festy's Alfa Romeo Alfetta GTV

[Holden202T]

the rebuilt engine looks nice and clean, but the old engine looks like it has a better idler shaft though

[festy]

the rebuilt engine looks nice and clean, but the old engine looks like it has a better idler shaft though

Not anymore it doesn't

[festy]

The shaft looks pretty reasonable after a very light polish - better than the original one even

newshaft.jpg

[festy]

My timing cover gaskets arrived from the US, so the engine is now back in one piece.
I finished welding up the exhaust manifold - if I ever make another one I hope I remember to weld the T3 flange to the RHS *before* welding the RHS to the manifold. There just wasn't enough room to get a #26 TIG torch in there the way I did it, drove me nuts trying to get it finished.
After that, I started machining the exhaust flange face flat. Even though I clamped it down during welding, it had still warped by almost 2mm.
Machining it was a very long and boring process, at 25mm/minute it's like watching paint dry after the first half dozen passes. I really need to make myself a *big* flycutter...

flat.jpg

Then I checked the welds for pinhole leaks, found a couple so fixed them up. Then I cleaned it out as best as I could, and gave it a quick coat or two of high temp black.

manifold.jpg

Fitted the manifold (complete with my "custom" nuts) and turbo so I could make up the oil drain hose which I ended up making maybe 10mm too long but it fits as long as it's done up before the turbo is bolted down

I made a bit of progress on the exhaust, I trimmed the dump pipe to length and tacked a 90* bend on, then realized I need a flange there or the only way the exhaust will go on or off is on a hoist so I stopped there until I can get another V band set.

t.jpg

I think I've pretty much got the turbo's oil and water lines sorted (in my head at least) - I was waiting on some 90* -6 fittings to finish the coolant hoses but they came today so will finish that next time I'm looking for something to do.

With the turbocharger in it's new home and the engine's internals no longer exposed, time to break out the plasma cutter and shoe horn some 3" intercooler piping in

ic1.jpg

It looks like the intercooler will need to sit *right* where the oil cooler was, so will have to see if the oil cooler will fit behind the LH headlights or something, unless I can squeeze it back in front of the intercooler.

[Holden202T]

progress is looking good man

and no turbo conversion I've heard of is complete without having to re-locate everything!

[antus]

I like...

[HQ355]

progress is looking good man

and no turbo conversion I've heard of is complete without having to re-locate everything!

Not just turbo's lol

[Holden202T]

hahaha yep pretty much

[festy]

It wouldn't be so annoying if I hadn't only just installed the oil cooler and made up the hoses *just* the right length
oh well, it could be worse...

[Holden202T]

yeah I mean its not like you broke your timing gear or anything