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Restoration of a 3rd Series Faema Mercurio (Tall Group)


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I just confirmed the purchase this weekend and I expect it to arrive in a week or two, but I have another project to show. It's an August 1957 Faema Mercurio 3rd series with the tall group. It is in fantastic cosmetic condition and was originally gas powered. I purchased it from a Dutch company for a little premium as a result. There is no heating element and the flange is capped off. Looking at the ID tag you notice the Watts, Voltage, and Phase are blank with an ID number of 12724.

I have no intention of rechroming, just some light polishing of the aluminum group housing. It is 15-20mm taller than the normal housing, and this uses the 180mm spring instead of the regular 165mm spring seen on the Zodiac Group. It also has only one piston seal, and I will show how this group works once I get it as it is really nifty.

I will be having someone likely make the heating element for me and also drill the flange to fit the element or have a reproduction made. I have never seen a boiler flange with the capped off holes in a Mercurio. 

This will be a fun project once I financially recover enough to purchase the needed parts and tools...

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  • Like 11

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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I just asked some of my contacts I developed over the past year if they had a machine I could snag to work on. This network developed organically and I did not actively seek new contacts. I just found them off chance in my online searches. The seller is actually Dutch and knows Henk Langkemper, a well known La Marzocco distributor and collector. This machine the seller found himself. I have not really bought much from Italy that I cannot see in person since I got back to the US.

With my contacts I have already found the 180mm spring replacement and someone to modify the flange/fab a new one to fit a 110V heating element. I also have the majority if not all the parts sourced.

  • Like 1
  • Thanks 1

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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Some various updates:

The Rancilio element will not fit the Mercurio as it is too short for the boiler, discussed with Pascal/Chromes D'Antan. I will have the 110V element made instead.

The bakelite is actually brown, and was not shown well on the seller's photos. However he does have a photo of it being picked up showing the brown colour, along with the nicotine splattered machine that has since been cleaned off mostly. The one exception is the lever handle, which is black. It must have been replaced at some point but I already sourced a replacement original brown bakelite handle for a very reasonable price (~£55 + shipping).

The machine gets shipped off today and hopefully arrives here quickly. I have the Harmonized Tax Schedule figured out and should be able to get it through customs easily.

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  • Like 5

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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After a mechanical delay from FedEx the Mercurio popped up on my doorstep today! The box looked pretty knackered but the machine and all the bits were undamaged (at least from transit). Even from looking at the photos from prior I am blown away at how pretty the Mercurio looks. The exterior is in [i]fantastic[/i] condition considering it is original and unrestored. I threw it on my dining room table and it took me a few minutes to look away as I admired it. 

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I am really curious to see the preinfusion valve once I start diassembly. I am reluctant to even start doing that but it will begin eventually. There is also not shutoff valve on the bottom like on other related groups.

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Some stuff I already notice: How on earth do I get the hot water wand out if the panels trap it? It looks like they inserted the piping and soldered the compression nipple afterwards! The preinfusion/hot water valve rod has some cracks so this might be the excuse to try out some soldering practice. It still functions nontheless. There is still water in the boiler as well which is pretty funny. I would hate to imagine what would have happened if this shipped below freezing...

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Finally here is the Pavoni for Scale photo. 
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  • Like 6

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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Big day today. Most of the machine is disassembled at this point. I will go in order to take stuff off. 

The first thing I needed to do was remove the steam wand. I saw that the tube was compressed at a portion of its tubing but it needed a little more squeeze with some pliers to get it out of the narrow panel slot.
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I took off the water sight glass cover after. It clips onto two metal fittings at the top and bottom.
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Next I proceeded to take off the back panels and Faema Emblem. The panels are held in place by two screws each on the front backsplash, and two additional screws each in the back where the emblem rests in front of. The emblem itself is held by one large screw on top and the lower brass screw. There is a second brass screw towards the top that just holds the FAEMA MILANO plastic piece to the brass decoration. Note this decoration is very beefy, weighing in at almost a kg!

