The Alfatross

The Alfatross
The Alfatross in 1965 and 50 years later in 2016

Wednesday, May 13, 2020

Snap! (Post # 151)


Snap!

The vent valve before restoration with cardboard "hood" taped on.
When it happened, I thought "no big deal" It's plastic.  I'll just glue it back together.  Little did I suspect how long it would take and what I would have to do to restore it. Because it was something that did not affect how The Alfatross ran or what it looked like--it was practically invisible, hidden away behind the glove box under the dash--I did not start to obsess on it until most of the "important" issues had already been addressed. 









The butterfly valve, control shaft, and broken paddle handle.

But when I did finally take a long hard look at it I realized that the "butterfly" valve controlling the flow of ventilation into the cabin on the passenger's side was probably a cylindrical prefabricated unit welded into the firewall as a single piece. The butterfly itself was made of a round rubber disk trapped between two stamped steel plates spot welded to a central shaft. The shaft was bent into an "S" shape at the bottom ending in a short paddle-shaped lever made out of what looked like black bakelite plastic. Notches in a steel plate welded to the bottom of the cylinder locked the butterfly in four preset positions ranging from completely open to completely closed.



I used the stump of the handle and the part that broke off to make a mold.  
That was the easy part!


You could take the nut and washer off the top of the butterfly shaft, but the butterfly was still trapped inside the vent pipe because it was spot welded to the shaft.

I got around that by grinding the spot welds down until I could pull the shaft out from the bottom--after marking the shaft orientation with respect to the butterfly angle! I knew I would have to make a mold of the handle but that was going to be a little tricky because part of it was still attached to the shaft and would have to be supported and aligned just right throughout the process.  





The clear Alumilite cast after drilling but before attaching it to the shaft. 




I used the wrong approach on my first attempt at casting a new handle. I thought I could keep the part of the handle that was still attached to the shaft and just replace the part that broke off, but the bond between the original material and the new cast was weak and broke again almost immediately. 










The finished and painted final assembly

On the next attempt I cast the entire handle using an epoxy resin called Alumilite. After removing the original bakelite part of the handle still attached to the shaft, I discovered that the shaft inside was cleverly flattened to resist twisting forces. I drilled a hole in the cast for the shaft, injected epoxy to lock it into place, and inserted the shaft at the correct angle.



The vent tube with butterfly valve secured with pins through the shaft.







Putting it all back together was pretty straight forward. I inserted the butterfly into the tube from the inside, ran the shaft through it, lined up the holes in the shaft with the ones in the butterfly, then inserted pins through the holes from the engine room to hold it in place.






A "foot's eye view" of the "re-manufactured" vent valve under the dash and behind the glove box.


Looking back on what I just wrote in a few minutes reminds me of how long it actually took, all the fiddling around to figure out how to do it, and all the wailing and gnashing of teeth when it didn't go as planned.  Maybe I should have started with a "Don't try this at home, folks!" warning.

Friday, May 8, 2020

Indexing The Alfatross (Post # 150)

Indexing 150 posts is harder than I thought.  It entails a lot of decision making, cross-referencing, and deciding what terms and themes will be most helpful to readers. What's the purpose of an index anyway? To find things fast(er)! The fast part is just as important as the finding thing. So, what kind of things? Well, things like Borrani wire wheels. That's simple enough, but what about the term "engine"? That's too broad to be useful, because it includes so many other things. It needs to be subdivided into its constituent subsystems like exhaust, carburetors, water pump, distributor, and even fasteners. I decided to go for more individual terms in alphabetical order rather than lumping categories together under fewer entries.

The blog includes a lot of other topics that are more difficult to capture in a word or two, like musings over all the different meanings restoration and originality can have, and what Carchaeologists can learn from Henry Jones. I decided to include a number of accounts of events The Alfatross participated in such as the Arizona Concours, and Santa Fe Concorso, as well as some others that I attended without her (she wasn't interested) such as the Big Bend Open Road Race, Radnor Hunt, and Keels and Wheels. I also list the names (last name first) of all the people I can remember who worked on, found parts for, or gave advice to The Alfatross as well as some company names, but most of these appear in association with the actual individuals I dealt with.  

