My Mikuni pretty well died on me and the Car Clinic quoted $504.00 to rebuild it. Upon doing a autopsy on it myself I realised there was way more wrong with it and decided to 'U-P-G-R-E-Y-E-D-D' (from the movie Idiocracy
http://www.youtube.com/watch?v=t7zqwnCR ... re=related) to a Weber.I am not a Mechanic at all but will try anything and have great patience so here goes.
I sourced a good 30 DIC Weber from http://www.fiaparts.com they are in Melbourne and Garry was a hell of a nice guy to deal with and very helpful.
Fiaparts
46 Alex Avenue
Moorabin VIC 3189
039532 0794
Cost of Carby was $120 plus $22 shipping to QLD (arrived next morning)
Airfilter from WeberPerformance http://www.weberperformance.com.au/prod ... cts_id=756
Whats required:
I have very minimal tools and equipment but managed to borrow some small items from a great neighbour (Thanks Ray)
TOOLS
- Cordless Drill
Spanner set
workbench
Angle grinder
Screwdrivers
Ball Peen hammer (for gasket making of course)
Protective Eye wear
Rotary Files for drill
Drill bits
Spray bottle
Kerosine
3/8 tap
Locktite
- Weber 30 DIC Carburetor from Fiat 850 spider $120
Base Plate off your old carby IMPORTANT $Free
4 x 3/8 UNC Worm screws (at local bolt supplier)$2
Various brackets from Bunnings (cost aprox $10)
Assorted screws $15
New cable connector ($10 at local boat cable shop fitted)
Ramflo Air Filter - 30 DIC Weber [RF432S] $67.95
Gasket Paper (Heavy)
Patience
GETTING STARTED
The three items we need to begin with are the Carby, the old Mikuni base, and the plastic spacer.
MAKING THE ADAPTOR PLATE
Dissasemble the base plate from your old Mikuni and give it a good clean with a wire brush
Get rid of those lumpy bits on the side to make room for the accelorator mechanism to open and close
Using a rotary file you need to carefully open out (funnel) the primary intake to match near enough the secondary intake.
I found using the plastic spacer as a template and marking it out with a Sharpie is easy.
You will need to use a spray bottle with Kerosine while doing the honing and regularly spray the bit to un-clog it.
Once that is honed out to match fairly closely to the Secondary intake you are ready to start blocking up those nasty holes in the side (4 in total).
Now carefully (I mean carefull) tap the holes to the 3/8 UNC size
Be sure to tap fairly deep as we will be using the threads again as mounting points for your brackets later on
Insert 3/8 UNC worm screws and be sure to put Locktite on each one.
Also on the plastic gasket open out the primary to match the same as the carby
Preparing the Weber
Ok, you will notice the holes in the Weber 30 DIC carby are smaller and 2 of them are threaded
Using a circular file bit that matches the same thickness of the old carby base plate holes we need to leangthen the holes towards the outer corners to accomodate the existing studs on the intake manifold.
BE SURE TO USE A SPRAY BOTTLE WITH KEROSINE WHILE CUTTING
take your time and go slowly, remember we dont want to cut through to the edges.
As you can see the holes on one side are now leangthned and moved outward to match the intake manifold studs.
on the threaded side we need to drill these out in preparation for cutting
**Be carefull not to hit the carby or lingages as you drill through**
Repeat the same steap and genlty work your way to the outsides
Remember this will be really close to the edges and will leave a flys dick of metal left on the outside edge.
What you will end up with is the carby mount holes resembling somthing like this.
Damn close to the edge as you can see without breaking through
Now give it a good blow with the air compressor and get rid of all the tiny particles.
MAKING THE GASKETS
I love this part as it reminds me of making gaskets for my RM-80 X out of old phonebook and wheeties boxes
Using a ball-peen hammer tap out the gaskets on some heavy gasket paper.
Watch the following video to see how its done RIGHT!!
http://www.youtube.com/watch?v=MdG10CR0Woc
You need to make 3 x gaskets to match the carby and the adaptor plate
Dont they look pretty
Probalbly an unecesary step but hey I like to do things right so might as well use that old bottle of gasket cement I have sitting around
INSTALLING THE WEBER
Place the gaskets on in the following order (Important as there is vacuum chambers on old plate that we dont need anymore.
You will need to get 1 x nut that does not have the flat base for the rear-left stud
It will be such a tight fit on the rear-left one that you will have to shave the edges off the hex heads so that it JUST clears the carburetor body.
Voila its bolted on now....yehaaaa
HOW TO BUILD A $10 Bracket in 10 Mins
Ok I like most people dont have fabricating tools and metal lying around so I resorted to what I know best 'Mecano' concepts
Ok run on down to Bunnings and grab some pieces from the hardware section that look similar to this.
Please note 3/8" Allen Key bolts I got at local screw suppliers.
You will need to build one of the following Meccano style brackets study the pictures carefully and it will make sense. NOTE: I cut part of the original bracket and drilled a hole so I can utilise the stock mount for cable.
Now mount that BadBoy in place using the 2 x 3/8" allen key screws into the holes we tapped earlier on for the worm screws. This is the reason we tapped them so deeply so as to utilise the same thread as a mount point.
And as you can see the allen head bolt clears the throttle cam perfectly
HOOKING UP THE CABLES
Ok the easiest and most reliable way as well as very affordable option is to run down to the local Marine Cable Factory (google them under marine control, repairs )
I used these guys here
http://www.marinecontrolsystems.com.au/
It cost only $10 for them to press on a proper attachment for my Webber.
As you can see the dilema is as follows: the old connector is a different style than the new weber style.
So they pressed on a Holley/Webber 6mm Connector i 5 mins flat.
PLEASE NOTE: the connector will be only 6mm as I realised when I got home and measured the ball and it was 8mm
Dont fret simply slide of the cover and drill a 8mm hole and replace the sleeve BINGO fits
The Choke cable will using the existing mount and 2 x washers and a screw to clamp it in place.
And ends up looking pretty stock
AIR FILTER INSTALLATION
Installing a air filter is pretty straight forward but requires very slight modifications for our application
Looks a bit tougher under the hood now eh!
STAY TUNED: Final step - how to setup the vaccum advance on Weber
