Can this 109 live again?

[mac]

Evening girls,

Those who know me are aware I am a shy retiring fellow whose hobby is collecting moulds, spores and fungi (just put that in to see who recognises the quote source) I mean of course collecting carburettors, especially those that have been neglected, abandoned and are living on the streets!

I recently aquired a fine (read broken, filthy, disgusting) example of a Weber 32DIR Type 101 from young master Derskine thinking vaguely of using it for spares but, it having been described and having found it to be genuinely awful I have decided (for sheer bloody mindedness) to restore it to health - it seems to suffer from all the usual DIR issues - so I can go through the repair procedures for each, and hopefully show that just about anything can be restored.

Barring a major failure of one of the main castings I should end up with a fully functional Weber. If this thread is a success I shall endeavour to repeat the excercise with Z10. A sort of "carbs in bits PLUS"

To start - a couple of pics of the unit as received,




In fact my workshop incense stick holder perfectly illustrates the general state of things,



The accelerator pump is falling off, linkages are seized,




And of course the top stud threads have pulled out of the top casting and will require "helicoiling",



Things might need a bit of a wash too - more to come!

Mac.

[trabitom99]

Mac, that looks like quite a "masochistic" piece of work you've got planned for yourself there!

Cheers

Tom

[volvomania]

I am sure that this will be some interesting reading in the weeks to come!
As for the carb coming back to life......no doubts

[bogbasic]

Did I see the grime-reaper then?

[mac]

And there is plenty of grime to reap!.

Rather than dumping the whole thing in my ultrasonic tank I prefer to clean off most of the "lumpy" crud (of which there is an abundance) with simple White Spirit - which allows me to at least see what's what.



After a quick slosh,



Then it's a general strip down of the linkages,





Even after the spirit wash it's still not a pleasant sight,



Naturally the connection tag on the idle solenoid had broken off,



Good idle solenoids are not common and the odd new OE one is very expensive so I try to recover any that can be saved.
On this unit, whilst the tag was broken off the connection wire was still visible and testing revealed that the solenoid was still functional - repair time!



Begin by soldering a wire extension (lots of flux) on to the remaining stub,



Next heat a replacement tag and "melt" it into the plastic head seal - secure it with a cover of epoxy.



Tomorrow - connect up the tag, complete the epoxy coating and hey presto should have a good solenoid..
More to follow.

Mac.

[macplaxton]

Have you done it yet? Why not?

[mac]

No, coz I's layzee.

[Chris_C]

I'll put 50p on it not working.

Only as that'll definitely make Mac prove me wrong.

[V6 Man]

As a total beginner to the world of these odd fixed jet carburettors I will admit to being slightly perplexed as to why, when this particular carb type thing is described as a 32DIR Type101, the thread title asks whether this '109' will live again. Has it mysteriously gained 8 somethings? Was it originally fitted to the Daimler-Benz engine from a Messerschmidt (I thought they were all fuel injected?) Is it a typo? Do things entering the Mac Cave automatically gain 8?

Yours,

Confused of Belper

[mac]

Reply to ignorant of Belper,

Make Weber
Model 32DIR
Series 109
Type 100 or 101 - in this case 101

The 32DIR used on the B14, depending on year and engine variant could be a Series 48, 57, 73, 74, 83, 84, 85, 93, 95,
104, 105, 109, or 110

Depending on Series the type could be a type 6200, 6201, 8400, 8401, 100, or 101

The full designation of this unit is a Weber 32DIR 109/101

Or, possibly, I've just fookled things up and am lying too you all - you decide.

Mac.

[V6 Man]

Ah! Suddenly it's all clear.

You failed to give us a crucial piece of information in your original post, thus leading to confusion

Yours,

Enlightened of Belper.

[mac]

I am indeed a worm!

Contrite and chastened of Dry Cave.

[mac]

Bit more work on the lost cause today,

First the solenoid came out quite well - a little excess solder to clean off but otherwise it works.



A quick measure of the base - and what do we find - how surprising it's distorted! Now the Weber DIR in no way matches the Solex Z series ability to imitate a banana but it can and does warp in response to overtightening the securing nuts.



Using my straight edge we find 0.010 - 0.015mm lengthwise and 0.020 - 0.025mm across the base. Yes, more distortion over the "short" measurement,




Time for the bare castings to be cleaned - considering the state of the thing it cleaned up quite well after the first pass through the ultrasonic tank,




And a second pass completed the job,



Just to prove it's the same carb,



More to come - the linkages (along with those from several other carbs) go off for re-plating tomorrow.

Mac.

[mac]

Bit more progress (in between various domestic wobbles).

The main castings having had the Soda treatment.



Nearly ready for the "putting back together" ritual.

Mac.

[mac]

Naturally it was found that the usual problem with the air cleaner housing securing studs being replaced with nuts/ bolts was present!

Setting up the top casting for drilling out the stud holes,



Tapping an oversize thread,



And inserting the new 5mm thread,



The top goes together,



And now the main body - looking good, glad I had the metalwork replanted,



We're starting to see how the finished article will look,



Not long now - I seem to remember a wager,



Finish it tomorrow (float, adjustments, heating plate etc.)

Mac - moderately chuffed.