A year in the life of BiTurbo228 - Part 1 (Fiat X1/9)

"BiTurbo228 - Dr Frankenstein of Spitfires" (biturbo228) 01/10/2020 at 10:05 • Filed to: Fix It Again Tony

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Hey folks, long time no speak! Been loitering around here less and less since work barred kinja websites so I can’t peruse at lunch, but thought I’d keep in touch with what’s been happening. Stick with me, it’s been a busy one!

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So, we last left the Fiat as having been !!!error: Indecipherable SUB-paragraph formatting!!! post- !!!error: Indecipherable SUB-paragraph formatting!!! . Since then there’s been many ups and downs over the course of an irritatingly low number of miles...

Running problems

Not long after fixing it, it started running rich again which similar symptoms to the last time (that was fixed with a new rpm sensor).

However, it would only do it while it was wet and cleared up when it was dry so playing around with the sensor so figured it must be something electrical with water ingress. Fiddled about with the sensor and noticed that the seal at the end of the wire was letting water in. ‘Aha, gotcha!’ I wrongly thought. Replacing that didn’t help. Bugger.

After months of on and off searching about, I noticed this little shitter:

Notice the tiny little drip poking out of the sheathing for the white wires at the top. This bastard was tracking out of this drain hole in the engine cover...

...soaking into this braided section of loom...

...and dripping out directly on top of the plug for the ECU! Man that took some figuring out! However, with everything cleaned, dried and waterproofed the running issues improved massively! Big success :)

Gearbox swap

Also, I hadn’t been idle while I was scratching my head about this. One of the things that bugged me about the car was the awful gearchange. Even with the phosphor-bronze bush it was still not great, and the gearbox was already showing the strain a little from just 130bhp and had started being pretty reticent to get into reverse...or fifth...or first...or any gear a little too quickly.

There’s a much stronger gearbox that people sometimes put on Uno Turbos from a Punto GT (which I can also fit an LSD to!). The only issue is that the gearchange is on the top so poses some problems when you try and put it in an X1/9. I read about someone converting one using MGF cables so figured I’d start there. Here are the two next ot each other:

The MGF linkage seems like a pretty good design. The only issue is it’s bloody massive. The previous chap only shaved down the counterweight and bolted it directly to the tunnel, but that required a modified centre console so I thought I’d have a go at cutting it down to fit. Shaved it down to:

With a bit of modification it’ll slot down into the gearbox tunnel.

Had to shave down the rotating part to clear the tunnel, and relocate the window switches but it fit!

At this point, feeling very smug for myself, I realised that the chap who used the MGF cables never got to the end in his thread. Turns out, they’re much too long...

While I was scratching my head around that I clearanced the body to fit the gearbox...

...and came up with this:

The bottom picture is the new cable end. The yellow is an M10 threaded sleeve which threads snugly onto the rubber of the MGF cable (I tested it with an M10 nut which held on pretty strongly so a 30mm run should be solid. If not I’ve bought some rubber-to-metal glue). That slots into an M16 threaded sleeve (pink) and is welded in place.

A 30mm (or better 35mm) M16 bolt (light green) is threaded into that which clamps it against the gearbox bracket (brown). An 8mm hole is drilled through the M16 bolt, and into that is pressed an 8mm hard nylon tube from an air line to provide a bearing surface (dark green).

The upper picture is the swaged on threaded rod that connects the cable to the gearbox arm (green). Onto that is threaded an M6 female rose joint (purple) and a locknut (red). The light blue is an M6 nut with a couple of tabs welded on that bolts to the first rose joint, and into which the pink male M6 rose joint threads with its locknut. The second rose joint then bolts to the gearbox.

The reason for having two rose joints is that the gearbox arm describes an arc as it moves, so the inner rose joint allows the outer one to follow that arc. Without this, the swaged rod would bind in the M16 bolt (or you’d have to widen the central hole through the bolt to allow for the movement which would make it wear oddly). The stock cables get around this by having the nylon tube that supports the rod swivel at its base.

Overall, the double-linked rod is only a couple of millimetres longer than the plain rod (could be less if you had half-nuts for locking, but I’m not sure how good of an idea that is).

Two weeks later and we had a working gearchange!

Man those clacky noises are satisfying :) Nice feel with the rose joints as well, although will need to compare that to the added vibration coming back through them when it’s running.

