Pirates repair carbs?

Since last we talked I’ve been trying to line up throttle shaft re-bushing service for my SU carbs. I explained the process in my last post and while it is not brain surgery many owners persuaded me not to try myself.

I happen to live in a densely populated area near Los Angeles so it is no surprise that there are a half-dozen or so shops within driving distance that claim to specialize in carburetors. What is a surprise is the shadowy existence of these shops. Maybe there is something inherently flakey about carb repair specialists? Let me re-enact the call I had with one such shop, Doctor Smith Carburetors.

Me: dial xxx-xxx-xxxx, brrrring, brrrring

Doc: Grunt, sort of like “Guh!” or maybe “Ugh!”

Me: “Hello?”

Doc: “Arrrrrr, I’m a pirate!” Well it wasn’t really those words but that’s sort of what I hear.

Me: Pause. What did he say? “Hello, is this Dr Smith Carbs?”

Doc: “Yeah” Hmm, maybe he had a chicken stuck in his throat?

Me: “Oh. Good. I’m looking for a shop that can re-bush the throttle shaft on some SU carbs. Is that something you guys do?”

Doc: “Arrrrrr, I’m a pirate!” Hmm, now I could swear that is exactly what he said… again.

Me: Pause. Try to digest his words. Any other possible meaning? “Um… I’m looking for carburetor repair service?”

Doc: “Nyuk, nyuk, nyuk!” or something really close to that, with a Three Stooges lilt. And he hangs up. The line goes dead.

I’m staring at my phone like maybe it isn’t working right. Only my phone is fine. And I’m not deaf or even hard of hearing. Who knew that pirates do indeed repair carbs? I’d have suspected a five year old got loose in his office and answered the phone but the voice was clearly a middle-aged man.

That exchange was so surreal, and sort of funny, that I had to share it with you. Yes, that is just how I remember the call. No kidding.

The two other closest shops, P&J Carb and Carb Care USA don’t seem to answer their phones the several times I’ve called. I have this vision of a single mechanic lying on a creeper under a car when the phone rings. But we’re talking about carbs here right? So, what, maybe loud engine-stand or flow bench testing? Dunno, but I left a message and we’ll see if they return the call.

Back to other things. You must have commitment when you decide to polish something. If you start but don’t finish it’ll be obvious and look like crap. Here’s the start of polishing up that air balancing manifold.

And here, presto change-o, like magic, is the polished air balancing manifold.

Do I really need to mention how many hours went into this? This photo represents more work than most of the rest of this post’s work. But would you really want to see a hundred photos of me polishing the same damn piece of aluminum? Didn’t think so.

I didn’t take pictures of it but I also worked on the throttle linkage bits (see bits in last post). The smaller pieces de-rusted okay in a vibratory bowl after about two hours in wet green pyramid media. Then I worked them with emery grit on a polishing wheel. I went all the way down to 200 grit sandpaper on the larger linkage pieces but even then I am not entirely happy with how they turned out. Some of the corrosion spots are just too deep, structurally sound but a cosmetic weakness.

Speaking of awful corrosion, here is the water manifold, rubber hoses going to the radiator.

Here is a closeup of the forward end.

That yellowish wire off some sensor (temperature? pressure?) turns green as it passes below the rubber hoses. The hose nearest the engine goes down.

The other hose goes to a box on top of the radiator. Here is the back end of the water manifold.

That hose off the end snakes behind the engine and ends at a what’s-a-whose-its (TBD) just under the firewall throttle linkage.

Here is the water manifold on my bench.

This was not the easiest part to separate from the air manifolds under it. It had corrosion-welded itself to a couple of the mounting studs. I banged around with penetrating oil for a while but I still had to pry it off. As I took it apart I began to despair of the possibility of reusing it. It has an awful lot of corrosion. And I started to get nervous about the other water passageways.

Here is one of the three water outlets that goes to (and through) the air intakes.

Here is the forward end, where the rubber hoses connect.

Hmm, I imagine this is where the thermostat goes? Nothing but an empty chamber right now.

Here is the radiator return loop split open.

At this point I threw the manifold in a box rather than spend time polishing it up. I think I’ll be buying a new one though the shaping makes it look expensive. Oh well, win some lose some.

Here is the engine without that water manifold.

I pressed on. Here are the three air intake manifolds on my bench.

They are completely different shapes and you’d have to be an idiot to remount them incorrectly. Hold that thought for a few months or years. These also continue the tradition on this machine of not allowing enough space around nuts to use a proper socket or Gearwrench. You can only fit open-end or thin box-end wrenches on many of the mounting nuts. And of course you can’t swing in a big arc. Tedious and far too common. If I was spoiled by my air ratchet and Gearwrenches, well, this machine will keep me humble.

Here’s a view of one of the water inlets on top of an air manifold. This delivers water to the head right between the siamesed air runners. You can see the rectangular outlet slot to the head on the center manifold in the photo above.

Nice corrosion. Here is the engine head without the intakes on it.

And a close-up.

On the carburetor side of the air intakes there were two stacked gaskets, thick and thin.

Here is another of those water inlets to the air manifold. The arrow points to a gouge where something took a bite.

Doesn’t leave much area for sealing water pressure right there. I can see I’ll be slathering the Hylomar or other gasket seal liberally.

And to end the suspense, cleaned up air intakes.

Nice! I still need to clean up the water interior passages. Does anyone have suggestions on the best fluids or technique to get rusty gunk out of there?

Here’s a preview of my next intended work. The arrow below points to an oddball valve cover nut on the front passenger side.

All the rest are chromed acorns. Why is that one plain? A mystery for another time.

So matey, keep a weather eye peeled for this here monkey with a wrench. I’m off to find a scurvy dog to work on my carbs. Abandon hope, all ye who enter here (I used to have a variation of that slogan on the front license plate frame of my Integra GSR, “Abandon hope, all ye who enter under here”).