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Thread: Bezzera BZ-40 rebuild

  1. #1
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    Bezzera BZ-40 rebuild

    Gene Cafe Coffee Roaster $850 - Free Beans Free Freight
    Well here it is my Bezzera BZ-40..... Not bad for $160.



    And here whats under the hood.






    After ripping the cover off and some basic safety checks, is the earth connected etc.
    All was well so plugged her in to see what happens.

    Boiler started to heat. good...

    Pressure building...watching the gauge...passes 1 and then 1.5 heading toward 2....getting nerves.....switched off
    what pressure would you expect the boiler to get to?

    Bleed out some hot water/steam from the hot water tap etc

    Also noticed the vibe pump wasnt working, power is getting to the pump but its not working or making any noises.
    [s]But a meter across the pump....bugger it open circuit reading megohms [/s]:(
    Oh well time to track down a replacement vibe pump.

    Craig

  2. #2
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    Re: Bezzera BZ-40 rebuild

    I dont see any pics?? :( :-/

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    Re: Bezzera BZ-40 rebuild

    mmmm...i see them.....must not me able to link to pic in yahoo photos......dooooo

    Ive attached one for now until I sort it all out.

    I also got the vibe pump humming, not pumping yet...didnt know about the diode in the plug, this thru me off.

    will continue to tinker

    Craig


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    Re: Bezzera BZ-40 rebuild

    and another


  5. #5
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    Re: Bezzera BZ-40 rebuild

    top


  6. #6
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    Re: Bezzera BZ-40 rebuild

    side looking at boiler


  7. #7
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    Re: Bezzera BZ-40 rebuild

    Great machine Craig,

    Looks like your time is going to be accounted for, for a wee while ;). What other bits and pieces came with the BZ-40? I can just imagine it taking pride of place on a benchtop in the kitchen or entertaining area. What a beauty....

    Cheers,
    Mal.

  8. #8
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    Re: Bezzera BZ-40 rebuild

    Thanks Mal,
    Yep sure is going to keep me busy for a little while, Just want to get it operational first, making sure everything works as as should and then the full pull down. First problem so far is the vibe pump, it not working, does nothing but get hot :-[

    The only other bits are a single porterfiller, and basket that needs a new handle.

    Craig

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    Re: Bezzera BZ-40 rebuild

    Good deal Craig, Im sure youll get a lot of satisfaction out of this project as well as the coffee. I notice it has a a sirai pressurestat. As its obviously done a few miles it would probably be a good idea to get a replacement membrane as these are one part that seem to need regular replacement, its only a cheap part, about $15. Symptom of a dodgy membrane apart from leaking are too wide a deadband between power on and power off. Id get spares for all orings and gaskets as well so when you rebuild you know you wont have to redo the job in a couple of months. Is there much evidence of scale btw?

  10. #10
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    Re: Bezzera BZ-40 rebuild

    Thanks Maurice.
    Yep looking at what I have to order for the refurb, main focus it getting it going ATM.

    Pulled apart the vibe pump this morning nothing obvious....bit of scale?and grime etc.

    Just got back from picking up a new one, cant wait to get home and fit it up.

    Also noticed that the group is different to the current model BZ-40 looks like mine have a water circuit thur it where the newer one rely on heat conduction thur the mounting bar.

    Craig

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    Re: Bezzera BZ-40 rebuild

    Craig:

    I have to say it doesnt look much like a 40-P.

    The boiler looks much smaller and has only one element in it that I can see. In fact the overall dimensions look somewhat smaller although it can be hard to see from the photos.

    When you are finished though you will have a nice machine. The hx machines are really quite simple and this makes restoration not too difficult.

    Grant

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    Re: Bezzera BZ-40 rebuild

    Hi Craig,

    Welcome to the used Bezzera club.

    You have an older style BZ40. It seems to have a thermosyphon style head, similar to the BZ2000 and Elisse.

    It should be a nice machine when you get it running.

    cheers,

    Mark.

