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nice work. I thought about turbo charging my my ecotec conversion, I have replace the rods with eagle rods and forged pistons. even have a turbo and manifold off a saab 9.3 ( same engine as ecotec.., just if I need more than 200-220 hp.
 

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Discussion Starter #42
Went by the paint shop to see the progress to-date. The good news is that my painter hasn't found any significant rust or crazy amounts of filler as he's started sanding down the body. Evidently, the car has been repainted at least twice before based on the layers of paint. Having been more used to painting American cars, he was very impressed with the design and quality of the Alfa body.

I've specified that this is more of a race car, and a show car paint job is not required, so some of the work will reflect that. However, he's also trying to make it look "nice" to someone who isn't a concours judge. Should be done in the next week or two, as he is down to just the Alfa in the shop.
 

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How about an update? Is the car back from paint jail??? What's left to do?
 

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Discussion Starter #44
It’s still in paint jail. My painter has pushed back the delivery date several times. He keeps finding little things to fix like dents on the underside of the hood. I’d rather him be a perfectionist, but I am missing my car!

I’ve started putting he bottom end together- have the crank installed, but I’m waiting on new lock tabs (easy to forget single use items). I’m also still waiting on the head- it’s been “two weeks” away since January.

Finally, my work time is severely limited by having a 6 week old daughter and a 2 year old son. Process will be slow, but it’s coming along little by little.
 

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Discussion Starter #45
Paint has been sprayed. Just waiting on the bumpers, some buffing/sanding, and reassembly. In other good news, the head is done and I should be getting it next week.
 

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Discussion Starter #46 (Edited)
It has been far too long since the last update. Between my last post and this, I ended up buying a new house! Wasn't in the market, but the stars aligned. The Alfa is getting a new home, and the new garage has enough headroom for a lift! Unfortunately the new house is one more project to attend to before I can devote my attention to cars, but as of last Friday, the spider is now out of the shop and home! It was a jailbreak from paint jail. No longer 80s gold, the car is now Alfa Biancospino White.

As often happens, the paint took a lot longer than it should have. The final job looks nice, but there are still a few flaws that don't show well in photos. The trunk will need to be resprayed, as the color match was poor. The hood will need some wet sanding as some unevenness shows in the clear coat. But at least I can start the hard work of reassembly.



Really like the look of the painted bumper and spoiler! I think it makes those items seem much better integrated with the car. Can't figure out why some of the photo attachments are loading sideways... I will try to fix later.
 

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Discussion Starter #47 (Edited)
As you can see, the new garage is a project in its own right. It had a saggy ceiling supported by a makeshift pillar (not shown). The ceiling is now vaulted to give 10 foot of clearance. I've put down racedeck flooring to cover up the stained 50 year old concrete. Photos are poor inside the garage because I can't yet open the doors! I have a high-lift garage door scheduled for Friday which will provide clearance for the lift. Then I can get some photos of the spider in its new home.
 

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Discussion Starter #48
Well, the home/garage renovation and move is FINALLY complete, so the project is starting to move (just a little). New garage features lofted ceilings for an eventual lift, 220v power, and air lines and a lot more working space now that it does not have to do triple duty as a gym and laundry room.

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Got the interior mostly put together (seats, steering, harnesses, fire bottle) and have started reconnecting brake lines. I will also be working on improving some of the wiring work while the engine is out and everything is easy to work with.
 

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Discussion Starter #49
No major updates from the last week. I did get the steering system back together and the throttle link reinstalled. Cleaned and repainted some of the various brackets including the throttle link, steering stops, and center steering link. It's easy to forget how much cleaning and repainting needs to get done when the car is apart (well, if you are like me and can't stand to reinstall greasy parts covered in surface rust).

I'm also pleased to announced that my new mechanic will now be assisting.

 

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Discussion Starter #50
Progress is happening... slowly but surely.

Brake lines are back in (pedal box and master cylinders pending better hardware).

Redid the wiring loom on the driver’s side, getting rid of some of the wires that are unused with the build that previously were just cut in-situ. Fixed the wonky speedo ground that was cut and mysteriously just twisted together (so that’s why my speedo was cutting out!). New wire retaining clips as well.

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Also starting to get into the fun stuff! Crank is installed along with cigarette seals, etc. Liners are in, but a bit of a question mark. I’m showing liners #1 and #2 at in-spec 2 thousandths. But Liners #3 and #4 are at 7 thousandths. Measurements are with 0-rings in and hold down torqued to 10ft/lbs.

