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-   -   Alfa Romeo 166 V6TB (http://www.motorworld.net/forum/showthread.php?t=64968)

peruccy 04-17-2014 03:21 PM

No problem! I'm just glad we sorted it out. I did however edited some of my posts, because all three were added now.

To be continued...
'talla

peruccy 04-21-2014 06:28 AM

Moving on...

Both my Bella's together
http://shrani.si/f/2b/XO/3Cz16SP7/ma-car1054.jpg

http://shrani.si/f/10/12q/1XqcJAKn/ma-car1053.jpg

Since my car didn't leave the factory with a CD-changer and amplifier, I had bought a second hand one
http://shrani.si/f/26/hB/3DG2tSq9/ma-car1055.jpg

I've also added new floor mats
http://shrani.si/f/2v/123/1P4QIpjx/ma-car1056.jpg

http://shrani.si/f/1i/2x/3Ootce9r/ma-car1057.jpg

Then, I've decided I wanted a "Dukes of Hazzard" style horn, so I got one :happy107:
http://shrani.si/f/36/co/2aV0DvOK/ma-car1058.jpg

Mounted
http://shrani.si/f/u/VX/gE1DJJJ/ma-car1077.jpg

I've also added a bit more undercoating protection on the inner wings. These cars have no rust, because they are zinc coated at the factory, but I wanted to keep it rust-free for years to come...

Before...
http://shrani.si/f/30/b6/1cCYwJOm/ma-car1059.jpg

http://shrani.si/f/3J/dd/1Lh2ScHK/ma-car1060.jpg

http://shrani.si/f/2e/HH/3zFBKV8G/ma-car1061.jpg

http://shrani.si/f/2S/K9/4ycxZVoU/ma-car1062.jpg

After...
http://shrani.si/f/2c/VD/4UBanWKN/ma-car1063.jpg

http://shrani.si/f/27/50/3w6UR8oQ/ma-car1064.jpg

http://shrani.si/f/v/Yo/MnVVG5m/ma-car1065.jpg

http://shrani.si/f/9/rd/39KEyDlj/ma-car1066.jpg

And a pic of our custom made exhaust. Downpipe is shortened a bit, so it had enough clearance with the bell housing
http://shrani.si/f/1n/12N/3AezqAGF/ma-car1067.jpg

Removed pre cat
http://shrani.si/f/18/rU/4As1Qyz1/ma-car1076.jpg

Removed main cat, with only a straight 3" pipe going through it
http://shrani.si/f/1t/w8/4Iby9GUk/ma-car1068.jpg

Mid silencer replaced with a home-made "S" pipe
http://shrani.si/f/3p/f8/1CXnK8jd/ma-car1069.jpg

And at the back, we couldn't get a 3" pipe to fit through and over the back cross-member. So I had a 2,25" stock pipe just before the backbox
http://shrani.si/f/3q/ap/CMhMp2g/ma-car1070.jpg

At the back I have an original Supersprint backbox. Although it is for the 164 model, we have modified the inlet, so it would fit on a 166
http://shrani.si/f/2d/121/4BdQnNab/ma-car1072.jpg

And front connecting pipes to the turbocharger
http://shrani.si/f/45/Tu/3omwnFof/ma-car1073.jpg

Barely any space between the connection from the 1-2-3 exhaust manifold to the turbo, and downpipe
http://shrani.si/f/46/we/21VpYi8s/ma-car1074.jpg

http://shrani.si/f/27/U4/1n16x958/ma-car1075.jpg

As for the interior. Color change from beige to grey was finally done, apart from that odd shape at the middle of the dash. That is a part of the dash, so it cannot be removed. I plan on putting some black vinyl on it in the near future, just so it doesn't stand out so much as with being beige in color
http://shrani.si/f/2f/ht/3vtCzjCA/ma-car1078.jpg

http://shrani.si/f/2M/Xo/3xhwJ0/ma-car1079.jpg

http://shrani.si/f/B/ZH/4m7oGVFe/ma-car1080.jpg

To be continued...
'talla

johnnny 04-21-2014 11:21 AM

Really nice to finally see the pics! I don't think they made it for the German market, but we got them, and pretty much all of them over here are rubbish by now due to hard driving and seriously poor maintenance - btw big hello from Belgrade :) Love the car, and the effort that has been put into keeping it on the road! How does it drive now?

It would also be nice to see that Trabant, it just seems wicked! You have to open a dedicated thread!

peruccy 04-29-2014 05:16 AM

Cheers!

I will open a thread for the Trabant in due time, don't worry.

It drives really nice. The suspension on the car is superb. It might be overkill when you think about it - three control arms on each corner, but it sure makes the ride enjoyable.

So, next I had to replace my emblems. Of course, OEM ones are way to expensive for a piece of plastic, so I got an alternative. Stickers might look cheap, but these are in fact of high quality and properly thick. Best 10€ I've spend on the car so far :)
http://shrani.si/f/2J/IG/4y9VCGDp/ma-car1083.jpg

Installed
http://shrani.si/f/1C/rs/3ywds128/ma-car1084.jpg

Then the oxygen sensor was replaced out of precaution, not necessity
http://shrani.si/f/1q/KC/3g8agTtn/ma-car1086.jpg

Manual boost controller was next
http://shrani.si/f/34/zD/1p5vswYh/ma-car1106.jpg

Then I got a wideband oxygen sensor as well, so I could see what the engine is doing
http://shrani.si/f/3Y/Ou/1QssWkhl/ma-car1108.jpg

Once I was going crazy with replacing electrical parts, sensors exc. I had to get an insert for the MAF, and also a crankshaft sensor. I know from experience that on Alfa's, faulty sensor can make you go mad trying to diagnose a problem. So I've decided to replace practically all the sensors on the car with new ones just to be on the safe side, and also for tuning purposes...
http://shrani.si/f/2z/zZ/3BkWp2Xb/ma-car1111.jpg

