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Discussion Starter #24
Well, it looks like the next-level for the build will happen a bit sooner than I had originally anticipated. Last month, I took the Spider autocrossing. It was running great, but I had zero traction in the cold weather and on summer tires with way too many heat cycles. On the way home, the car started sputtering and my wideband 02 gauge started showing way lean. Ended up having it towed home.

My first inclination was fuel pump, and it was due for an upgrade anyways and I had no idea when the filters were last changed. After replacement, the car seemed to be running ok, but I kept having odd misfires (and of course, the wideband shows full lean when the engine is misfiring). This last weekend, the problem presented itself more directly:



Yep, that's coolant coming out of the head gasket. Time for a built motor. Was hoping to push the stock motor for another few trackdays, but I have to admit it took some pretty hard abuse before giving up the ghost.

Took the opportunity to start disassembly of the motor I bought a few months ago. It turned over freely, but it was a little gross inside. I think it should be Ok as a core.



Plans for the new motor:
Mild headwork- at least a valve job and port and polish. Not sure if it's worth messing too much with cams on a turbo setup.
Forged pistons/rods. Current thought is 8.5:1 compression. A touch lower than stock, but hope is the head work will keep off-boost response similar to where it is now.
Additional oil passages for #2 and #4 pistons
Ductile iron liners- o-ringed and piano wired to hopefully prevent future head gasket failures

Last, but not least: 15-20psi of boost. Target will be 300whp, though the beauty of the boosted setup is I can run less boost for a tamer car (and drivetrain preservation) most of the time.
 

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Discussion Starter #25 (Edited)
It's been a while since my last update... but I have some stuff worth showing. More to come tomorrow as I get around to taking photos of what I've been up to.

I spent more hours than made any rational sense getting the old block cleaned up. The steam cleaner helped a bit, but man it was hot work. The old engine looked pretty clean from the outside and turned over nicely, but it must have had just water in the coolant system for some time. It was corroded badly. Fortunately, it was the liners that took the brunt of it.

Old motor is out as well. First time in this car went surprisingly smoothly. Without the clutter of the stock engine bay, everything went pretty smooth. Took around 5-6 hours of work to get it ready to pull. The pulling itself went down in under 10 minutes. With the motor out, I've started stripping the engine bay. This baby is getting painted!
 

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Discussion Starter #26 (Edited)
As for the build itself, key items have arrived! (more photos to come):

Rear end:

OS Gikken LSD
Hydraulic handbrake conversion from Alfaholics
Alfaholics Watts Link Kit


Head:
"Stage 3" Head From Steve Hannaford at Progressive Automotive

Bottom End:
8.5:1 Pistons from JE
Darton Sleves
Carrillo H Beam Rods
Windage Tray From Spruell
King Race Bearings
Spruell "Race" Timing Chains
Surpell "Race" Motor Mounts & Transmission Mount

Oil Control:
Oil Pump by Gordon Raymond
2L Accusump

Clutch: Alfaholics "Fast road/rally" Clutch with 10.5lb Aluminum Flywheel

I have to say the oil pump rebuild by Gordon was worth almost for the write-up and service alone! He turned my pump around in under a week with 20+ photos and a very detailed description of the rebuild.
 

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Discussion Starter #27
Pictures as promised! I went at it with the teardown today. The question was: will this thing have carpet when I am done? I'm tired of taking things apart, but I decided I've gone to far and I need embrace the racecar. With the seats and carpet out, I was met with some incredibly nasty insulation. I then commenced to 3 hours of chipping away at the coating over the floor pan. I think I have at least another 3 ahead of me before it's ready to prep for paint.
 