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Factory manual says 0 to 2 thousandths is spec but at least one aftermarket manual says up to two hundredths! The copper o rings on the liners liners will protrude a lot more than 2 thousandths, so I’m not sure how much it will matter. Worth trying to muck with or just send it?
 

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Discussion Starter #51 (Edited)
The COVID-19 shut downs have slowed progress from what I had hoped due to the closure of my regular day care, but I have another shop assistant.
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And I have made some progress. Pedal box and brakes are back together, and the bottom end of the motor is almost done! Just the oil pan and clutch (waiting on the alignment tool to come). The head is ready to bolt on, so we are on the home home stretch.

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Ran into an interesting issue with the inter cooler. It was originally fitted when the front lip was partially broken due to an accident at some time in the car’s history. My painter fixed the lip, but I lost intercooler clearance in the process. It took some judicious cutting of the radiator ducting to get it to fit again. Next step will be a removable plate so the duct can do its job.

1620387
 

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Discussion Starter #52 (Edited)
More progress. Bottom end is complete! Alfaholics “rally” clutch and flywheel kit installed. Even though this is going to be mostly a track car, I decided against the full race because it’s a bit too light and too grabby- worried about unnecessary stress on the driveline. It’s a beautifully made piece of hardware- hopefully it can hold up under the torque.

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The next step is a bit tedious. I mentioned earlier that the liners would be wired in to help keep the head gasket holding and the liners in place under high cylinder pressures. Now, it’s time to cut some copper wire to fit into the grooves that were machined in to the liners. This is a rather tedious job of test fitting and filing. Some have recommended stainless steel wire for this purpose, but copper is far easier to work with. You will notice that these liners are fully round rather than squared off at the meeting points like stock. Supposedly a much stronger design. We shall see.


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Doesn't the fully round liner mean they are thinner?

Pete
 

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Discussion Starter #54
Doesn't the fully round liner mean they are thinner?

Pete
On average, yes. However, the thinnest spot is thicker than the thinnest in a stock liner and the shape is less conducive to a fracture. The stock liner had a weak point in the transition to the flat spot. The material is also stronger.
 

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Discussion Starter #55 (Edited)
Copper o-rings done. Took about 2.5 attempts per ring. I eventually discovered the key was filing the ends of the wire at a 20 degree angle, not the more radical 45 that I first attempted. I also realized that I could file the length only after the rest of the ring was in place.

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Unfortunately, I also have a potential disaster on my hands. The machine shop that drilled out my 2 and 4 bearings for oil removed two head studs. Got the head on. Did first round of torque to 45 all good- did second round to 55 and one of the head studs turned into the block. Upon removing the stud (a very old original) I noticed that it was actually threading beyond the threads a bit. I am hoping a new stud and some red lock tite will keep it in place enough so I can torque the nut. Otherwise the whole thing is coming apart for a timesert.
 

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X2. I used such liners on my last engine rebuild. Did you get yours from a supplier in the Pacific northwest?

On average, yes. However, the thinnest spot is thicker than the thinnest in a stock liner and the shape is less conducive to a fracture. The stock liner had a weak point in the transition to the flat spot. The material is also stronger.
 

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Discussion Starter #58
Sadly, the new stud did not hold- barely made it past finger tight before giving way. Even worse, I found out why after pulling the head off. The shop that drilled out my 2 and 4 mains put a helicoil in without telling me! The helicoil pulled right out of the block.

Even if it had torqued down, a helicoil would not have been good in a high performance motor so I suppose it’s better I found out this way instead of from a blown head gasket. They aren’t owning up to it and want 8-12 weeks plus a fully disassembled block to fix it.

Looking for another shop that can put in a timesert. I was tempted to try my hand at it, but an m12x1.5 timesert kit is a $500 proposition.
 

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Discussion Starter #60
I got good news from the (new) machine shop. They were able to get the timeserts done with everything still assembled and I'm picking up the motor tomorrow. Fingers and toes crossed that everything torques down properly this time.

In the meantime, I've been working on odds and ends. Got door weatherstripping back in, sill plate, headlights, some chrome trim, and worked a bit more on wiring (still a big project to be done in terms of wire management). I also had a successful experiment with using nutserts to replace some of the sheet metal screws that had been used on the chassis. Really neat way to get a nice clean threaded hole for brackets and such. Also ordered some metal footrests to raise the floor to where it was before the carpet and padding was deleted and add a dead pedal for the clutch foot.
 
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