Modifications for rallying

[Teo]

I have a Lancia Fulcia Coupe 2nd Series and i would like to make it a rallying car. Could you give me some suggestions on what modifications should i make to the engine and suspension to make it a serious race car? Thanks in advance!

[P. de R. Leclercq]

This one has come up many times, I suggest that you search the archives first and then have a look at all the Fulvia tips.

Obviously the car must conform to all the regulations that relate to the kind of competition you are aiming for: roll-cage, fire-proof bulkeads, seats, belllts, extinguisher, battery cut-off switch etc., etc.

Meanwhile, the Fulvia is heavy, you should try to find a set of aluminium panels for the car, remove the bumpers, fit a polycarbonate rear window and quarter lights (all were production items - 1300HF - so no homologation problems there).

Ideally you should try to find a set of 1600 wishbones (negative camber) and a 1600 steering box - 3.2 turns lock-to-lock rather than 4.2) but these are hard to find, as are the Cromodora 6 x 14" magnesium alloy wheels that you should also have. EBC does excellent brake pads for the Fulvia; despite what many say I recommend Yellow Stuff - rallye tested too by the owner of the Fanalone I prepared for historic rallying.

As for the engine, well difficult one. The Fulvia engine is hard to develop as it already has quite a high specific HP output, but is a bit light in the torque department. I would try to find a S2 sedan gearbox (4.1/1 final drive rather than 3.9) and build (if I could find them) a 1600S2 gear set into it: first gear is way too low on S2 1300s.

With the engine, first job is to gasflow the head (expensive) with bigger valves if possible (use 1600 ones)and try to find a decent exhaust manifold; Fulvias respond very well to exhaust work, by which I do NOT mean a fancy tail box which makes no difference. Matching the inlet manifold to the head is very important, S2s were pretty poor in this regard and incluse the rubber mount too. Jets for Solex carbs are impossible, but you can modify the ones you have. After you are satisfied you might then wish to consider camshafts. First source some 1600 cam wheels and make sure that you buy camshafts with vernier timing to suit, the one-pin-one-hole system on S2s and S3s is rubbish for competition or performance purposes.

If you wish to lighten the flywheel, it is necessary, because of the offset crankshaft to re-balance the entire bottom end, a very specialised job. For clutch, use a FIAT Uno Turbo 1400 one, lighter and better all round than the original.

Spax makes good dampers which are easily adjustable and not expensive, I think that they are better than the usual Konis.

This lot should keep you busy for a while...

Paul

[Peter de Wit]

Paul, Agree on the points and am interested in your EBC tip. I EAT std brake pads since my only set competion ones ran out after 10000km. Now I do a 1000 with a set and only have fun for 50km. I use Girling brakes in the front as you might know and these brake like modern cars, meaning produce a lot of heat. I have experience with EBC brakes (and their prices) but I was not able to locate Fulvia ones in Yellow. Any tips??

[Paul de R. Leclercq]

Hello Peter,

This one will have to wait until I am back at home - I am in Paris at present.

I think that EBC will make brake pads for you (I am assuming S2 here) if you can provide some old pads so that they can re-use the backing plates. I do not know which Girling calipers you have - more details please. My friend's Fanalone is fitted with S2 calipers at the front.

You might recall that I have FIAT coupé calipers on my Fulvia; these use Evo-style pads. Despite the size and yellow stuff material I have had no problems.

All the best

Paul

[Peter de Wit]

Hi Paul,

Thanks very much for your help!! The blocks are being made. One referal to your (lady)friend's name was enough to get their computer going!!!!! Price is reasonable (170eur) given the fact that they are custom made and improve the overall performance of a car so drasticly.

Cheers, Peter!

[P. de R. Leclercq]

That's it Peter, Bob is usually very helpful...

I am sure that you will be pleased with them.

Paul

[mortuza]

Hi there everyone I'm back from Italy and work on Fanalona has stopped. I will like to put up some pic of her on here but when I get a bit of time.

What I would like to find out though is more info on carburetters.

One of the esaiest modifications is to change the carbs on 1,6 but what I'd like to know is what are the pro's & cons with reference to Dellorto DHLA or Weber DCOE especially the 45's.

What I'dlike to hear is something like dellortos are such and such over so and so rev range, weber are like this...but I use....

The works teams had 48 dellortos but I think that 45's are the best (not solex)

Can we please have a bit of a debate on carbs and what peoples experiences are of them

Many Thanks in advance

M

[P. de R. Leclercq]

Well,

Once I drove a very smokey 1600 that was fitted with 40mm Webers. I was surprised at how "torquey" the engine was.

I had always assumed that the works preferred Dell'Ortos over Webers, until I saw the engine of Munari's "No 14". This had 48mm webers.

I would think that 48s would be acceptable on a low-geared rally car.

To my mind the problem with fitting any DCOE/DHLA onto a Fulvia is the awkward shape of the manifold. I prefer the adaptors that were made - No 14 had the nicest I have ever seen.


Paul

[Peter de Wit]

I know, Paul, that the no14 in the museum has webers fitted. But look at this pic:
http://www.lanciaracing.com/images/c32_File0014.jpg

This foto was published 2 months after the monte win and is the no14 car. It has dellorto carbs. And you see the beefy adapter for the carbs as well.

I had a 1600 with 40mm webers. 30mm venturi's. Great low down torque and it stopped at 6200revs. Not because of the small carbs, but the standard valve train not keeping up. I think that if you do not vastly improve your engine 40mm is the best choice.

I use 45mm dellortos now. Have my idle revs set at 1800 to help me getting of the spot. But also to keep good oil pressure (use mechanical meter). Torque starts at 2500revs and modified engine goes easily above 7000revs, so the 45mm (36 venturis) might be helpful there.

Good thing about dellorto's: Works cars used them IMO, the fuel lines are on the REAR side of the carbs, and the choke tower can easily be cut off of the front one (you do not need the choke anyway)

Bad thing about webers: the front fuel connection will cause problems (look at buldge in bonnet on my old car: http://www.lanciaracing.com/images/c51_1600pdwsls.jpg)

Good thing about webers: parts availability and better accelartion pump (not on bottom).

Last remark is that I believe the float chambers are oriented differently between the two. I had problems with fuel starvation in longer fast corners with the webers. No probs with the dellorto's.

Plus: no return fuel line needed.

[Huib]

I agree with Peter. In general the Lancia engineers did their home work well and produced a balanced package. Changing a single item like carbs hardly improves the overall performance. You have to make a complete new plan.

On the other hand, the 40's were bad, very bad. If you give me your email address I will give you the name of an old guy where you can send your 40's and have them modified into real carbs. You will have a different car.