As often as possible I tried to compare The Alfatross with other examples of 1900C SSZs for the purpose of determining details of "originality".  Fourteen of these are listed under their chassis numbers.

A shortcut to locate the post you are looking for is to first check the "Post # Sequence by Year" below and use the Blog Archive in the column to the right to call it up. 

I would be amazed if I got everything right. Like I said, it was a lot harder than I thought. Comments with suggestions, corrections additions or omissions will be gratefully appreciated.



THE ALFATROSS BLOG INDEX BY POST NUMBER

Posts 1-150, from Jan 01, 2013—May 05, 2020

Post # Sequence by Year

2013:01-46

2014:47-72

2015:73-100

2016:101-123

2017:124-135

2018:136-146

2019:147

2020:148


ADAMS, CORK, 05, 12, 79, 111
ALFA 1900C SSZs, 21, 31, 32, 40, 41, 54, 63, 65, 73, 110, 112
ALFATROSS, 10, 13, 77, 80, 82, 97, 107
                EARLY HISTORY, 01, 02, 06, 07, 16, 47, 141, 145
                PREVIOUS OWNERS, 04, 09, 14, 15
                NAME ORIGIN, 03
                CONVERSATIONS WITH, 77, 117
ALLEN, DANIEL, 105, 114, 120, 124, 129, 130, 134, 147
AR1900C *01747*, 81
AR1900C *01844*, 70, 21, 112
AR1900C *01845*, 31, 63, 79, 81, 125, 112
AR1900C *01847*, 79
AR1900C *01915*, 39, 40, 54, 70, 79, 125,
AR1900C *01931*, 21, 36, 65, 81, 112
AR1900C *01947*, 70, 73, 112, 122, 125, 135
AR1900C *01954*, 36, 70, 79, 125
AR1900C *01997*, 79
AR1900C *02016*, 13, 77, 92, 100
AR1900C *02056*, 61, 63, 65, 73, 81, 122, 125
AR1900C *10003*, 79
AR1900C *10279*, 70   
AR1900C *10593 *, 70, 73
ARIZONA CONCOURS, 101, 102, 103, 105
BABCOCK, SCOTT, 81
BALLANTINE, RICHARD, 79, 105
BIG BEND OPEN ROAD RACE, 108
BERGESEN, BERGE, 32, 72, 79
BODY WORK, 35, 44, 51, 58, 65, 66, 67, 85, 88, 94, 95
BORRANI WHEELS, 05, 17, 29, 38, 48, 79, 111, 12
BOSISIO, MATTEO, 12, 17, 29, 65, 79, 111
BRAKES, 140, 139, 138, 130, 129, 34
DRUMS AND SHOES, 34, 111, 129, 130
FRONT SCOOPS, 34
MASTER CYLINDER, 137, 142, 143
LINES, 34, 109
RESERVOIRS, 34, 36, 140
WHEEL CYLINDERS, 34
BRICKLEMYER, BO, 46, 79
BRINKER, MARK, 79, 128
BUMPERS, 38, 41
CAR TABLE, 62
CARCHAEOLOGY, 23, 45, 98
CARRELL, DAVE, 18, 79, 95, 101, 103, 105, 131
CARRELL, TONI, 18, 79, 101, 103, 105
COOLING SYSTEM, 22, 106
COSTANTINI BRANCADORO, GIUSEPPE, 02, 82, 97
COSTANTINI BRANCADORO, ALESSANDRO, 04
CRAWFORD, BRUCE, 05, 33, 79
CREATIVE WORKSHOP, 32, 39
DIFFERENTIAL, 16, 147
DIPSTICK, 124
DRIVING LIGHTS, 70
DUBOIS, DAVID, 24, 79
