03-27-2007, 04:59 PM
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Are you going to make it???????
Jes,
No updates since yesterday afternoon, are you going to make it to Buttonwillow this coming weekend?
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Gifford
'72 Super, '67 GTV --> SOLD
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03-27-2007, 05:19 PM
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Still trying... Too busy to post updates. Left to do:
1. Intake plenum aluminum welding - Colin is having problems with the breaker at his house cutting.
2. Custom alternator bracket
3. Some exhaust fab'ing
4. Start-up and trouble shoot
A mad dash and a lucky NO issues at start-up mean I will make it. Any kind of issues (which is likely in a complex project like this), and I'll be spending the weekend on the sofa catching up from weeks of sleep deprivation 
Jes
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87 Milano Verde - daily driver - Juliet
87 Milano 3.0 Motronic - budget race car - Roxanne
87 Milano 3.7 24v - race car
(Repeating what I suggest or do is at your own risk - be critical)
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03-29-2007, 02:59 AM
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Some good progress on completing Roxanne. Inching ever so close to fire her up after the 164S engine conversion 
It took quite some time to get the custom bracket for the 6 lbs mini Denso alternator just right. At last it is installed, belt on, anf wires hooked up. I also spent time installing the seat, harness, and fire extinguisher. The seat and harness required some effort since the seat mounting has been changed (=simplified).
Jes
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87 Milano Verde - daily driver - Juliet
87 Milano 3.0 Motronic - budget race car - Roxanne
87 Milano 3.7 24v - race car
(Repeating what I suggest or do is at your own risk - be critical)
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03-29-2007, 03:06 AM
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Colin finished welding my 180* aluminum bend to the 164 plenum and the throttle body mounting plate to the other end of the bend It came out well, and everything fits nicely 
The plenum, idle stabilizer, oil vapor separator, and various vacuum lines were installed. Only an aluminum straight pipe between the throtlle body and air flow meter remains to be installed. It will have a couple of vaccum fittings for the idle stabilizer and oil vapor separator.
That leaves only the exhaust before the car is complete. We plan to do the exhaust tomorrow, Thursday, evening and should be able to attempt start-up then 
Jes
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87 Milano Verde - daily driver - Juliet
87 Milano 3.0 Motronic - budget race car - Roxanne
87 Milano 3.7 24v - race car
(Repeating what I suggest or do is at your own risk - be critical)
Last edited by AR4me; 03-29-2007 at 03:10 AM.
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03-29-2007, 09:59 AM
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Oooh....the pressure is on, Jes!
It's pretty exciting stuff! Who needs '24' when you have the Roxanne Show to watch.
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Graham
'86 GTV-6 daily driver
81 GTV-6 racecar project
'67 Spitfire racecar (GP)
"if your car handles like it's on rails, you're probably not driving fast enough" ~ Ross Bentley
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03-29-2007, 10:04 AM
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Plenum
Jes why did you go with the 90 degree bend and not in the middle of the plenum like JJ has. An engineer told me that if you are forcing the air at one end like on the 90 degree the cylinders at the other end are getting a bit less air vs in the middle so all cylinders get the forced air more evenly.
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03-29-2007, 10:58 AM
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 Quote:
Originally Posted by GTV6PASSION
Jes why did you go with the 90 degree bend and not in the middle of the plenum like JJ has. An engineer told me that if you are forcing the air at one end like on the 90 degree the cylinders at the other end are getting a bit less air vs in the middle so all cylinders get the forced air more evenly.
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It makes another 25 HP this way, certified, dynoed, and approved Don't tell me you went with the inferior design Just kidding.
On a serious note:
1. Right now the air enters the plenum at an angle as designed by Alfa. I'm not saying this is better, but it cannot be all that bad. Besides, the 180* bend is a smooth bend and should not create any turbulence (if that is a concern).
2. I wanted factory reliability and wanted the 164S engine as close as possible to the way it was designed by Alfa in order not to jeopadarize performance with ill designs (although in good intention). Lets face it: no matter how clever and educated we believe we are, we are still amateurs (at least nost of us are) and don't have the knowledge and experience of the engineers who designed these things. So, as you may, or may not know, the 164S has the idle stabilizer and oil vapor separator on the side of the plenum. The oil vapor separator can be relocated fairly easily, but relocating the idle stabilizer is more complicated since it has a unique fitting on the plenum. I'm sure it can be done, but there really wasn't any point.
Jes
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87 Milano Verde - daily driver - Juliet
87 Milano 3.0 Motronic - budget race car - Roxanne
87 Milano 3.7 24v - race car
(Repeating what I suggest or do is at your own risk - be critical)
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03-29-2007, 03:29 PM
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Hey Jes, what pully did you use with the alternator? looks more narrow than the stock 164.
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03-29-2007, 05:13 PM
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A random serpentine pulley that would fit on my light weight Denso alternator - basically out of the bin at a starter/alternator rebuild place - whatever would fit - practically free. It is only a 4 groove pulley, but should do the trick.
Jes
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87 Milano Verde - daily driver - Juliet
87 Milano 3.0 Motronic - budget race car - Roxanne
87 Milano 3.7 24v - race car
(Repeating what I suggest or do is at your own risk - be critical)
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03-30-2007, 09:42 AM
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Roxanne is going to Buttowillow
YES! 
Finished up the car late last night. Checked everything in my mind to make sure I wasn't missing anything, and then cranked the engine - sprung right back to life
A quick status revealed no oil leaks, no water leaks Denso mini alternator conversion works Good oil pressure, radiator fan comes on... Only little thing is an inoperable low oil pressure warning light. The regular oil pressure gauge works, so I know there is good pressure.
I'll post some pics of the final conversion a little later.
Jes
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87 Milano Verde - daily driver - Juliet
87 Milano 3.0 Motronic - budget race car - Roxanne
87 Milano 3.7 24v - race car
(Repeating what I suggest or do is at your own risk - be critical)
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03-30-2007, 10:45 AM
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Congrats!
Kevin
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86 Spider Veloce
87 Verde
Milano registry custodian( www.alfamilano.com)
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03-30-2007, 03:19 PM
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Thanks!
Below a few pics of the engine bay after completion. Appologies for the blue silicone couplers at the intake - the only ones available locally 
I just took Roxanne for a 30 min spin to see how everything is - seems good and ready to go Only problem is I'm dead tired after working to 2:30 am for the past days, and still get up early for work.
When putting the exhaust together last night we took a slightly different route than initially intended. Instead of keeping the cat and replacing the exhaust ahead of the rear axle we took out the cat but kept the stock exhaust ahead of the rear axle. Points-wise it is a wash, but given how perfectly the CSC downpipes fit with the stock exhaust, and that more power is probably gained this way, well, that was the route we took. A big plus: it reduced the downpipe and exhaust install to simple bolt-on
Jes
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87 Milano Verde - daily driver - Juliet
87 Milano 3.0 Motronic - budget race car - Roxanne
87 Milano 3.7 24v - race car
(Repeating what I suggest or do is at your own risk - be critical)
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03-30-2007, 03:49 PM
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Looks Nice
You made it look so easy I'm scared you're going to convince me to try the same thing 
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84 GTV6 - 3.0L, headers, Sport Rear springs, Bilstien Shocks, LSD
87 Milano Platinum 74 GTV
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03-30-2007, 03:52 PM
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How great. One request and I'm sure alot of other people are keen to know: can you get it weighed?
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03-30-2007, 07:27 PM
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Looks great Jes. Glad you got it ready on time.
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'85 GTV6
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