festy's Alfa Romeo Alfetta GTV

[festy]

Soooo, take a couple of deep breaths, cut it off and start again.
Second attempt looks much better:

fitted.jpg

My oil feed line fitting is probably a bit too restrictive for an old journal bearing T3, so I'll have to bore it out a bit:

restrictor.jpg

And I think I need a 90* fitting for the oil feed hose, teflon hose doesn't like being bent...

oilfeedheight.jpg

My recently relocated oil filter will need re-re-locating, and I bet my hoses will be *just* too short for wherever I move it to

relocate.jpg

Still so much to do to finish this, but slowly getting there...

[Holden202T]

nice work man ... and yeah leave that warning label off, or turn it over

I know how you feel about having to move everything or modify it, seems very familiar to when I put my turbo on the Gemini!

that oil feed looks like a roller bearing turbo one with that restriction..... from what I've read the journal bearing turbo ones have a step down inside the housing and that's the size that restricts it to what it needs.

[vlt304]

I would drill the hole out to 1.5-2 mm they don't need much oil and too much will kill a turbo real quick. most bb turbos have 0.8 - 1mm oil restrictors and bush bearing turbos 1.5 - 3mm depending on engine oil pressure.

[festy]

Yep according to Garrett (https://www.turbobygarrett.com/turbobyg ... restrictor) it shouldn't need any restrictor at all.
The 1/8" NPT fitting it's feeding from has a 3mm ID, so no point drilling this out any larger than that.

Little bit more progress - I cut out a hole for the manifold outlet, would have been a lot easier without the flange attached but oh well.
First I roughed it out with the plasma, then over to the mill to tidy up

open_port.jpg

While I was there, I noticed that by complete fluke I'd come very close to a 90* angle between the two flanges - if I'd realized that earlier I would have made it exactly 90 because facing the flanges would be a million times easier.
Actually, it's probably not too late to make a slight adjustment.

so_close.jpg

[Holden202T]

geez, you could nearly mill the two faces on a slight angle to get that difference removed!! looks like its only 1-2mm max!

[festy]

Yeah, sooo close...
If I machine the faces to 90* it will mean the studs and holes will be slightly off perpendicular, probably not a huge issue but I think I can adjust the turbo flange angle slightly without too much hassle.
Or, I can just leave it as it is and shim it up when I mill the faces.

I dropped the sump today to start on the oil drain, it was all going well enough until I found these in the pan:

bits1.jpg

I've identified the broken bolt and woodruff key as being parts of the cam that broke, but the third piece has me a bit worried.
It looks like it fits a 20mm shaft, all I can think of is a conrod small end, or a chunk of timing gear.
If it's either of those, I would have thought I'd have known about it by now but thew engine was running fine so I'm a bit confused

[HQ355]

Bonus pack ! Spare parts ! Conrod small end would be bigger than 20mm wouldn't it ? It's not a cam retainer plate or anything like that as a cam would be in the 20mm region ? I'd be pulling the motor down and checking everything if it's had bits in the sump, good luck !

[festy]

I take that back - the woodruff key isn't from the cam, and I know what the third mystery part is from...

idler1.jpg

idler2.jpg

That's the timing idler gear, nothing important

Here's a cutaway showing just how unimportant it is, kind of like an appendix...

alfa-romeo-engine-cut-away.jpg

So please excuse me while I take a brief detour from this turbo build to pull the engine down

A few months ago I was tossing up whether to take it to the track as it was or hold off and fit the turbo, I have a feeling it would have completely destroyed the engine if I'd ran it hard like this. I can't believe it even ran at all - it's been like that for 2 or 3 years

[HQ355]

Lucky !

[Holden202T]

yeah that's not cool at all!

do those gears need to get hammered onto the shaft or are they a loose fit ? you might find if its tight enough on there you just might not have given it enough curry to spin ? either way, certainly caught it at the right time!