1982 GTV renovation

[Alfetta77]

Thanks Anth, enjoying the story. Who is doing your engine work?

[Anth73]

Thanks Anth, enjoying the story. Who is doing your engine work?

Monza Motors is doing all the disassembley and reassembley work. Orger Engines (aka Original Engines Co) in Kilsyth are doing all the porting and polishing work on the heads, runners and inlet manifold, and will hone the cyclinder bores for my new 10:1 QV spec pistons.

[Anth73]

Another early Friday morning visit to Monza Motors and the Busso symphony from this little red beast was, just as Jeremy Clarkson said, like having my soul licked by angels. I vividly remember first sighting "Il Mostro", the Monster, in my Wheels Magazine as a 16yo teenager. It still looks as weirdly odd but beautiful at the same time now as it did all those years ago!

[Anth73]

I also had a good chat with Hugh and Mick, and am happy with the progress being made. The twin spark is out ready and waiting for it's new owner to collect it and hopefully it lives on under the bonnet of a 105 series in the not too distant future. Next to it are my V6 heads, valves and inlet runners going to Orger Engines to be cleaned, ported and polished using their state of the art machinery which looks quite impressive at https://orgerengines.com.au/

Hugh's attention to detail is coming to the fore as he will provide Orger my headers so they can precisely match my exhaust ports for size, as well as the inlet manifold matched to the inlet runners. At this time we believe we don't need to go crazy with upsizing the inlet runners and plenum throats as Hugh feels it will hurt low end torque and driveability.

[Anth73]

The V6 block is on the engine stand and in Mick's safe hands. The old pistons and liners need to come out and then the block is off to Orger Engines, where the new liners and QV spec 10.1:1 pistons will find their new home, all nicely honed and playing nicely with one another.

We also had a lengthy discussion about my injector dilemma and reached a consenses. Given the cost differrential isn't too significant, the 164Q Bosch Motronic ECU, wiring loom and airflow meter approach is scrapped. In their place will be a Motec ECU, wiring loom and ancillaries from Melbourne Performance Centre. This way I can use the standard GTV6 injectors (low impedance I know Festy but they supposedly fire faster and they're readily available) and tweak fuel pressure if needed, as well as custom map the ECU to get the most from my higher compression and better breathing Busso.

[Anth73]

And in what eventuated as a busy Alfa day we also resolved the engine mount issues by locating a donor Alfa 90 2.5V6. We'll call her Renata, as she will be reborn via her precious engine mounts that will live on in my GTV's engine bay, as well as a few other bits and pieces we'll likely need along the way.

Renata arrives on Thursday. Grazie Renata, you're making the ultimate sacrifice!

[Anth73]

Great progress this week by Hugh and Mick to complete the disassembley of my V6 block and prepare the jig for the V6 engine mounts to be welded in place. There is something strangely exciting about seeing a bare crankshaft, it almost appears like a sculpture. The block, crankshaft and connecting rods will be sent to Orger Engines to be cleaned, checked and prepared for reassembly with my 10.1:1 pistons. We also agreed to use a 164 Motronic front pulley as it runs standard V-belts and has the 60-2 timing ring required for the timing pickup by the Motec ECU and have Orger Engines balance the entire front pulley, crankshaft and flywheel assembly as they are from the factory for each specific engine. Orger Engines also reported that my heads and valves are in good shape. Only one valve was less than ideal but that's an easy replacement. Likely turnaround time for the porting/polishing work is three weeks.

Hugh has also been progessing my Motec setup with Melbourne Performance Centre, discussing the crankshaft and camshaft timing pick-up points. I was keen to explore the option of coil-on-plug ignition rather than using a distributor. Seems like that poses lots of challenges sourcing the bits and pieces needed for it to be setup on the 12v motor. Fellow Alfisti and forum member Julian (GTVeloce) did mention "wasted spark" ignition as another option to eliminate the distributor, must read into that further and discuss with Hugh.