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The upper group came off next. It is held by three screws like most Faema Zodiac groups. I had to take out a screw for the pre-infusion assembly on the side as it blocked me from taking the group out. The cap came off via two chromed bolts on the front. I could pull out the upper group by hand with some tugging and confirmed my thoughts that this is only a one seal piston. 

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Here is the boiler with the panels off. You can see the thermosyphon loop running from the side of the boiler to the group via two elbow fittings. There is a water inlet on the bottom and the steam valve connects at a multi-use fitting at the top where the wobbler weight resides. The other side of the boiler just has the water sight pipes. There are two capped off fittings that I could use in the future. 

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The boiler has the machine number stamped on it that matches the front ID tag.

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I then moved the machine outside to empty it of the remaining water via the gas tube. I can definitely see myself adding a drain valve in the future there or the lower fitting. I worked on the water inlet/hot water valve, but I was only able to take off the chrome portion that is also part of the 1-way valve. Unfortunately I cannot take out the valve even when loosening the hex bolt securing it to the frame due to odd sizing. I know that people sometimes experience issues with it due to scale build up so I still need to address it.

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The sight glass came off pretty easily. It's similar to my President's sight glass where two fittings screw and secure the sight gaskets but without the little springs.
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At this point I started working on the boiler screws. I finally went out and bought a flame torch from Ace Hardware and it appears very effective. I was able to get off all 8 boiler bolts with no snapped or damaged threads! I kept the one bolt that attaches to the frame tightened so I would get the other fittings off securly. The bottom boiler bolt is missing from action so I will need to get a replacement M8 or M6 bolt. I had issues taking out the boiler because the thermosyphon pipes were blocking the way. I had to loosen them [i]and[/i] tilt the boiler so I could fit the 26mm wrench properly. 

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I got the group bolts loosened but the elbow fittings were blocking the escape route. What I ended up doing was having a second person (Dad) hold the group out so I could fit my 22mm wrench to the elbow head. After taking my torch to everything first!
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The lower panels were next now that the frame was getting pretty light. I put it on its side to take off the two blind bolts in the back, and the two screws per lower panel. One of them had a stripped thread but that is the first 'big' issue I have run across so far. I left the lower front panel on as I did not take off the rivets holding the tag and also the panel. I will probably take a flathead and tap off the rivets from the back.

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The sight glass fittings are secured by a square hole, which allowed me to whack my wrench on the two nuts securing them easily. At this point I could take off the front backsplash and gas flap. The gas burner and the boiler fittings were the last thing I took off before calling it a night. I still have to take apart the steam valve and inlet/hot water valve but I am making pretty good progress.

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Current things to address are the stripped skirt screw, some cracked joints on the boiler probably due to the missing lower boiler bolt, and the bottom fitting on the group that is part of the inlet mechanism.
 

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  • Like 6

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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Posted (edited)

One final wrap up before bed. Taking a look at the group spring I saw some markings. Apparantly the spring has its own birthday, where it says 'FAEMA 7 57' on the coil. It is apparantly one month new than the machine (or at least the manometer). Pretty cool stuff.
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Here is the flange from below. Pretty weird to see no holes in it. The Mercurio is scattered somewhere on the storage rack...
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Looking at the back of the grouphead I see a flat screw stuck inside. Could this be similar to a Faema curved group where this screw is used to plug a hole if something is missing, or could it be preventing my bottom stuck nut from unscrewing?
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Edited by IamOiman
  • Like 3

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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Posted (edited)

The screw I questioned is indeed for plugging a hole made during machining of the group so it's staying put. I am working with Pascal/Chromes d'Antan for the boiler flange and a replica 1500W heating element. I am taking my boiler to my metal worker guy that did the Faemina shaft repair. A 30mm wrench and 28mm socket are on order for the valve nuts and group nut respectively. 

