ALFAGTV6.COM

cchan · Post by **cchan** » Sat Mar 31, 2007 4:24 pm

Hi Rhodes1,

We are looking for a new one now as well. If we are lucky enough to find one I'll let you know.

cchan · Post by **cchan** » Mon Apr 02, 2007 6:16 pm

Hello Everyone,

Well met with Hugo today to go over some of the things that still need to be done to sort out the new injection system sytem.

1). Tap new hole in plen. for the Brake booster.
2). Tap new hole in plen. for the Gotech Sensor.
3). Tap new hole in plen. for the Fuel Sensor.

Need to be extra careful on this since the plen is alluminium and we don't have an extra one laying around.

We also need to configure the air intake tube.

1). Weld in new fitting for the Oil seperator hose.
2). Weld in new fitting for the Fuel Hose vacuum.
3). Drill hole for Air sensor and set in place with expoxy.

I am off to find the correct fittings and taps to do this this week. I will post some picture of this when it is done. There are alot more small items to do but I am again using my divide and conquer so I don't give up.

Glad to have JJ guide our team to finish the project up. Don't worry JJ, next time you come we pray there are no more starter issues, oil issues. Only working lifts, beer for you, and an Alfa that is ready drive. I am also getting us a consultant that knows the electrical knowlege for the power relay for the gotech system, the electrical fan set up, and the misc wirings on the drivers front. I let you know if I can get this for us.

We have the GTV6 manual from Centerline but it really is not clear. This is a Milano manual and it does not referrence correctly. Does anyone have a referrence that shows what the purple wire is for on the Relay that the old L jet hooked up to. We also need to see the wiring for the fans.

Thank again for looking at our project and any suggestions on the above is well appreciated.
__________________

cchan · Post by **cchan** » Sat Apr 07, 2007 1:51 pm

Hello Forum,
Stopped by to check the status of the interior while we take care of the last issues on the engine set up. Interior material are all here to complete the interior. Just need to get the Alfa there. One of the Seats is almost put together and the rear cover has been made and they are fitting it on. Here is some pictures of the progress:

cchan · Post by **cchan** » Fri Apr 13, 2007 8:38 pm

Hello BB,

So the weekend is here and I went to look for the tools to complete the plen. set up. Its been along time since we had the speed shop so I forgot how carefully you need to find the right supplier to purchase and measure your bolts correctly. After spending a couple of hours looking for this we determined that for the size for the fitting for the Brake Vacuum hose for the plen. and the size for the fitting for the Oil Seperator for the air intake are the same. JJ gave us the one fitting for the Brake Vacuum hose and we found one that was the same size for the Oil Seperator connection to the air intake pipe.

The drill size is 7/16" and the tap is 1/4" x 18 NPT (National Pipe Tap).

Here is the picture of the connectors and tools for referrence

cchan · Post by **cchan** » Fri Apr 13, 2007 8:40 pm

We also were able to find two new connectors that matched the connector that JJ gave us as an example for the Go tech vacuum hose and the Fuel vacuum hose.

The drill size is 21/64" and the tap is 3/16 HB x 18 MPT (Male-National Pipe Tap.)

Here are the pictures for referrence.

cchan · Post by **cchan** » Fri Apr 13, 2007 8:42 pm

We finally purchased special oil to cool down the tapping process and make it smoother to accomplish this task without any errors.

Here is the last picture of this. We were all tired from work so we decided to do this tommorow if time permits so to have a fresh start. If anyone has any suggestions on a proceedure to do this let us know. It looks straight forward but of course we have no room for error.

cchan · Post by **cchan** » Fri Apr 13, 2007 8:45 pm

I also had a chance to go by and see the status of the interior. Basically, there was no progess from last week except that they started to put the rear seat together. I did not have a chance to take a picture but I will soon. I am looking at the center console and how were are going to finish this. It is currently blue and plastic. I was thinking of covering in leather if possible. I need to determine the stereo system for the car since the installation of the head unit will detemine the main console holes.

I originally was going to put back the Blaupunk Berlin that would be the correct radio for this time period and have it set up to play MP3's. However, I could go with my Kenwood set up similar to a company car. I don't know why I am still thinking original condition since I changed the seats but what does the Forum think. Modern Kenwood set up (TV/DVD/Back up Camera/Nav) or the Classic Blaupunk Berlin??

Here is a picture of the Kenwood Head and I have already posted the Blaupunk Berlin in a prior post.

MR2 Zig · Post by **MR2 Zig** » Sat Apr 14, 2007 4:31 am

cchan,
With drilling and tapping aluminum go easy (it is really soft) and keep the drills and taps square to the hole and steady. Its very easy to wallow out your holes to where the fittings won't seal. See if you can't get the part clamped into a drill press and use the drill press to guide your tap after drilling your hole. (put the tap in the drill chuck and turn it by hand.) Don't tap using the drill motor as it turns too fast, doesn't stop where you want it to, and doesn't reverse.

HTH,
Scott

cchan · Post by **cchan** » Thu Apr 19, 2007 4:06 pm

We have been able to complete the tapping and installing the connectors to hook up the engine management hoses. Everything went well and we just need to tighten everything down. I'll wait for JJ to come back to have him suggest how much we need to thread this into the plen. and the air intake pipe. Here are the pictures of the status of this.

cchan · Post by **cchan** » Thu Apr 19, 2007 4:09 pm

We also needed to tweek the throttle mount and bend it upwards so that the cable will attach correctly. Once we did this we then noticed that the stock throttle cable will not work and we need to source a new one to connect properly. This should be no problem but is one more detail that we were not aware of. Here are more pictures.

cchan · Post by **cchan** » Thu Apr 19, 2007 4:12 pm

More Pictures

cchan · Post by **cchan** » Thu Apr 19, 2007 4:15 pm

The only last connection we need to do is the Air Temp sensor. We will Drill a hole and place this on the side of the air intake up stream from the oil seperator and this will complete this part of the system. Then all we need to do is hook up the tubing and were done.

Now that this is almost finished we are going to start doing the center console and restore it so that we can have a sound system in the Alfa. JJ also gave us some reinforcements for the front sway bar to have them welded on. We will be doing this next along with testing, painting, and restoring my fans.
This is where we are at now. The seats should be done by now and I will stop by and drop off the center console this Friday. I hope to have some pictures of the interior to post then. If everything goes right, we will have the Alfa running and dyno tuned next week and have the interior finished as well.

x-rad · Post by **x-rad** » Fri Apr 20, 2007 9:27 am

CCHAN..did you put any sealer (or teflon tape) on those fittings? I had a similar setup on my turbo Mitsu and had small leaks at the fittings before sealing them...

cchan · Post by **cchan** » Fri Apr 20, 2007 2:47 pm

We did not use any sealer or tape as of today. The pictures that we posted everything is just finger tight. We are hoping to do the final install next week. Do you have any suggestions for sealers and /or tape? The connectors go in easily but are tight already.

cchan · Post by **cchan** » Fri Apr 20, 2007 5:12 pm

So it's Friday and I went to look at the seats. Things are moving ahead slowly and the sear seats are done. We just need to recondition the plastic insert tray. Here are some pictures of the rear seats. The front seats were not quite done as there was a small issue. This will be taken cared of and I will post pictures when I go there again.