The shortened cables worked a treat. Bought two long MGF cables and cut them both down to size (the short cables would have worked for the shorter of the two, but they’re always in worse condition than the longer ones second hand). Here are the dismantled bits for it.

Unfortunately, at this point I discovered that one of the linkages operated the gearchange in the wrong direction :S so reverse and 5th were on the left, and first and second on the right. Not good.

Luckily, the MGF linkage isn’t overly tricky to swap around if you have a decent welder. Little swingy arm from the right to the left and we’re good!

Stuck everything together, and fixed the window motor switches into some blanks on the switchpanel and the linkage was sorted :)

Then it’s just the niggly little bits to fix. First off was the old engine mount not fitting nicely. Bit of fabrication with some Ford Cortina rear leaf spring bushes and I came up with this:

Next was the speedo drive. I should have changed this for the X1/9 type when I had the gearbox open to fit the LSD, the issue being that the speedo cable on the Punto is much bigger. Some headscratching, some nicely fitted brass square tubes and some chemical metal fixed that :)

After that was the alternator. Because I’d also fitted equal length driveshafts (Uno Turbo Mk2 intermediate shaft and a second X1/9 LH driveshaft), the alternator mount had changed place slightly. Quick chop and weld of the tensioning bracket and it was all good :)

As a bonus, the Punto gearbox comes with a neat lightweight gear-reduction starter which saves 2kg. Combine that with all the bits and pieces I’d chopped out of the linkage, and the lighter gearbox mount, the whole swap only added 1.8kg despite the beefier gearbox and equal length driveshafts.

Last little niggly problem was another headscratcher. Bled the whole system up using the Punto GT slave cylinder, but the biting point was on the floor of the car, right at the bottom of the pedal travel. According to parts catalpgues there’s two types of PGT slave cylinder, one with a 25.4mm bore and the other with a 20.6mm bore. The latter is discontinued so I’d bought the former, which evidently didn’t work with my particular setup.

Spent bloody ages looking for a NoS slave cylinder, but eventually came upon a Fiat Doblo diesel that uses a 20.6mm slave cylinder. Had a weird quick-disconnect fitting which I had to carefully cut off and tap for a banjo fitting, but that was the last piece of the puzzle :)

Works beautifully, and the LSD is great fun :) dropped the RPM on the motorway from a heady 3800 at 70 to a much nicer 3200.

Cooling issues

Had a couple of thousand trouble-free miles before I realised the temps were climbing after long runs again. Seemed like it had trouble bringing the temperature down after it was raised above the fans cutting in. Started with the easiest fix by fitting twin 9" fans :) one compared to the old beastie:

Better, but still no dice. Noticed a couple of coolant spots under the car so my new stainless coolant pipes weren’t sealing properly. Added some flanges and switching back to good old jubilee clamps from mikalors fixed that.

Still no dice.

Next, we noticed that if you upped the revs it would bring the temperature down a bit quicker. I’d replaced the water pump with the timing belt recently, but had to go through a couple before I found one that I thought was built properly (and even then it was only the best one I could find). Perhaps the end-clearances on the pump are a bit wide on repro parts. Whipped the water pump out (again) and my suspiciouns were confirmed. Haynes figure says 0.8-1.2mm end-clearance and we had variability between 1 and 1.5mm.

With a bit of grinding, and using sealant instead of a gasket I got the clearance down to a uniform 0.5mm. Bit tight, but doesn’t touch even when hot. Time will tell of that fixes it!

Compression test

One of the other causes for the cooling problems could be head gasket issues, which would fit with the slightly rough running at idle. Borrowed an aircraft mechanic mate’s compression tester and got some not-so-great results. Plugged 80psi in, and got 76, 68, 66, and 78 back. Apparently those numbers in isolation aren’t particularly bad (66 would still be airworthy), the spread does seem to indicate that there’s something up with the middle two cylinders.

Rings for these engines are very difficult to find, so I’ve been on the eye out for a set before I take the top off and see what’s going on. Either that or save up and get a forged set, rebuild the R32 Skyline turbo I have for it, and swap over to the PGT management I have for 180-230bhp ;)

That’s it for the Fiat this year! At nearly 2000 words I figure I’ll do separate posts for the Spitfire and other projects ;)

Part 1 - X1/9

Part 2 - Spitfire

Part 3 - The wider fleet

RamblinRover Luxury-Yacht > BiTurbo228 - Dr Frankenstein of Spitfires 01/10/2020 at 10:12

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Quality post, my lad. Been missing this sort of content from you, so at least we get the digest posts.

