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Gaggia Nuova Eta restoration project
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iko
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Joined: 30 Aug 2013
Posts: 58
Location: Toronto
Expertise: Just starting

Posted Tue Sep 17, 2013, 7:14pm
Subject: Gaggia Nuova Eta restoration project
 

Came across a one group Gaggia Nuova Eta at a good price. Thought I'd get it as a long term project. Couldn't test it, but all the parts seem to be there. Seems to need a lot of work.

Facts:

  • operating voltage: 220V
  • rated power: 1350W
  • heater elements resistance, measured cold: 119, 123, and 125 ohms; they are connected in parallel, resulting in a resistance of about 41 ohms which sounds about right 220^2/41 = 1180W (Power = Voltage squared / Resistance)


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iko
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Joined: 30 Aug 2013
Posts: 58
Location: Toronto
Expertise: Just starting

Posted Tue Sep 17, 2013, 7:24pm
Subject: Re: Gaggia Nuova Eta restoration project
 

Taking it apart.

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iko
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Posts: 58
Location: Toronto
Expertise: Just starting

Posted Tue Sep 17, 2013, 7:27pm
Subject: Re: Gaggia Nuova Eta restoration project
 

The Gaggia make pump is separate, 220V as well.

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iko
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Posts: 58
Location: Toronto
Expertise: Just starting

Posted Tue Sep 17, 2013, 7:29pm
Subject: Re: Gaggia Nuova Eta restoration project
 

Opening up the boiler didn't go very well. Three bolts snapped. They seemed to turn fine, but that was because they broke.

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iko
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Posts: 58
Location: Toronto
Expertise: Just starting

Posted Tue Sep 17, 2013, 7:37pm
Subject: Re: Gaggia Nuova Eta restoration project
 

How to get out the broken bolts? Drill right through the middle of the bolt with larger and larger bits, until there's very little left of the original bolt. Pull out the empty shell of the bolts somehow. Well, easier said then done. One bolt was drilled slightly off center. The other two, although drilled right through the center, and only a thin outer shell left, couldn't get the remainder of the bold to budge. So I made a thin chisel out of a punch, and sculpted them out of the hole, as careful as possible. The original threads got damaged, of course. I redid all the threads with the right size tap, which was M10x1.5 but the three holes that were damaged I don't trust to torque the new bolts as tight as the others. I'm thinking maybe I should use some JB weld to reinforce the threads? Not sure. Maybe the lid will not leak even when only lightly torquing the three problematic bolts.

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iko
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Posts: 58
Location: Toronto
Expertise: Just starting

Posted Tue Sep 17, 2013, 7:39pm
Subject: Re: Gaggia Nuova Eta restoration project
 

The other "fixed" hole.

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adpopulum
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Joined: 12 Aug 2010
Posts: 1
Location: Toronto, Canada
Expertise: Just starting

Posted Wed Apr 16, 2014, 11:33am
Subject: Re: Gaggia Nuova Eta restoration project
 

So what happened? Did you ever complete this?
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iko
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Joined: 30 Aug 2013
Posts: 58
Location: Toronto
Expertise: Just starting

Posted Fri Aug 8, 2014, 10:17am
Subject: Re: Gaggia Nuova Eta restoration project
 

Well, here's an update. This project was on the back burner for about a year. Then, about two months ago I decided to work on it again. The machine was all taken apart. Ordered all new gaskets from cafeparts, they had one on back order, so it took another month to get them. Got stainless steel bolts to replace the rusted original boiler bolts.

Cleaned the boiler and all pipes by boiling them for a while in a citric acid solution. Couldn't find real citric acid, but found a really good substitute. It's called Lipton Langis Lemon Professional bar mix. It's cheap and has a high concentration of citric acid. Cleaned all brass and copper amazingly.

Several parts of the machine were broken. Both gauges (pump and steam) were non-functional. The Gicar RL40 water level controller was gone. It's a simple electronic circuit which uses a stainless steel probe at the front of the machine, and when the water level rises and it touches it, the circuit's supposed to turn off the pump. Took me several hours to fix this one; had a burned rectifier which otherwise measured perfectly, but didn't to its function in the circuit.

The dark brown panels were chipped and scratched, so I sanded them by hand, and spray painted them. It's not a 100% professional finish, but IMHO it looks pretty good. Chose a colonial red for this.

I also replaced the pump with one that I had around, a diaphragm pump, much more quiet, and able to provide acceptable flow and pressure.

Here's the first shot pulled out of some old decaf that I had around since forever.

https://vimeo.com/102922986
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iko
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Joined: 30 Aug 2013
Posts: 58
Location: Toronto
Expertise: Just starting

Posted Fri Aug 8, 2014, 10:57am
Subject: Re: Gaggia Nuova Eta restoration project
 

Some pictures follow.

New brew head gaskets.

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iko
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Joined: 30 Aug 2013
Posts: 58
Location: Toronto
Expertise: Just starting

Posted Fri Aug 8, 2014, 10:58am
Subject: Re: Gaggia Nuova Eta restoration project
 

Another new gasket.

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