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    Re: Bezzera BZ-40 rebuild

    Sparky:

    It is a completely different machine to the newer BZ-40, probably the same size as the BZ-99 and similar to the BZ-35 as it has a horizontal boiler, probably about 2.5litre.

    The thermosyphon head is interesting. I will be interested in how the group temperature behaves with the thermosyphon.


    Grant

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    Re: Bezzera BZ-40 rebuild

    All you guys will be able to start up a Bezzera Owners Group pretty soon :P.... seems like Bezzeras are going to feature in the CS Forum almost as much as the venerable Silvia ;). All the best guys,

    Mal.

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    Re: Bezzera BZ-40 rebuild

    Hi All
    Been busy at work over the weekend *:(

    However I did find time to get it going pretty well.
    1st problem was a shot vibe pump which Ive now replaced
    2nd was a minor wiring problem a connector was loose
    3rd was good old scaled up group and some pipes current soaking in a bucket.

    Boiler was very dirty, it really took some effort to get the heat exchanger out and the element both very scaled up.

    Its all now stripped down for cleaning, just got to pick up some gaskets so it should have all it cloths back on Thurs night, If work doesnt get in the way.


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    Re: Bezzera BZ-40 rebuild

    Quote Originally Posted by wattgn link=1129810367/0#10 date=1129865048
    Craig:

    I have to say it doesnt look much like a 40-P. *

    The boiler looks much smaller and has only one element in it that I can see. *In fact *the overall dimensions look somewhat smaller although it can be hard to see from the photos.

    Grant
    Yea not sure what it is Jack seemed to think an old BZ-40?

    Yes it has a smaller boiler just 2L
    No other info on the inside of the machine, just a serial and make on the boiler.
    This is the name plate on the front of the machine.



  17. #17
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    Re: Bezzera BZ-40 rebuild

    That looks exactly like the old BZ40 that Jack has in the shop. It must be the model that was superceded by the current lineup. The boiler, HX unit and element look to be the same as those of my BZ35, so that means parts are readily available and not too expensive. The addition of the thermosyphon head looks interesting. I wonder how that will affect the shot performance. Most commercial machines seem to use thermosyphon heads. They are very tunable, by adjusting pipe length, width, gicleur size etc. It seems that once you have them dialed in they work well. Keep us posted.

    Cheers,

    Mark.

  18. #18
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    Re: Bezzera BZ-40 rebuild

    Quote Originally Posted by Sparky link=1129810367/15#16 date=1130137423
    That looks exactly like the old BZ40 that Jack has in the shop. It must be the model that was superceded by the current lineup.
    Mark your exactly right.
    Its the same unit.
    Ive known Jack for many yrs, he used to work at the same company as me in a different area.

    Cheers
    Craig A

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    Re: Bezzera BZ-40 rebuild

    Good luck with the rebuild Craig. I really enjoyed rebuilding my BZ35, which I also bought from Jack at Barazi (and a mate bought the matching sister BZ35 as well). Id be interested in hearing how it stacks up against the PIDed Classic.

    Cheers,

    Mark.

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    Re: Bezzera BZ-40 rebuild

    Heres the Frame after sandblasting and a repaint.
    As you can see from the grass in the background Ive been spending two much time on my machine...neglecting other task at hand ;)


  21. #21
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    Re: Bezzera BZ-40 rebuild

    And the boiler.....gee it took some time to descale the inside. All spotless inside now.


  22. #22
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    Re: Bezzera BZ-40 rebuild

    Nice and clean heat exchanger....half of this was black. inside was tricky.


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    Re: Bezzera BZ-40 rebuild

    half way thur reassembly


  24. #24
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    Re: Bezzera BZ-40 rebuild

    and another from behind


  25. #25
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    Re: Bezzera BZ-40 rebuild

    It sure looks a bit different to the before pics, excellent job. Did you use anything stronger than citric acid for descaling? Im guessing you had to manually chip/grind away at scale in the boiler.
    BTW how much did the sandblasting set you back? Im trying to decide if I should sand blast or just wire brush and touch up a couple of rust spots on my current project.

