visible side by accident, and not creating any pleats. Working alone is a challenge for stretching a tough fabric onto complex shaped while holding everything, and never touching the glue. Within setting time of it. A special challenge presented itself in the form of the sunroof opening as the fabric has to be stretched around inside a concave overall shape while still meeting correctly at the centreline on the header rail. No pleats, no missing fabric, just right. I have no idea how this was done during production. It took me 4 hours to glue the basic fabric, and another 4 hours to trim it all around the edges and holes. Installing it alone is another challenge; you need to push, squeeze, pull, move, position all at the same time. It's back in the car and looking very neat.
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  2. afterburner

    afterburner Formula 3
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    Thank you. I have scraps available should someone need.
     
  3. afterburner

    afterburner Formula 3
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    #53 afterburner, May 23, 2017
    Last edited by a moderator: Sep 7, 2017
    Roof Grab Handles - three shades of aged plastic on the remaining original handle, black on the replacement handles. All repainted with Sikkens plastic primer and Tamiya paint, a perfect match for what I believe to be the original beige (the soft handle section), and the headliner fabric. Assembling them is challenging, and without scratching the rather fragile paint, almost impossible. Paint brush re-touch was needed. They are holding the headliner up and aren't for any practical use as grab handles as they are far too fragile.
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  4. afterburner

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    #54 afterburner, May 23, 2017
    Last edited by a moderator: Sep 7, 2017
    I had recurring issues with the A/C belt snapping, often taking off the combined alternator/water pump belt in my "single belt" car - we are talking every 6 months average. As A/C is not optional in Hongkong's tropical climate, and with the original York compressor's poor performance (no A/C when standing still) I decided to convert the car to the later "double" belt version with Sanden compressor. I need to stress that my car's mechanical state is by no means substandard:
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  5. afterburner

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    #55 afterburner, May 23, 2017
    Last edited by a moderator: Sep 7, 2017
    The result of the conversion is fantastic: The A/C is permanently working even in traffic jams in summer, and all belts have been on for the last 17'000 miles (1 year now) with none showing any signs of wear. I haven't switched the A/C off since the conversion. Here the result:
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  6. sixcarbs

    sixcarbs F1 Veteran
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    Is that a Pioneer BBi Equalizer? If so, well done and sweet!
     
  7. afterburner

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    #57 afterburner, May 23, 2017
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    What I found is that someone had "upgraded" the original spec Aspera HG850 compressor with a larger displacement York 210 and replaced the orignal serpentine-type copper condenser with a modern (theoretically more efficient) aluminium cross-flow type. Well, it didn't exactly work. Below a chart that summarises the various Aspera/York/Climate Control and Sanden compressors in relationship to their capacity, power requirement and output at 3'000rpm. It's obvious that the Sanden is good, and with 5 pistons on a wobbly plate it cuts in and out so smoothly it's hardly noticeable.
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  8. afterburner

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    #58 afterburner, May 23, 2017
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    There is an early and later version of double belt cars, incl 3.2L. The early ones use 3 Polyflex belts, the later 2 Polyflex and 1 traditional V-belt. I opted for the early version. Here the summary of all belt and pulley variations with diameters and part numbers for your reference:
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  9. afterburner

    afterburner Formula 3
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    :) and original TS-107 rear speakers too
     
  10. afterburner

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    #60 afterburner, May 23, 2017
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  11. afterburner

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    #61 afterburner, May 23, 2017
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  12. afterburner

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    #62 afterburner, May 23, 2017
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  13. afterburner

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    #63 afterburner, May 23, 2017
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  14. afterburner

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    #65 afterburner, May 23, 2017
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  15. afterburner

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    #66 afterburner, May 23, 2017
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    Restored second hand compressor brackets and tensioner, plus correct compressor head and new pulley/clutch assembly. NOS SANKYO SD-508 compressor off eBay.
    308/328 use the smaller SD-507. The Mondial has approx 40% more internal volume compared to the 308, with 2 people on board.
    The only non-OEM element is the condenser fan, a locally sourced Japanese after-market product. Its power is lower than the original's, but it seems perfectly capable of handling the air volume needed for the heat transfer while drawing less current.

    Important note on Ferrari 308/328 and Mondial application of Sanden compressors: For packaging reasons, the compressors are mounted reversed to traditional applications (they face the front of the engine, unlike the water pump and alternator that are turning the same way as the crankshaft). The SD series of the Sankyo/Sanden compressors (R12 generation) are compatible with either direction operation as they incorporate a straight cut conical gear set driving the wobbly plate.

    When R12 got replaced with R134a, Sanden released a replacement series of compressors with the same performance and form factor for plug'n'play applications during repairs and refrigerant upgrades. Those compressors are designated SD7 something. They were also internally redesigned for lesser resistance and reduced noise by the use of angled cut gear sets.

    SD7 compressors cannot be used in reverse application as they will self-destruct after a while due to the gears pushing the wrong way (much like using your final drive in reverse). I have double checked this with Sanden in Britain because certain tech sheets state that SD7 compressors can be used either way. Except for 1 product code (incompatible with Ferrari application) this is NOT true.

    I don't know if the Chinese knock-offs use straight or angled cut gears.
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  16. afterburner

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    #67 afterburner, May 23, 2017
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    The fluffy strip in the sunroof's gasket became so hard that the panel started to bind, eventually leading to the breakage of the pin moving the panel. The second-hand replacement cable had a bent pin axle and a broken plastic sleeve without top cap... With the help of remaining parts, FC members and my father's skill I have a good as new sunroof cable.
    I removed the fluffy bit of the gasket and treated the rest with Silicon Paste to soften it as much as possible. The restored roof now works normally again.
    Also, the deflector spring blocks and guides had become brittle and broke apart. Rapid Prototyping parts solved that problem - how long they'll last we shall see. They could always be milled in aluminium from the same data set.
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  17. Jeka

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    Excellent job!
     
  18. afterburner

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  19. theunissenguido

    theunissenguido Formula 3
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    I'm always impressed with the things you make !
    Keep going on...

    Guido
     
  20. afterburner

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    Thanks Guido! The car keeps going thanks to your electric board ;-)
     
  21. ronfrohock

    ronfrohock F1 Rookie
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    Just incredible work! Seriously very impressed. You are very talented!
     
  22. afterburner

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    Appreciate it, thanks, Ron.
     
  23. afterburner

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    2016: 10'228 miles, no break-down to report. Average fuel consumption in mixed driving condition 12.4L/100km - 19mpg (US) - 22.9mpg (UK), with full A/C and in hot air, which reduces the engine efficiency as we all know.
     
  24. jjeffries

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    I too find your work incredibly impressive. Not many people have your skill set(s). Lovely car, too. John.
     

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