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Discussion Starter #1
I decided to document my build to share my experience with others, get advice and encouragement as I go alone. So constructive comments are welcomed. My goal is to build a fun car for track day use and still be able to drive on the street.

Build specs to date:

Alfaholics
Cams TS08 Inlet TS07 exhaust
Omex Ignition System

Paul Spruell
Stock valves
85 mm 10.5 pistons
Windage tray
TS Rebuilt kit - gaskets / misc

Classic Alfa
Intake manifold for 45 Carbs

EB Spares
Exhaust header for TS

Estimate I get from Alfaholics this should be a 185hp motor so that is my goal. It should pull strong to 6500 rpm.

For the most part I am playing check book mechanic and letting all the heavy work to be done by our local Alfa specialist Eurotec. They have build me strong motors in the past and I know my limitations. Parts are loaded up and getting dropped off tomorrow.

Tom
 

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Discussion Starter #2
Here are some pictures.

Carbs are 45 that I had

Car is 1976 Alfetta GT just picked it up locally. Has more rust then I would like but it was pretty inexpensive and most important local.

Motor I picked up off the BB.
 

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Discussion Starter #5
Picture of the truck loaded. Can you tell I am excited to get this going.

I also have a crank from a 2 liter Nord engine that I am thinking of using. As I understand it this is a direct swap and allows the option to use this motor in a 105 car down the road.
 

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I noticed you are getting the exhaust headers for twin spark. Are these the ones for conversions? If so, I think they are for the GTV/Spider conversions. Alfettas have essentially the same layout as the 75 from whence the engine comes. The stock exhaust fits or if it's a header, should be a header from a 75.

I have an Alfetta with a twin spark and it just slipped right in with the intake and exhaust manifold stock. I'm converting it to a stand alone computer now with the stock wiring and the old Spica throttle bodies grafted to the intake to allow the Spica air box.

Following this project with interest. Stop by the shop often for pictures. They often make the progress without telling you what's going on if they know what you want to achieve. Good luck!
 

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Discussion Starter #10
My Twin Spark engine did not come with an exhaust manifold so I went ahead and purchased, CSC TS manifold kit from EB Spares. They tell me this will bolt to the rest of the exhaust system.

I did not think the stock Alfetta exhaust manifold would work as the heads are different.

I would love to see some pictures of your car.
 

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That looks like a nice header. Make sure to replace all three motor mounts and see that the exhaust system has a lot of freedom to move. Alfa engines move around quite a bit under load. Tubular steel headers are more prone to cracking than the stock cast iron Alfa headers. I learned the hard way with an Alfetta ANSA header years ago.
 

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tom.lagos....I like the build and think Alfa should have put into production a twin spark engined road alfetta gt since they were already using these engines for racing long before the alfetta gt came out in 1974...anyhow i wish to see the finished product and wish you well

Just a few personal opinions regarding the exhaust headers. In Jim K's book on how to power tune alfa romeo twin cam engines, in the chapter about exhausts discussing modified alfettas it states that a real problem with 116 series cars is to do with breaking headers due to poor exhaust support arrangement. If a steel tubing header type exhaust manifold is installed to replace the cast iron one, sooner, rather than later, breakage will be experienced just behind the front expansion chamber...because this is now the weakest point in the system since the headers are no longer so easy to break.
The book recommends if you are investing in a complete new exhaust head to tail it would be a good idea to fit a special flexible exhaust pipe connection behind the front expansion chamber to allow freedom of radial motion while forming an effective gas seal.

I also wish to give my experience of the CSC exhaust headers and complete CSC system head to tail which I have tried on our alfetta 1.8.
The headers while having noticeably longer primary pipes of larger diameter and made of steel that is much, much lighter than the original cast iron one (improving weight distribution) and also do not heat the engine bay as much as the cast iron ones in my opinion (we sprayed it with exhaust heat protection anyway)....has all unequal lengths which is not good. Also the primary pipe merging points are also in my opinion poor.
The whole system allowed our car to breath a lot freer as there was a lot less back pressure due to larger diameter tubing all round, giving much freer top end in rev range and better fuel consumption....at the expense of low revs torque.