  26. #26
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    Re: Bezzera BZ-40 rebuild

    Quote Originally Posted by mauricem link=1129810367/15#24 date=1130842703
    It sure looks a bit different to the before pics, excellent job. *Did you use anything stronger than citric acid for descaling? Im guessing you had to manually chip/grind away at scale in the boiler.
    BTW how much did the sandblasting set you back? Im trying to decide if I should sand blast or just wire brush and touch up a couple of rust spots on my current project.
    Hi Maurice
    I used citric acid at first it cleaned up the copper tubes and surfaces ok.
    I was out shopping and saw this kettel cleaner called Kettle magic by Rubbedin basically seems like a stronger citric solution, anyway worked a charm at descaling the boiler, still require a good soak, scrub, soak scrub etc.

    As for the sand blasting, I have access to these facilities at work after hours so it only cost me my time.

    I got the boiler and all the copper work in tonight, tomorrow is switch on and flush out etc :)

    Craig A

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    Re: Bezzera BZ-40 rebuild

    Craig:

    Looking good!

    The first coffee will taste so sweet!

    That is what Jack told me after two weeks of messing with my BZ-40P!

    I finally solved the problems and he was right. In fact aside from changing an o-ring in the hot water tap, I havent touched it since I fixed it up.

    Beautiful machine.

    Grant

  28. #28
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    Re: Bezzera BZ-40 rebuild

    Great restoration job, Craig, and very satisfying too, I bet, especially having a new-looking frame on which to hang the other fruits of your labour.

    Perhaps in the distant future grown boys with toys and lots of spanners will turn to restoring coffee machines. With parts sourced from the numerous local coffee machine wreckers yards.

    Cheaper, much quicker, cleaner and more do-able than the 56 Pontiac rusting out the back (in my dreams, that is).
    Good work.

    Robusto

  29. #29
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    Re: Bezzera BZ-40 rebuild

    Ive finally got it all back together [smiley=2vrolijk_08.gif]



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    Re: Bezzera BZ-40 rebuild

    And from the back


  31. #31
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    Re: Bezzera BZ-40 rebuild

    And from the Front.

    Been running a lot of blank shots thur flushing it out etc. now I have to roast some coffee to put thur it.


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    Re: Bezzera BZ-40 rebuild

    Craig:

    Yours looks like it has a circumcised steam tip or has it been removed? (it is illegal to do this unless you are a rabbi anyway).




  33. #33
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    Re: Bezzera BZ-40 rebuild

    Quote Originally Posted by wattgn link=1129810367/30#31 date=1130989272
    Craig:

    Yours looks like it has a circumcised steam tip or has it been removed? (it is illegal to do this unless you are a rabbi anyway).
    No it must be the old type or modified in the past it doesnt come off just a single hole at the bottom :(

    May have to look at modify it to something decent, I MUST have micro foam......

    Nice setup....Bezzera is soon releasing a new remodelled BZ-40 with those ball joint type moveable steam and hot water wands. Also heard they are to release an E61 group type machine too.

    A couple days ago I also saw the insides of an ECM unit. Not impressed at all, looks like they spent all the money on the group casting and flashy case and filled it with crap - all plastic tube, plastic fitting, not a quality part in sight, I wont even consider one now.

    Craig A

  34. #34
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    Re: Bezzera BZ-40 rebuild

    Craig:

    Steam wands are easily replaceable about $60 for the unit so if you need to replace your wand I would ask Jack what a suitable one might be. Anyway, it might surprise you and produce good foam.

    Interesting about a remodelled BZ-40P. Theyre pretty conservative these italians when it comes to updating the models.

    Interesting what you say about the ECM. I have heard it does have sphagetti innards but I havent had a look myself. Plastic tubing is OK on cold water only lines but not on anything hot or pressurised.

    Roll on Bezzera.

