We received a phonecall about 6 weeks ago, from a gentleman who saw our WEBER DCZ triple carburettor restoration page, liked what we did and decided to ask us to restore his WEBER IDA3PC triple Choke Carburettors for his Classic Porsche 911..

And of course, we said Yes!

 

So, here they are – Genuine Italian Made 1960s WEBER Triple Choke 40 IDA3PC & 40 IDA3PC1 Carburettors (with manifolds).

Before, during and after restoration – Photos

 

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The challenge here is to carefully strip and separate all the miniscule parts without damaging any of the obsolete parts i.e. castings.

The screw threads – male & female –  require special attention as many are sized due to age and the environment they have been subjected to.

Correct engineering practice, suitable tools, necessary equipment and patience are essential!

 

A slip of the hand here, could literally cost thousands of pounds/dollars (depending where you reside) and weeks/months of additional time & effort!

Thankfully, we managed to get the job time drama-free 🙂

 

So, after careful external examination, we began the stripping procedure and opening the carburettors to look inside..

 

 

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Removing the plastic trumpets

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Removing the top cover(s)

 

 

 

 

 

 

 

 

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Opening-up the carburettors

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Needle valve removal from top cover

 

 

 

 

 

 

 

 

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Brass floats and brass retaining pins/screws

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Pump jet & screw removal

 

 

 

 

 

 

 

 

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All 6x pump jet assemblies

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Main jet assembly

 

 

 

 

 

 

 

 

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Punching a single spot on carburettor #1 to match it with it’s respective top cover for when re-assembly time arrives

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Punching two spots on carburettor #2 to match it with it’s respective top cover for when re-assembly time arrives

 

 

 

 

 

 

 

 

 

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Specialist fast release penetrant is very useful when stripping classic Weber carburettors – This one (on the right) is a variety of WD-40

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Separating the alloys/metals (and plastics) as stripping takes place In the middle are the top covers & inlet manifolds

 

 

 

 

 

 

 

 

 

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Brass parts container almost full!

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Idle jet assembly removed

 

 

 

 

 

 

 

 

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Fuel well/chamber drain plug screw and washer removal

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Progress..

 

 

 

 

 

 

 

 

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Pump cover removal

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Pump diaphragm & spring removal

 

 

 

 

 

 

 

 

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Pump main body and studs

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diaphragm removal

 

 

 

 

 

 

 

 

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1x complete Pump assembly

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Pump cover and cam seperation

 

 

 

 

 

 

 

 

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Punch tool used to separate pump cover from cam/lever

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Carb #1 & #2 stripping progress

 

 

 

 

 

 

 

 

 

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Pump rod mechanism dis-assembly – removing split pin and retaining washer

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Removing the pump-rod actuating cam pin

 

 

 

 

 

 

 

 

 

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Idle mixture screw assembly removed

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Auxiliary venturi locking screw and safety wire

 

 

 

 

 

 

 

 

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Throttle stop/isdle speed screw

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Throttle stop/idle speed screw 2

 

 

 

 

 

 

 

 

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Auxiliary venturi locking screws removed

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Throttle stop/idle speed screw & spring removed

 

 

 

 

 

 

 

 

 

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underside of Weber IDA3PC triple choke carburettors (#1 & #2)

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This is where the float normally sits. That shiny stuff is gunk. dirt, oil, carbon and fuel residue that has built up over the years.. All that will disappear 🙂

 

 

 

 

 

 

 

 

 

 

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Both throttle lever assemblies

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We use a small rotary grinder to grind off the backs of the throttle valve screws before attempting removal

 

 

 

 

 

 

 

 

 

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Grinding away the excess screw material to ease the removal of the throttle valve screw

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Throttle valve screws removed – ready to slide valve up & out

 

 

 

 

 

 

 

 

 

 

 

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Throttle valve removal

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throttle valve removal

 

 

 

 

 

 

 

 

 

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Throttle valve spindle/shaft connector before removal

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throttle valve spindle/shaft connector – grub screws (allen type) removed

 

 

 

 

 

 

 

 

 

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Spindle removal initiation

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Spindle/shaft removal – Note: PTFE bushing strip coming out also

 

 

 

 

 

 

 

 

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Throttle spindle/shaft removal (other end)

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continuing with throttle shaft removal – almost out! PTFE bushing strip coming out too

 

 

 

 

 

 

 

 

 

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Here is one part of the split throttle shaft that each carburettor features – this is the smaller/short one

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Removal of spindle/throttle shaft connector

 

 

 

 

 

 

 

 

 

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complete throttle shaft/spindle before removal

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Both spindle/shaft assemblies laid out next to each other

 

 

 

 

 

 

 

 

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Auxiliary venturi removal

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Throttle valve spindle/shaft – PTFE bushing strip removed

 

 

 

 

 

 

 

 

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Auxiliary venturi removal

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Choke removal

 

 

 

 

 

 

 

 

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more choke removal

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and even more choke removal..