I also met Renata in the flesh, my Alfa 90 donor parts car. She's a little ragged and faded in places but her prized engine mounts, power steering, A/C compressor mount, A/C wiring, spare wheel, pedal box (TBC) and a few hard to source rubber grommets in the door jambs will find a loving home in my GTV. Her 2.5V6 will also be put to good use by Julian for his own GTV V6 conversion using a 164 V6 motor as his starting point.

Lastly I also ordered a Brise lightweight starter motor from the UK. It replaces the smaller starter motor fitted to SZ and 75 Potenziata cars (Bosch part no. 0 001 108 098) and should resolve any potential clearance issues with the CSC headers. Plus it's lighter, so it must be better!

[Anth73]

Renata, my donor Alfa 90 parts car, gave up her precious engine mounts this week. It took a lot of delicate work by Mick and his angle grinder to relieve Renata of the three engine mounts. They will be aligned to the jig Monza Motors use and welded into my engine bay this week.

I also ordered a front doughnut cage and rally top extended arm ball joints from Richard Melvin at Chris Snowden Racing. The doughnut cage is cheap insurance in my view, whilst the new ball joints will help provide better turn in and address a known suspension geometry issue with lowered Alfettas. The rally spec provides a sealed GE17C replaceable bearing making them well suited to road use. I've had a few email and messenger conversations with Richard and cannot recommend him enough. He's been very helpful and also offered to provide me a base Motec map for my V6. Check out his website for all the goodies he has available.

Planning for the Motec installation continues with attention turning to the various sensors needed and also trying to confirm a compatible coil on plug approach. From a few posts on Alfabb the 06B905115 series coil fitted to various Volkswagen group models throughout the early / mid 2000s is the right size for the 12v motor. With a bit more searching I found Bosch 0986221024 and NGK u5003 are equivalent and newly available. So I bit the bullet and purchased one of the NGK coils from Sparesbox to try...fingers crossed!

[shiny_car]

Nice progress.

Our cars are sharing some similar upgrades, like the Brise starter and CSR extended top ball joints.

My research also suggests VW/Audi COPs are a suitable choice, and probably what I'll choose in the future.

Keep the updates coming. 

[GTVeloce]

Great work!

It was lovely to meet Renata on the weekend as I completed her organ donation. Those engine mounts looked pretty good - I'm jealous! As I am about the rest of your build. It's really coming together well.

[pasey25]

great thread. thanks for sharing. look forward to seeing the progress.

[Anth73]

Nice progress.

Our cars are sharing some similar upgrades, like the Brise starter and CSR extended top ball joints.

My research also suggests VW/Audi COPs are a suitable choice, and probably what I'll choose in the future.

Keep the updates coming. 

Thanks Richard, I've been amazed at your own detailed project updates and the level of work you are taking on yourself. Thanks also for the pointer to the supplier of the tarox rear vented discs.

[Anth73]

great thread. thanks for sharing. look forward to seeing the progress.

Glad you're enjoying it. Was that your "Il Mostro" at Monza Motors Friday week ago? I'd give my first born for a ride in an SZ...just don't tell my daughter though!

[Anth73]

Great work!

It was lovely to meet Renata on the weekend as I completed her organ donation. Those engine mounts looked pretty good - I'm jealous! As I am about the rest of your build. It's really coming together well.

Don't be jealous, you'll have a great build once you're completed with the satisfaction of doing almost all of it yourself. Plus in hindsight the 164 spec motor is a better basis for the conversion and any future mods down the track given Alfa improved several key elements of the busso architecture. Plus you'll have those damn sexy, torque enriching chrome intake runners!

[pasey25]

Glad you're enjoying it. Was that your "Il Mostro" at Monza Motors Friday week ago? I'd give my first born for a ride in an SZ...just don't tell my daughter though!

yes it was. I already have 2 daughters though, more than enough!