    Grant

  35. #35
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    Re: Bezzera BZ-40 rebuild

    Excellent job Craig,

    Also, a good series of "work in progress" pics too [smiley=thumbsup.gif]. I bet youre hanging out for that first drinkable brew ;),

    Mal.

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    Re: Bezzera BZ-40 rebuild

    Craig,

    re "........it doesnt come off just a single hole at the bottom .....May have to look at modify it to something decent, I MUST have micro foam......

    Is that not a removable nipple / nozzle at the end of the pipe? It would have to be pretty unusual for it not to be ;) Sometimes the nozzle and the union it screws into on the pipe are rubbed (by operators that wont be told NOT to use scourers) smooth down to a point where they look like a single piece. But if you put a small shifter on the end of the nozzle & turn, you might be surprised. During manufacture they also use a good dollop of loktite and the first time you remove them they are usually extremely tight. There after they just seem to "fall off". We prefer plumbers tape to loktite in that application.

    In any case it always takes time to get used to a new set up, different steam capacity, steam pressure and design of nozzle etc requirng a modification to your existing technique, so Id suggest giving it some time before changing something that might be perfectly good as is.

    Regardz,
    FC.

  37. #37
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    Re: Bezzera BZ-40 rebuild

    Craig, I think youve really raised that machine from the dead. How does the coffee taste from it? I found a huge difference going from my PIDed Classic to the BZ35. From push buttom simplicity, I had to find a flush routine that worked. Im still trying to get my machine operating in the sweet spot.

    Great work.

    Mark.


  38. #38
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    Re: Bezzera BZ-40 rebuild

    Hi All

    Been flat out at work :-[ and installing a mother of a ducted air con at home so time on the machine has been limited.

    Its all back together and operational, :) Yesterday I check the brew pressure with one of those pressure gauge PFs and it ok and consistant 9.5Bar.

    As for taste Im still flushing out the unit, I have a funny taste from the Hotwater/steam (Boiler)......
    Brew is ok. A result of cleaning.
    I pulled a couple of shots and all seams ok, still got to dial my grinder in to suit etc, not much time lately.

    SO the flushing will continue until the bad taste has gone.

    More later
    Cheers,
    Craig

  39. #39
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    Re: Bezzera BZ-40 rebuild

    Well my ducted air con project @ home is complete so I can pull my shots in comfort all year round now so back into my project Bezzera.

    It been up and running now for a couple of weeks the espresso fine but I havent been able to stream my milk right no matter what I do and I pretty sure it tip releated.

    FC. I think you maybe right about it being a very worn original fitting but its completly unrecoverable.

    Due the age of my machine my style of steam wand in no longer available, so heres the plan, pickup current style steam want, cut the end off and put in on my current wand...should do the trick. Picked up a doner wand this morning.

    Im also fitting a drain to my drip tray, fittings shown in pic as well. I know its petty but I hate having to empty the tray. I also plan on converting it to a plumbed unit later down the track as well.

    Cheers
    Craig A


  40. #40
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    Re: Bezzera BZ-40 rebuild

    Well I just brazed up the new tip onto my steam wand, cant wait to get home 2 give it a go.
    If it works I clean it up and have it replated.




  41. #41
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    Re: Bezzera BZ-40 rebuild

    Now for an update
    Ive fitted my new modified steam arm and have run into the same difficulties as others with the 4 hole tip. Why they sell this useless tip has be mistified....anyway today I picked a up 2 hole tip :) sooooo much better but need more pratice as I still cant get microfoam as good as I could with my classic.....yet....

    Now I need some help.
    After my machine rebuild I still have a slight metallic after taste to what ever I steam.

    Any recommendations on how to get rid of this? I though it would have disappeared by now....but I havent really been using it much lately due to being unable to steam correctly, but nows that all changing. especially with Christmas so close

    Cheers
    Craig A

  42. #42
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    Re: Bezzera BZ-40 rebuild

    Behmor Brazen - $249 - Free Freight
    Try flushing the boiler and getting fresh water in there. :)

    Java "Back to the future days of Steam Power!" phile



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