I have been speaking with Enrico Maltoni about my machine. It's complete as I thought and he notes it's the final/last ("l'ultima) series of the Mercurio. He also believes there are four, maybe five series total rather than my previously thought three series. Supposedly they are less 'desirable' than the earlier curved group first series but I am saving that group for a Marte down the road. He does like a Mercurio of any series a lot nonetheless. Maltoni also noted it sometimes occured where brown and black bakelite handles would mix and is not unheard of, which makes sense as the black bakelite is original from that time. 

Edited by IamOiman
  • Like 3

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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I have a new ultra sonic cleaner on the way that will stop me from starting to clean the little bits until it arrives. I got the hot water/inlet valve off the frame. I needed to maneuver it carefully to take it out as it was close to being stuck on there without unscrewing one of the fittings. I do not want to take it apart as it currently has water scale built up very heavily and old seals. I want to soften them up first before attempting disassembly so I do not end up with a broken/sheared off fitting.
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  • Like 3

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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Posted (edited)

I got the frame stripped completely after deciding to take off the serial tag. It was pretty simple to do, just take a small punch and tap out from the back to knock out the rivets.  The tag is a little bent so I hope to flatten it out a but before returning it to the frame. The frame itself is in very good condition. The only true rust I could find was a little bit where the group head bolts on, and I partially think that rust was from the bolts rather than the frame. I might just keep it as is since I do not see serious pitting or rust but the frame definitely needs a serious cleaning in terms of nicotine residue. Any suggestions on how to do that?
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The backsplash is quite grimy as well. Normally I would just directly use Autosol for cleaning up but I think I may need to use something before to get the grime off first, at least for the back part. I'll take suggestions on that to ensure the chrome is not affected.
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The boiler is starting its soak. Once cleaned up I'll get the stress cracks soldered up.
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The manometer bezel is intact. I think the manometer design is one of my favorites. 
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Last thing tonight is looking at the gas valve. Taking a closer look and being informed by a member for Kaffee-Netz I see that it is the same valve used for temperature regulation on the Faema V-groups! Very interesting use for it as I presume it was a surplus valve needing to find a home.
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Edited by IamOiman
  • Like 2

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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I got my new sonic cleaner, a 6L Vevor. It's quite bigger than my old Harbor Freight one, which I burned up during cleaning the Faema President bits and more powerful. I immediately set about de-scaling my fittings in citric acid. I was able to take off four out of the seven fittings from my steam valve and hot water/inlet valve before I decided to spray penetrating fluid and let them sit for a while. They were really gunked up, especially at the hot water fitting since water likely remained in the pipe after use. Fortunately my sonic cleaner made them nice and clean.

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For the chrome bits I focused on getting the nicotine build up off using Glo-Joe to great effect. I was able to fit the lower group in the cleaner and at this point for most of the chrome bits they just need a little polishing or are already set. Some of the pieces like the preinfusion mechanism I did not know where chromed until after the cleaning! I even cleaned up the boiler flange pretty nicely. It appears to be iron or steel? A question I have is can I keep the cylinder in the group as is or should I take off the remaining chrome inside?

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Finally, on the preinfusion rod there is a very small gasket, measuring 7x4x4mm. I can likely just stuff it with teflon tape but I am asking if there is somewhere I can buy a spare.
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  • Like 3

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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I got my boiler and some bits dropped off with my metal guy to fix up. The powder coating guy is on vacation so I will not have that done until at least 21 October when he gets back. The boiler flange is mailed off to Pascal for adaptation to accept a new element.

I finally got the bottom group fitting off after some soaking in penetrating oil and the arrival of a 28mm socket. It needed my 3 foot pipe wrench to wrestle loose but now I can do a final cleaning and polishing of the inside and exterior of the group body
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The last thing at this point I need to take apart is the upper group assembly. The piston is stuck so I started letting it soak after a heating session with the propane torch. Hopefully I'll get it off soon to start its cleaning process. I can consider myself to be fully in the cleaning portion of this project and since I see what's apart I can place my parts order. The valves use the same gaskets as the E61/President and I have some leftovers from my past projects. The more esoteric stuff is the boiler and group gasket, which I do have a source for. 

