Series 1 canvas discs

[Huib]

I have now 4 S1 Fulvia's in my workshop with bad canvas discs. The disc (also called Hardy disc or rag joint disc) is the coupling between the shaft coming from the steering wheel and the steering box itself.

The original disc has five layers of canvas-like material. On both sides of the centre layer thin sections of spring steel give the disc its required strength for the way it is applied on Fulvia's (and Flavia's). On the original discs these steel sections have rusted away. The canvas then quickly tears.

Replacement discs that I have seen so far do NOT have the steel sections. They are utterly dangerous as shown on the picture below. As you can see from the grease and dirt around the disc, the disc was put in recently and has torn already.



I have the thin spring steel (stainless steel variety) and I am ready to laser cut the sections. However, I cannot find a suitable canvas like material of 1,5 mm thick. It should either be impregnated canvas, natural or synthetic, or fibre reinforced rubber which can be either laser cut or water cut.

I someone can help, let me know.

[P. de R. Leclercq]

Huib, Try industrial suppliers - and get some line shaft belting. This stuff is very tough - although probably a bit thick although I don't see that this should be a problem.

I once bought some for a similar application, but never used it.

Paul

[Huib]

Thanks for the tip, Paul. Although I would like to have 1,5 mm thick material like the original. The steel quarter cirkels are stacked around the center layer which is 1,5 mm.

[Walter Barra]

When I rebuilt my fulvia many years ago, the LMC magazine recommended a replacement disc from a mercedes. It had the same dimensions but was made from rubber. It seemed to work ok. DOn't have the reference number any more but knowing Mercedes you can probably still buy the item.
Walter

[Huib]

Thanks Walter. I used to do the website for the Mercedes Benz club here in Holland. I still have some contacts there.

[Huib]

I went to the Mercedes dealer. Very good. The parts catalogs with exploded views of these 50's / 60's cars were on the computer. Same computer told us instantly there were two on stock in a warehouse near Koln and 10 in a warehouse near Stuttgart. I ordered 2. We shall see.

There are also repro discs for Lancia made in Australia in red PU. I already decided against those as there is no fail safe back up. If the rubber tears, one looses control.

Apparently Mercedes Benz at the time did not trust the safety of the rubber either as they made a rather nice steel thing around the disc that takes over if the rubber disc fails.

Thinking about it again, my idea is now that the actual device for the linkage on Lancia are the steel parts hidden on both sides of the center layer of canvas. The five layers of canvas are the fail safe back up. If the steel has rusted away or breaks, the canvas does the job but it does so with more play. This is the first warning. Soon after the canvas layers start to separate and wrinkle around the edges which is the second warning.

For the time being I consider the rubber Mercedes disc as a temporary solution and I will still continue to make canvas (or carbon - kevlar fabric) discs with steel inside.