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BDR Inlet Manifold removal - and now to refit


anthony1956

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I agonised over whether to remove this inlet manifold applying "if it's not broke, don't fix it". However, I found an exception to this idea. Which is when I cannot discern whether it is broken or not. I found this when fixing the cooling system overflow system. Everything looked "not broken" but the overflow system was not working. Air was ingressing somehow, somewhere. In the end I replaced every single component and suddenly it worked for the first time for me in 23 years. So I fixed something though to this day I am not sure what.

In that same vein the carburettors tuning has been very erratic and every time I fix/replace something it gets easier. Given that the carbs are off and access is easy I chose to remove the inlet manifold for inspection and cleaning. The old gasket is brittle and left many marks on the interface, which I have cleaned with acetone and fine grade Scotchbrite.

Here are some pics:

after cleaning with acetone and fine Scotchbrite

IMG_2723.webp

 

after cleaning with acetone and fine grade ScotchbriteIMG_2724.webp

 

after cleaning with acetone and fine grade ScotchbriteIMG_2725.webp

after cleaning with acetone and fine grade Scotchbrite

IMG_2726.webp

 

after cleaning with acetone and fine grade ScotchbriteIMG_2727.webp

 

this shows a code I found on both inlet manifolds, Z2 or 22 

IMG_2729.webp

shows the new Cometic INLET MANIFOLD GASKETS  test mounted. Nice and flexible unlike the brittle old ones (which did well enough after nearly 40 years "applause").

IMG_2730.webp

 

the bundle of gaskets from Burton Power, purchased for just one gasket andI bought the bundle thinking over time I will need many if not all of these. No Head gasket. (inlet manifold gaskets removed). We can play "spot the gasket".

IMG_2731.webp

Showing the Motorsil D gasket sealant I hope to use if it has not gone solid all the way through.

IMG_2732.webp

From the Cosworth doc issue 2.     Torque settings for bolts of 
1/4" bolts 5-7 lb.ft.               5/16" bolts 10-15 lb.ft                3/8" bolts 20-24 lb.ft
Conversions - to convert lb.ft to Nm, you multiply by 1.35582
1/4" bolts = 6.35mm is 6.78nm to 9.49nm        5/16" bolts = 7.9375mm is 13.56nm to 20.34nm           3/8" bolts = 9.525mm is 27.12nm to 32.54 nm
So my inlet manifold 11mm nuts will be say 35nm.

So I figured out which order to re-install these with an old photo zoomed in: thant blanking screw is only on one side, so the same spot on the other side of each is not drilled, just the spot is marked in the moulding.

IMG_8197-WHICHWAYAROUND.webp

To my amazement getting 1/4"UNF Nylocs has proven practically impossible in my locations so I am very grateful to Threadfast of Congleton supplying all I need for £8.50 all included and posted to Europe. I used them years ago to rebuild this same car as it happens and they are real engineers for fasteners.  Threadfast of Congleton, Ask for Anthony Heeley Anthony@threadfast.co.uk +441260278236 , see if he remembers me. Vast stock of everything last I was there. I used to work in Congleton in the 80s. They are hidden down the back streets.

Edited by anthonym

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Yup, I have a couple of those gasket sets for just a couple of them too! 
It is nice just calming down and going through something properly rather than patching all the time….

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UPDATE RE GASKET SEALANT - AIR LEAKS ON CARB 1

ok so I gave in and once more, this time with patience, at idle, sprayed Easy Start on the front carb inlet manifold, several times, each time waiting for the engine to slow down, squirted and it went faster.

We have new Cometic gaskets and only the rear one has additional sealant round it. This was an experiment which now bears fruit and demonstrates that the extra sealant was a good idea. 

I found this was the case when fixing the coolant system and dealing with metal surfaces that are very old and mottled. In the case of the coolant system I replaced with new parts. It seems with these inlet manifolds the sealant is effective. 

So next task is remove carb 1 (again), remove and refit inlet manifold 1 front this time with sealant.

The clue to all this is the Manometer shows a MASSIVE difference between carb 1 and carb 2, carb 1 showing it has vastly more air getting in somewhere

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Have you checked for flatness of the mating surfaces (with a straight edge) Anthony?  I have never found the need to use sealants on an inlet manifold (although never had a BDR)

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Ah well, I did one with sealant and one without to see what happens. Now I know. The gasket was sopping wet on both sides, pic 3535 below.
Also below shiny one 3545 where I did the scrapey thing 7wow suggested, but tbh I have found with this age all the surfaces are suspect even when they look ok. It wasn't until I accepted this idea that I got the cooling system to work again after 20 years not really doing so.
The rest of the pics just show my progression through application, it squidges everywhere inside and out and then I slowly clean it all up with an acetone soaked cloth. I find the RED Motorsil D difficult to apply,

https://arexons.it/en/products/car-care/professional-car-care-and-maintenance/guarnizioni-liquide/motorsil-d/

it doesn't squeeze on from the tube and requires my finger to splurge it around. BUT it says its easy to clean off and indeed it is.

all sopping wet - so air leaks

IMG_3535.webp

after WD40 on 600 wet and dry

IMG_3545.webp

one side sealed

IMG_3546.webp

both sides sealed

IMG_3548.webp

cleaned a bit, it likes some time to part cure

IMG_3549.webp

inlet manifold fitted, no torque setting, just tight not F tight, because no tools can be fitted to the reverse side nuts except a very small 11mm open spanner.

IMG_3550.webp

and checking for sealant inside - more to do

IMG_3553.webp

IMG_3554.webp

IMG_3555.webp

underside to clean excess

IMG_3557.webp

topside to clean excess

IMG_3558.webp

more checking

IMG_3562.webp

IMG_3563.webp

more to do

IMG_3564.webp

cleaned the rest and left to cure overnight

Edited by anthonym
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Right then. All put back together, dizzy cap included (it's far too easy to forget that, I need some sort of visual reminder. Maybe just to disconnect the coil's HT lead at the coil end; or perhaps better the coil ignition wire so nothing can spin.

Well, Gordon Bennet, it was like going back in time a week or two; impossible to start, lots of backfires and so on. Gave up and tweaked the timing with the dizzy a bit, got it started (this is long frustrating story very short), strobe light, reset the dizzy timing and running nicely, reduced tick-over, balanced Carbs using Manometer, no need to tweak mixtures or air compensations because both pairs of barrels practically identical, to my pleasant surprise.

Anyway, the massive air leak problem has clearly gone. Forgot to check the accelerator jets, but that can wait; I have turned over all the pump jet "weights" all of which have ball bearing impressions worn in to them. TRICK: blow compressed air down the weight's hole and the weight jumps out - and hard to catch. 

Raining again so further tuning has to wait, but bit of a celebration at this balanced point.

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Dribbling : NONE AT ALL! 

So it was the ball bearings wrongly placed.

And MAYBE the weights having been worn down at the ball bearing end (weights all now the other way up).

Edited by anthonym
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