Project costs from what I am estimating will likely be around £900 with everything including parts, tools, and labor purchased in the process, and that is a worst case estimate. This is still within my personal budget tolerance with the base cost of the Mercurio.

  • Like 4

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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My metal guy was really quick and I picked up my stuff today after 24 hours. The boiler had three welds added with silver solder, and the cam extender for the water inlet valve was fixed up as well.
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I did some more descaling of some little bits. The valves are now all apart and I am ready to place my parts order after seeing everything I need. One thing I am concerned about is the cam for the inlet/hot water valve is very stuck on the large fitting and cracked on the tip. It appears at some point the rod became stuck with this fitting and the cracks are from someone exerting force on it in an attempt to move it. I bet that is what also caused the cracks on the now fixed rod extender. I hope I get all the scale out and coax out the rod to see if I can salvage it or if I can manage it in its current state.

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This is the entire preinfusion mechanism apart. I'll explain how it works once I get it assembled again. The group I noted easily accepts an IMS shower with an E61 gasket. I will need an 8mm height for proper locking of the portafilter.

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The group piston is still stuck so I have that soaking still in penetrating oil after heating it.
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  • Like 3

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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My parts order is sent out. The only odd gaskets of the bunch was the boiler gasket and the small 7x4x4mm gasket in the preinfusion mechanism. Brooks espresso/Thijs was able to custom order that gasket for pretty cheap and he sells the former by default. All other gaskets like the valves, sight glass, and group gaskets are still commonly available today which is incredibly convenient. There is no group gasket and instead the group is bolted directly against the frame. My Gaggia lever group gasket would fit however the thermosyphon fittings prevent this without modification. I can cut the gasket to adapt the fittings but my current decision is to keep it original and have no gasket. I have the old gaskets chipped out mostly, using a small pick and hammer to lightly tap the chunks out.

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I've been polishing and cleaning pipes, fittings, and panels up. Of all the body panels I only used Autosol on the backsplash, group cap, bottom front panel, and the lower rear panels just to get rid of the last of the nicotine. Everything else will essentially remain original, even on the inside. The only notable difference I saw in the polishing was the rear of the backsplash. You can note on the photo of the rear backsplash the little holes on the right side where the rivets would go for the old style labels for the massimo and minimo pieces.

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one inlet hole.jpg

  • Like 3

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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I'll clean them up a bit but I care more about their functionality than looks since it will be covered by the panels. The boiler is currently soaking again as I had more scale remaining than I initially thought. The stuck fittting is also soaking with the boiler as I think there is scale inside the fitting that holds the cam shaft.

  • Like 1

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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Well until I figure out what thread direction the piston is (pretty certain it's right handed/loose ccw but I like to check) I'll try going at it from above and make a jig. It has been painful to get it unscrewed with a leftie-loosie mantra. I spray penetrating oil almost every day, whack the piston with a mallet to shock the threads a little, and heat the thread area with a propane torch, the whole shebang. I do not want to be doing all this effort only to find out the thread is opposite to what I am trying to get loose and am actually tightening it.  

I am looking at the clips for the lever fork and they are different from the ones seen on the Zodiac. They are much thicker and are very sturdy. My ring pliers are not having a good time getting them off but that may be due to gunk build up. If there is a different tool that I should use I'd love to know.
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I did my best for what I had but I just could not get the piston off today. I had a small chisel that I struck the notch where the c-spanner went and tried pulling after with no success. I had the lever nearly cocked fully and had zip ties added and tightened to the point the spring was exerting almost no force against the piston thread and I could very slightly jiggle the fork. 