Might inspire me to be a little more active with my own projects again, who knows. Mostly have been putting time into the big Ford, but there’s really not much *to* be done with it at present.

vondon302 > BiTurbo228 - Dr Frankenstein of Spitfires 01/10/2020 at 10:31

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Great post! That trans linkage wow. I'd of gave up. Quality wrenching right there.

BiTurbo228 - Dr Frankenstein of Spitfires > RamblinRover Luxury-Yacht 01/10/2020 at 10:50

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Thanks man :) great to see you still knocking around!

I’ve been hanging around Retro Rides more these days as it works with the work firewall (and it’s rather a good site!). Your bits and pieces would be appreciated over there as well I think ;)

What’s up with the battle-barge these days? Is it running and driving?

BiTurbo228 - Dr Frankenstein of Spitfires > vondon302 01/10/2020 at 10:52

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Thanks man ;) I do try ;)

Of all things it was the slave cylinder that was the biggest pain. There’s nothing quite like knowing that exactly what you need used  to be made, but isn’t available anymore. Glad I found a solution :)

RamblinRover Luxury-Yacht > BiTurbo228 - Dr Frankenstein of Spitfires 01/10/2020 at 11:18

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I’ve been driving the ‘63 Galaxie 500 sedan every day. Been doing quite well despite the intake manifold or timing cover gasket leak that loses me about a teacup of coolant a week. Soon will be redoing the seat covers on it and possibly the door card “chrome”, as I have new mylar for that. If I do that and fix the rust spots in a door or two and the right front fender tail, I’ll have almost nothing needed to do other than the paint job.

The Benz has been sort of pending a turbo rebuild, as it’s miserably low on power. I did replace the vacuum pump so it won’t attempt to grenade the engine.

The strange Ranchero project hasn’t progressed much since the space under it was usurped by the brake table and the new industrial sized band saw and assorted other things... and to do properly some of the things needing done, I need a rotisserie, which I haven’t sprung for yet. Need to get the 40' space next to the shop properly under cover, which hinges on coordinating with my dad and doing some steel work.

The giant ‘59 Lincoln I got off Jarod Rose here on Oppo has to wait on that space as well for its rocker panel rebuild.

As to the Rover, haven’t had it out in several months, may need to remove putrid fuel from the fuel system again. Such is life.

Meanwhile, there’s a ‘59 Edsel Villager down at a place in town. I musn’t think of it, but then again, perhaps I must.

Next to it, a Galaxie 7-litre.

RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars > BiTurbo228 - Dr Frankenstein of Spitfires 01/10/2020 at 17:25

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Hello mate! Glad to see you back around! Also glad to see the little FIAT getting some love, you’ve done a lot of work to it! :D

BiTurbo228 - Dr Frankenstein of Spitfires > RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars 01/10/2020 at 17:59

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Hey man, glad to be back ;)

Yeah looking back I have done a lot to it! Doesn’t feel like it as it’s not on the road at the moment (bought a £50 oil pressure sender to repair an oil leak, lost £50 oil pressure sender, decided £50 is enough to wait until it turns up rather than buying a new one!).

Soon though :) big clearout of the garage at some point soon will hopefully pay dividends :)

How’s the 126 treating you?

BiTurbo228 - Dr Frankenstein of Spitfires > RamblinRover Luxury-Yacht 01/10/2020 at 18:08

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Sounds good to me :) wish I lived in a place where dailying a Galaxie 500 wouldn’t require remortgaging the house ;) nice to have something that close to needing no work as well (although that is, as ever, a transient state).

Shame the Rover hasn’t had much love, but as you say, such is life. The Spit sat unloved for 3/4 of the year, but the bad weather recently has forced me inside and I’ve found progress moved on quite quickly after that :) funny how things are at the whim of  circumstance...