However for me personally there was a major issue in that for the alfetta 116 specifically the CSC steel used is for me too hard, meaning little flexibility and this was transmitted as vibration through the transmission which I found personally unpleasant and nothing related to fitting since our Alfa trained guy spent a lot of time making sure the system was in complete alignment. We tried fitting a CSC front expansion part (second part of headers) since the version we bought omitted the front expansion completely but although it improved, the vibration was still there. I chatted with the current ansa exhaust builder who used to work for the old ansa and now is reproducing similar new ansa exhausts (but to better quality) and he said that the original alfa tubing material and the ansa material did allow this flexibility. Indeed changing back to original alfa system and there was zero vibration but inadequate tube diameters meaning backpressure issues again and added weight. CSC told us they could fit a "flexible" joint behind the expansion chamber as the book I mentioned suggested but from other reading on the net it seems flexible joints break also depending on engine tune.

When I get around to it I will try to get a system made up from similar flexible material as that used in alfa and ansa systems for all piping with equal length primary headers and optimal pipe merging points at a diameter between the CSC and original one because the CSC one was too top endy, perfect for racing but not for road.
 

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I did not think the stock Alfetta exhaust manifold would work as the heads are different.
Yes, was referring to the stock TS manifolds. They are meant for the 116 chassis. I have never seen TS Headers for 116 chassis. Have they arrived? Do you have a picture? I'm quite curious. I could not find them on EB Spares website. Do you have a link?

Thanks
 

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Discussion Starter #14
Algal thanks so much for sharing your experience with this header. I missed DHL on Friday so I don't the exhaust yet. Will have it on Monday. Here is the link for what I bought EB8. Dupri see the stock exhaust works.
 

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Discussion Starter #15
EB8

Got to turn spell check on this tablet. Totally changed some of my words. I am curious now if the stock exhaust manifold would of fit. Also alfettapb not sure if I understand where manifold cracks.
 

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Ah, yes. That header will work fine on the Alfetta platform. There are so many conversions into GTVs and Spiders and all of them have to use a custom made header that I thought you had made the mistake of buying.

This one you linked is meant for the TS in its original vehicle, the Alfa 75, which is the same platform as the Alfetta and GTV6. Does it come with the lower portion as well or just the primary header section?

The original TS manifold matches the secondary pipes Alfettas outside of the US had. I had long ago found the euro manifolds and secondaries for my Alfetta, so when I got the TS engine and manifolds, it bolted right up the the secondaries. Here is picture of the exhaust side of my TS in my Alfetta with the stock TS manifolds:


.
 

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Discussion Starter #17
I only see 4 spark plug wires. I guess you plugged one of the spark plug holes? How does it run? Looks like a nice option since omex is so expensive.
 

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In this picture, only one distributor cap is on. You can see the one in front is off. The picture was taken before it ran. I kept it totally stock for the first stage, except for the cone filter. It ran great and the Alfetta came alive really well. I even dyno'd the the car on a roller and the guy said with the losses factored in, the 150 hp stock figure is believable.

I've run it since 2006 and a couple years ago I took it off the road to install throttle bodies and a stand alone computer. I wanted to ditch the AFM and really wanted the Spica airbox installed for a near stock appearance. I don't believe in carbs for this very modern engine, so stand alone computer was the only choice for me. This last step has taken a very long time with some setbacks, but I am closing in on finishing the project.
 

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Discussion Starter #19
Here is a picture of the Exhaust Header from CSC. I must admit very well built definitely a lot heavier duty than previous headers I bought domestically for my spider. I was thinking of painting this with some high temperature paint to protect it from rust down the road. Anybody have any suggestions.
 

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Discussion Starter #20
My bad this exhaust is stainless. Put a magnet to it and nothing just sticks to the flanges. Thanks Peter very happy camper.
 
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