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Discussion Starter #28
Engine bay is almost fully stripped. Can't figure out what to do about the steering box. It will be hard to push the car around once it is out, so I'm reluctant to pull it now. Wonder if my painter will let me do it at the shop? Also, mock up of where the Accusump will go. It's going to be a tight fit with the turbo, but it should just squeeze in there. Lots of cleaning left to do for the engine bay. It was filthy!

https://www.alfabb.com/bb/forums/attachment.php?attachmentid=1518180
 

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Discussion Starter #30
Final post showing the goodies.

Carillo rods came out to +- gram as expected. Sleeves are interesting. Instead of having flat sides like the stock sleeves, they are round. Despite having less material, this should be a much stronger design. Note also the groove for the "o-ring" of piano wire that will bite into the head gasket. I still debate whether 8:5:1 was the right call with the pistons. I suppose proof will be in the pudding. Alfaholics flywheel nice and shiny.

Finally, dropped the block and crank off at the machine shop today. It's getting drilled for additional oil passages. The crank will be polished and the oil pickups chamfered. Machine shop is not an Alfa place, but they specialize in race motors and were intrigued by an Alfa project!
 

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Glad I found this thread, Neal. I've been kicking around the idea of doing a turbo Nord 2L...
 

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It's a lot of work, but worth it. Happy to answer any specific questions or provide a base map if you are using a megasquirt.
Ok, have you had it on a dyno yet?

Also, do you know if Alex had any more intake manifolds made?

Thanks
 

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Discussion Starter #36
No dyno yet. I had plans to do some dyno tuning before the head gasket blew. It was good enough to chirp third gear at 7psi on older 200 treadwear tires. Plan is for ~300hp from the built motor in high-boost mode although I will likely run a low-boost tune for safety.

Unfortunately, the manifold is a one-off but a basic log manifold is not terribly difficult to have fabricated. You can even buy kits for fabricating tubular manifolds, but that’s a more difficult proposition. There are also turbo manifolds floating around from the old Jafco kits but you’d probably want a new flange welded on to run a modern turbo.
 

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Discussion Starter #37 (Edited)
Things are coming along more slowly than I had hoped, but at last some signs of progress. Finally got the block and crank back from the machine shop. 2&4 mains drilled, crank balanced, cleaned up, and chamfered oil passage openings. Car itself was sent off to the body shop for paint back in November, with an ETA of mid-late January for completion (though I wouldn't be surprised if that slips knowing what such jobs entail). The car will be Biancospino white when it's done. While I was at it, the turbo hotside and manifold went in for ceramic coating, while the crank pulley went in for powder coating. Should have those next week!

Question for the engine build gurus out there: The shop removed the main cap studs when they drilled out the 2 & 4 mains. Any trick to reinstalling them? Are they torqued down or installed hand tight like head studs?
 

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Discussion Starter #38 (Edited)
Small update today: Picked up the turbo manifold and hotside from being ceramic coated. While I was at it, I had the crank pulley powder coated. Excuse the dirty workbench! I'm wrapping the downpipe. However, because header/downpipe wraps are sometimes accused of causing rust, I'm also doing a coat of VHT flameproof paint underneath. Hopefully, that will erase that worry. Idea is to keep the under-hood temps down- turbos are quite the space heaters.

Should get the chassis back from the painter in a few weeks, then the fun will really begin.
 

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Big job!
Who made the exhaust header?
Does your set up include an intercooler?
Pics did not show.
I ran a turboed Alfetta Sports Sedan as a DD for some 18 years.
:)
 

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Discussion Starter #40 (Edited)
Big job!
Who made the exhaust header?
Does your set up include an intercooler?
Pics did not show.
I ran a turboed Alfetta Sports Sedan as a DD for some 18 years.
<img src="http://www.alfabb.com/bb/forums/images/smilies/smile.gif" border="0" alt="" title="Smilie" class="inlineimg" />
The exhaust header and downpipe was the work of a friend of a friend around 10 years ago who is a very talented welder. The setup includes very nice front-mount intercooler that attaches to the front bumper mounts. Post 10 (the on track photo) shows how the intercooler mounts.
 
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