Hum, Edsel. On the one hand, existing projects. On the other hand, Edsel estate ;)

RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars > BiTurbo228 - Dr Frankenstein of Spitfires 01/10/2020 at 18:35

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It’s not as I don’t have one yet. :P

Money saved up, but living situation not yet conducive to actually importing it yet as I have nowhere to store it. :(

...I got the Haynes manual for it already though! :D

BiTurbo228 - Dr Frankenstein of Spitfires > RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars 01/10/2020 at 18:37

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Haha shows how g ood my memory is :S

Get one with good enough paint and it might be able to live outside? Or is it parking full stop?

Haynes is a definite step in the right direction ;)

gmporschenut also a fan of hondas > BiTurbo228 - Dr Frankenstein of Spitfires 01/10/2020 at 21:05

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you’re nuts in the best possible way!

RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars > BiTurbo228 - Dr Frankenstein of Spitfires 01/12/2020 at 08:59

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I’ve thought about getting one and then using a car cover to protect it for now as many people do around here, but 126s rust quite easily, so a garage would probably be the safer bet...

duurtlang > BiTurbo228 - Dr Frankenstein of Spitfires 01/14/2020 at 02:42

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You've been up to a lot! Impressive work on the frankenspit too. Is the Fiat now (almost) ready for Tuscany around Easter? ;)

BiTurbo228 - Dr Frankenstein of Spitfires > duurtlang 01/14/2020 at 16:47

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Thanks dude :) unfortunately I don’t think the Fiat’s up to any long-distance runs just yet. Inching closer though! We were just talking here about how we want to get to another oppomeet of some variety (me, Matt and Phil). Phil’s without a car at the moment, but we’ve been nudging him to get one ;)

Need to test the Fiat against the 205 ;)

BiTurbo228 - Dr Frankenstein of Spitfires > gmporschenut also a fan of hondas 01/14/2020 at 16:53

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Haha thanks man ;) fingers crossed it pays off ;)

duurtlang > BiTurbo228 - Dr Frankenstein of Spitfires 01/14/2020 at 18:04

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I can imagine Tuscany being a bit ambitious for the Fiat at this time.

You could theoretically fly to Tuscany and rent an Abarth or something similar. Or wait (and influence the polls) for a later meet. I’d love to drive the 205 back to back with the Fiat. Mine is mostly ‘tuned’ for comfort though. With things like heated seats, a Xantia hdi diesel gearbox (but smaller wheels) and 150 kgs more than a 205 gti. Although, with the Billstein B6 suspension and maybe the turbo pressure tuned up it is most certainly not slow.

BiTurbo228 - Dr Frankenstein of Spitfires > duurtlang 01/16/2020 at 09:13

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Just a little ;)

Plan is to save up now to get the fun cars sorted (have big plans for the Jag and Alfa as well!), then head to wherever we’re going after that :)

As they stand at the moment I think the X1/9 and 205 would be quite close. Although the Fiat’s lighter, in its current state of tune it’s not massively powerful. Only 130bhp max, and X1/9s are heavier than their size lets on (about 920kg for mine I think).

Oh, and the new gearbox in mine has quite an overdrive 5th as well. Gets up to 100 quite quickly, but then starts crawling much further than that :S

duurtlang > BiTurbo228 - Dr Frankenstein of Spitfires 01/16/2020 at 18:25

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You’re sounding way too sensible :)

What would be a good time of the year and location for you? On the British isles, or on continental Europe but not too far from Calais? We might have to wait for the dust to clear after brexit happens though .

From a purely straight line perspective my 960 kg (empty) 205 seems to have the upper hand. But when corners come along...

BiTurbo228 - Dr Frankenstein of Spitfires > duurtlang 01/17/2020 at 05:13

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Haha not in the slightest ;) the plan is to get 3/4 project cars working this year and still progress on the fourth!

Yeah British Isles or not too far from Calais is probably ideal, but we don’t overly mind travelling down to places. The Nurburgring trip was fine distance-wise. You’re right though that we should wait until the brexit mess clears up. Was hoping that the country would see sense at the last minute, but I suppose I shouldn’t be surprised!

That’s probably quite accurate as the Fiat’s running now, but I’ve done a little tweaking on the engine. Stock they’re limited to 0.7bar (apparently insurance companies freaked out about the higher power...). However, if you take the wires off the boost cut solenoid and add a bleed valve you can tweak it back to the 1 bar they were designed for :)

If it was running properly it should be 130bhp at 540 0 and 197nm at 4000 :)