Had same dilemma here in Hungary, with a 164. Not to hijack your thread, but here is my saga.
I work in IT, have no car building experience.
Had a late model diesel 164 for long commutes that I simply LOVED but sold, wanted to get a strong petrol variant this time.
I decided to go crazy and got a '93 2.0 v6 tb super in really BAD condition but dirt cheap to use as a sort of chassis and engine part donor (see first two pics). Out came the 2.0 block, in went a 3.0 12v (pics 3 and 4). Kept most everything from the TB inlc. ECU, CR was dropped to 8.5, fuel system was converted for 100% e85 operation.
Long term target is a reliable 600ish wheel or crank hp (FWD! Unusable! Crazy! Family car! I know!)
Stage 1 had the small turbo from the v6, 510cc injectors, uprated walbro pump, bov, wastegate, uprated gaskets, 70mm straight exhaust, temporarily withouth mufflers :-> Nice sound.
BUNCH of fixes (steering, custom suspension based on the OE, custom engine mount rubber things, electrical stuff)
Stage 1 quickly ended like this: shouldn't have kept the old oil pump. Lost oil pressure on a short 120 mph highway cruise. Pump was worn out, couldn't pump hot and thin oil. Turned out the turbo was in no good shape either, and was way too small so decided to go for a new one. Bent rods, busted bearings, the usual :-/
Now has a 3082R turbo, new and bigger intercooler, oil cooler, mid and rear mufflers for sane sound levels & police compatibility (still sounds nice, still no cat). Accel 200 to give 18v for ignition. This is pic 5. Not very nice but wanted to keep close to stock bumper, giving up fog lamps.
Stage 2 Part 1 ended just 4 Kms (2 miles) after pickup from the shop. Car ran on 3 cylinders, some e85 got into the oil... Back to the shop asap. Ignition gave up. Replaced a bunch of stuff again. Got brand new ignition system.
I hope to pick it up next week.
Running 0.8-0.9 Bar (11.6 psi?), stock but reprogrammed ECU.
Don't know HP or torque figures since I have stock rods and pistons, flooring it in 4th and 5th is out of the question. Will get MAP selector next month (need a map for daily and engine-safe driving, and one for surprise drags in gears 1-2-3)
Mechanic estimates 400ish hp (crank or wheel I don't know). You do the math (E85 has a higher Octane rating than the standard 95 here in Europe and the car is programmed for it)
Still this year
- LSD, tranny rebuild (something wrong with the housing, already have proper housing)
- Brake upgrade
- Hood cutouts (excessive heat). Will look bad on a 164. Maybe NACA ducts would look better or using ceramic coating on some stuff would lower temps.
- Just saw a set of Zender Milanos on the local Alfa Forum, Instant get (was stupid and sold the old set with the old car)
- New wiring built from scratch (engine bay)
THE FINAL Stage will only happen next year (as $ allows)
- Custom JE pistons and rods
- Custom, stronger Cometic gaskets
- Custom profile C&B cams (maybe not, depends on budget)
- 1.5~1.8 bar (21.7+ psi)
- something done to the hydraulic tappets to take higher revs nicely (now it revs to 7k happily and in power)
- Valve and valve spring work
I can't recall the rest...
Serious amount for me, but lotsa fun I hope. And bit of cure for my anhedonia.
BTW the he car still looks ugly as hell, needs a decent paint job etc...
$20k and counting, including the car. A good portion of this is because of the worn out oil pump and ignition...
One short post with a few more pics and my .02 coming up.