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  • Like 1

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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These are my notes for the jig I plan to make. I need the jig to hold the group by the two ledges on the sides of the group head one 'level' below where the bearings rest. I took out the bearing guides so I had more ledge to hang off of. The jig top may need to be cut into from a side as the bearings stick out 4mm further than the ledge wall. I'll have some wiggle room with it though if I just cut a rectangular hole in the middle. This is a beefy group so I will be using four threaded rods and 1-1.5" plywood (real plywood not that compressed wood shavings stuff) for compressing the group.

The wood will be pretty thick and I will use fender washers to distribute the force more evenly. Double nuts will be used on the bottom so I do not unscrew anything while tightening from the top. I need start from a mininum of 10" of height since the 7.5" measured contains a somewhat compressed spring already and I also need to include the wood height for the top board. To be safe I will do 12" for a reasonable maximum height allowed by the threads. I am thing of 1' square boards but I believe I can shrink it to 8". The rods will be 3/8" and if needed I can go bigger to be overkill.

I need the center of the bearings to be at least 2" above the top board as my bearing separater needs to fit properly to take the bearings off to access the rod smuggling pin. Once that is knocked out I got a disassembled group. Besides getting the materials those thick c-clips are the thing stopping me from proceeding.

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  • Like 1

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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Today was a good day.

First thing this morning I went off to Home Depot to get my materials. The jig costed about £20 in materials. I used the following:

12 x 1/2" Fender Washer
25 x 1/2" Nut (it was cheaper for the bag than 18 individual nuts)
One 3/4" x 2' x 2'  BC sanded Plywood where I cut out two 9" x 9" pieces.
4 x 1' 1/2" threaded rod

I marked out the cuts on one of the 9"x9" pieces with a right edge. Threaded holes were two inches away from the edges and I made a rectangular hole with a jigsaw to snugly fit the group housing. The holes were drilled out with the little drill press I have with both pieces clamped together and marked on one side so I would always keep the holes together. Two nuts and a fender washer are on the bottom of each threaded rod with one nut and fender washer on top. The top piece also had one nut and one fender washer per threaded rod.

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The security/c-rings were so buggered they came off in pieces. I have no idea what happened to them but I used a dremel to get the remaining chunks cut off. These can be replaced so it's not the biggest upset. I compressed the group such that I could fit my bearing separator onto the bearings. One of the bearings could be taken off by hand and the other one did not show much resistance against the separator. The pin was finally unearthed and tapped out easily. It is likely not original as the original had a knurled end on a side. In fact my new pins look exactly like the old one. The group is now apart and literally the only thing still together is the water inlet rod and its fitting. Something wild happened with it and it's still stuck fast. 

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I used just enough threaded rod for this jig!

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jig on group.jpg

  • Like 2

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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I quickly worked on cleaning the group. The bearings are pretty stuck but I have new ones if needed. I am very happy I have an ultra sonic cleaner that fits bigger parts. Check out the before and after on the inside of the aluminum group housing. Most of the sludge came off after the first cycle but I left it in a little longer to get all of it. The piston is plated and is brass underneath. I will likely not attempt to remove the rod since I have a method to reassemble the group when parts arrive.

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The rubber stops for the fork were so dry and worn there is a permanent mark on the lever fork where the chrome was rubbed away by the hardened rubber. I needed to drill into the rubber and take a punch to leverage it out. I've never seen this hard of a rubber part.
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I did a quick polish of the aluminum parts and at this point I have very little to do until parts arrive. It's just a waiting game at this point.

  • Like 3

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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double post please ignore

Edited by IamOiman

-Ryan

"Using a spice grinder violates the Geneva Convention"

2018 Bosco Sorrento, 1957 Faema Mercurio 3rd Series Tall, 1963 Faema Faemina, 1964 Faema President 2 Gr, 1977 Faema Zodiaco 2 Gr, 1979 Gaggia Tell 2 Gr, 1991 La Pavoni PRG & Elektra MCAL, Eureka Olympus 75E, Quickmill Omre, Lido E, Virtuoso, 30+ Moka Pots, Chemex 8 cup, Siphon 5 Cup, French Press 1L, 75 espresso cups, a basement to hold my bits n' bobs

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