 

 

 

 

 

 

 

 

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Choke & aux. venturi assemblies removed

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Chokes & aux. venturis removed

 

 

 

 

 

 

 

 

The most challenging removal was the air correctors/emulsion tubes and throttle valve screws.
Also the studs that mate the top cover to the body were pretty much seized..
An impact stud-extractor was used to remove these.
Some stubborn studs had to have blow-torch treatment.
The protruding stud is heated with the flame until it is red hot and then immediately quenched in cold water. The sudden ‘shock’ tends to break the ‘seal’ which has formed over many years, and the stud comes out..  in one piece 🙂

Below photos:
Fully stripped castings and top covers ready for vapour blasting, steel fasteners such as studs and throttle levers ready for yellow zinc plating, throttle spindles, springs and roll-pins ready to be re-black phosphate coated, and the brass parts get dipped into warm hydrochloric acid.

Hydrochloric acid can be quite deadly, and is for industrial use only.
37.5% is for industrial use only and is purchased by licence-holders only.

If you do happen to have access to it, use it but treat it very, vary carefully.

At this stage of the restoration process we’re preparing the parts ready for inspection after their refurbishing processes have been completed and preparing for re-assembly and setting-up.

Below are photos of the stripped/dismantled carburettors and their parts.

 

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Stripped bare WEBER 40 IDAP3C carburettor bodies – underside view

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Stripped bare WEBER 40 IDAP3C carburettor bodies – top view

 

 

 

 

 

 

 

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Bare top cover castings

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Inlet manifold castings – These will also get vapour blasted and fitted with new studs, nuts & washers

 

 

 

 

 

 

 

 

 

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All the parts in one photo

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Another photo of dismantled triple choke IDAs

 

 

 

 

 

 

 

 

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Parts ready for treatment now..

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Steel parts for black phosphating on the left – steel parts for zinc plating on the right

 

 

 

 

 

 

 

 

 

 

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Plastic Trumpets

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Top covers ready for vapour blasting

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Chokes & Aux. venturis ready for vapour blasting also

 

 

 

 

 

 

 

 

 

 

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Brass parts are going to be dipped in hydrochloric acid for around 30-45mins

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steel parts for yellow zinc plating

 

 

 

 

 

 

 

 

 

 

 

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steel parts (throttle shafts mainly) for black phosphate coating

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Remaining parts kept safe and treated by hand (most get thrown away after restoration has been completed.

 

 

 

 

 

 

 

 

 

 

 

Here are the carburettors and their parts after treatment(s).
It is vital to use clean, compressed air to remove any debris and loose particles from all carburettor castings and parts.

Stud, screw hole & mixture orifices in particularly must have special attention.

Once carburettors and parts are sufficiently clean – rebuild can begin!

 

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And here they are the carburettors & manifolds installed on a Classic Porsche 911 engine…

 

 

Porsche 911 WEBER IDA Triple Carbs - restored and now on engine

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The idle mixture screws, air by-pass screws were set to manufacturer specifications – Ready to start the engine!

Also the floats needed some attention. These were measured after installation and two of them were found to be out of tolerance. So adjustment was necessary. Very delicate and intricate procedure, but equally important to get correct fuel level in the chamber.

 

Carburettors & manifolds are now ready be plumbed in, fit the throttle linkage, pump the gas and start the engine!

After this, the car will have a rolling-road tuning session to balance the carburettors and get the very best out of these 50 year old Italian beauties!!

 

Thank you for looking at our restoration page.
We do have a few more, similar restoration pages you can have a look at here:

Classic Ferrari 330 WEBER 40 DCZ/6 Triple Carburettor restoration
Classic Ferrari 246 DINO WEBER 40 DCNF 13 Triple Carburettors

If you’d like to have your carburettor(s) serviced, tuned or restored as above, please send us an email or call us to see what we can do for you and your classic car 🙂

email: support@classiccarbs.co.uk

You can also get in touch with us on facebook

 

Thank you,

 

Emmanuel Grigoriou
classiccarbs.co.uk