DUNBAR, DERRICK, 72, 76, 79, 87, 99, 109
ENGINE, 13, 47, 93, 101, 103
ORIGINAL STATE, 36, 53, 87
UNDER RESTORATION, 25, 37, 42, 47, 72, 74, 78, 86, 91
FINAL APPEARANCE, 100
CARBURETORS, 09, 68, 100         
EXHAUST, 136, 144
FASTENERS, 104
FELIX, CHRIS, 136
FOGG, GEORGE, 79
FUEL, 24, 146
GALAFASSI, PAOLO, 136, 137, 144
GAUGES AND SENSORS, 120, 121, 148
GAUTIER, SCOTT, 79
GOMPELS, JOOST, 34, 61, 79, 111, 134
HAYES, JOE, 47, 54, 79
HEADLIGHTS, 71, 101
HEAT SHIELD, 135, 136
HENDERSON, WILL, 04, 46, 47, 92, 97
HYDROVANE COMPRESSOR, 26
INSTRUMENTS, 75, 121
INTERIOR, UPHOLSTERY, 20, 40, 47, 55, 67, 72, 76, 99
INTERIOR, DASHBOARD, 50, 75, 81, 90
ITALIAN LICENSE PLATES, 07, 97
JAEGER CHRONOMETER, 10
JOSEFSSON, HANS, 28, 79, 109
KEELS AND WHEELS CONCOURS, 128
KELLER, ARTURO, 61, 63, 73, 79
KEYS, 82
KRAMER, JEFF, 18, 79, 83, 89, 101, 103, 110
LEERDAM, ED, 29, 33, 39, 47, 79
LEWIS, SONNY, 97
LICENSE PLATE LIGHT, 04, 113
LINTON, TOM, 43, 44, 79
LOPRESTO, CORRADO, 31, 63, 79, 125
LORTON, ROGER, 25, 42, 53, 74, 78, 79, 86, 91
MARANGHI, GIUSEPPE, 122, 124, 134
MARINOS, TIM, 102, 105, 109, 125, 144, 147
MARSHALL, PETER, 72, 79, 127, 132, 134, 142, 143
MICHELS, CARL JOSEPH, 04, 97
MIRRORS, 81
MOLDING AND CASTING, 49, 52
MONROE, BO, 34, 79
MONTEREY AUCTION, 63
MORGAN, TERRY, 101, 103
NARDI WHEEL, 33, 39
PERFOMETER, 10, 83, 90
SAMUELS, DEWAYNE, 25, 42, 53, 59, 64, 68, 72, 74, 78, 79, 86, 93, 102, 109, 124,
SANTA FE CONCORSO, 43, 64, 94, 114, 116, 117, 126
STRICKFADEN, GERRY, 101, 103
OIL PAN, 68, 134, 147
PAINT, 66, 88, 94
PARTIFACTS, 29
PLANNING, 05, 23, 38, 103
RADNOR HUNT, 54
RECORDING, 98
REINWALD, MARK, 43, 79
RIDE HEIGHT, 127, 132
ROBISON, JEFF, 89, 101, 122, 131
RONDELLAS, 136
ROTISSERIE, 08, 11, 17, 18, 44
ROUTE 66 FUN RUN, 84
SCHNITTGER, BOB, 79
SHED, 02, 17, 67, 119
SIMPSON, DAN, 79
SMITH, DAVID, 125, 131, 132, 135, 144, 146
SODA BLASTING, 05, 19, 26, 30, 42
SUPPORTERS, SPECIALISTS, 79
SUSPENSION, 52, 87, 89, 96, 132, 133
STANDARD MACHINE, 25, 39, 47, 53
STEERING, 33, 89             
TIRES, 56
TRAFFICATOR, 59, 123
TRAILER, 44
TRANSMISSION, 69, 96, 147
TRUNK, 125
TURNER, PAUL, 04, 14, 46, 47, 48, 87, 97
VENTURA, LUIGI, 92, 136, 137, 144
VINTAGE AUTOCRAFT, 44, 66, 88
VW TRANSPORTER, 01, 44, 56, 62, 145, 146
WENIG, JASON, 29, 32, 39, 57, 79, 131
WHEELS, 12, 111, 128
WILLIAMS, HAROLD, 52, 62, 79, 127
WINDOWS, 27
WIPERS , 75
WIRING HARNESS, 28, 32, 50, 72
YNZ YESTERDAY’S PARTS, 28, 72, 79, 109
ZAGATO, ANDREA, 17, 92, 102