This car's engine is very quiet. The Italians made sure of that, since it was suppose to be a luxury cruiser. I don't like quiet. So going in that direction, the resonator chamber in the intake was blocked off
http://shrani.si/f/1i/nD/1d3PWAFJ/ma-car1124.jpg

http://shrani.si/f/2d/xH/3jXXkb1q/ma-car1117.jpg

http://shrani.si/f/3x/111/2HI90y1h/ma-car1125.jpg

Next I replaced the gasket for the windscreen wiper cover, and the windscreen washer fluid hoses
http://shrani.si/f/3j/uT/36qzKM8R/ma-car1118.jpg

http://shrani.si/f/2Z/RD/1Z3a4o3k/ma-car1121.jpg

http://shrani.si/f/1L/7R/3tmb8KFY/ma-car1122.jpg

Then I got connectors for the injectors. I was being methodical with the electrics - once you own an Alfa, you understand why :):rofl3:
http://shrani.si/f/33/jl/4aCuSvDL/ma-car1126.jpg

http://shrani.si/f/Z/QO/4fDYtXQg/ma-car1127.jpg

Next was the front speaker system which got uprated
http://shrani.si/f/3z/ao/1R9rGhaK/ma-car1136.jpg

Since I had a FMIC on both of my previous cars, I've decided to go down a different route on this car. I've decided to use a chargecooler system. So first item to get was a CC. 3" inlet / outlet
http://shrani.si/f/t/vc/3A77IUUa/ma-car1137.jpg

http://shrani.si/f/2Z/w1/1flXXhpi/ma-car1138.jpg

Difference between stock and 3" intake
http://shrani.si/f/n/3Z/2M7ZNoAU/ma-car1139.jpg

Since this car does not have an oil pressure gauge, nor an oil pressure sensor, an universal one was installed. Some modification was needed of course, to get the sensor installed in the head, where the turbo gets it oil feed
http://shrani.si/f/2o/YX/2hXsMn1N/ma-car1140.jpg

http://shrani.si/f/2x/r1/3QZHPaDx/ma-car1141.jpg

Next on the list, was a bigger throttle body. Since my car uses a fly-by-wire TB, I basically had two options:
- A Ferrari 360 TB
- A Porsche Cayenne Turbo S TB

Both have exactly the same pin-out as Alfa, but have a bigger inlet. Ferrari TB's are getting rare and expensive, so I got a Porsche one instead... Stock vs. Porsche
http://shrani.si/f/2m/KY/4CApiZgR/ma-car1147.jpg

http://shrani.si/f/j/J/3pMsZsRl/ma-car1148.jpg

http://shrani.si/f/1y/Nk/4XVwUBSt/ma-car1149.jpg

http://shrani.si/f/3w/12e/2g6H0u4k/ma-car1150.jpg

http://shrani.si/f/3e/Df/3o79fdq1/ma-car1151.jpg

Stock has 69mm inlet
http://shrani.si/f/1m/Pi/xEaxfdT/ma-car1152.jpg

Outside 75mm
http://shrani.si/f/3F/AF/1poElDr1/ma-car1153.jpg

Porsche has 79mm inlet
http://shrani.si/f/3J/iM/3gkofhmJ/ma-car1154.jpg

And 87mm outside
http://shrani.si/f/3r/Qq/6rvDWW4/ma-car1155.jpg

To be continued...
'talla

peruccy 05-12-2014 03:07 AM

Next on the list were the vacuum lines around the intake manifold. Since we installed an intake manifold from a 3.0 24V, which has a completely different vacuum line plumbing and mounting holes on the valve cover, we used what pipes/lines there were lying around, so the car was drivable. Now I have decided, it's time to install these lines properly...

New vacuum line
http://shrani.si/f/1e/uR/4bksT4TR/ma-car1128.jpg

Replacing the old vacuum line
http://shrani.si/f/3S/Db/2nWQkZ7b/ma-car1129.jpg

Some more vacuum lines
http://shrani.si/f/D/lo/13RHghvo/ma-car1157.jpg

Replacing this piece of spaghetti of lines (we had to botch something together, to make the car drive, this is what came out) :)
http://shrani.si/f/41/3X/3e5hCz4b/ma-car1162.jpg

And installed
http://shrani.si/f/2I/CD/3EdYYjNz/ma-car1163.jpg

http://shrani.si/f/3C/Bj/2bcqkS5a/ma-car1164.jpg

Then I got a special tape as used by the factory for wiring harnesses
http://shrani.si/f/n/wZ/3akeyHZI/ma-car1156.jpg

Some more connectors for the engine sensors
http://shrani.si/f/2S/yK/291SYCbd/ma-car1158.jpg

I have also decided to use a 3Bar MAP sensor, so I could squeeze a bit more boost out if the engine. Since this car has no MAP sensor so to speak - with a nipple for reading manifold pressure directly from the intake. Instead, it only uses an old school altitude sensor which has a set value for every altitude and then it translates this into manifold pressure for the ECU. Anyways, this "technology" goes back to the 80's when Audi Quattro's used it for the first time...
http://galleryplus.ebayimg.com/ws/we.../1000x1000.jpg

Replacing that thing above, with a new 3bar MAP sensor. Now at least, my ECU will have proper manifold pressure readings, not just approximate set values
http://shrani.si/f/2t/6A/3KsWHw4L/ma-car1161.jpg

I've also got a special oil for the engine. Mobil 1 10W60 full synt. It's not cheap, by I know it's one of the best 10W60 oil's out there...
http://shrani.si/f/1W/Vm/4ry84Gby/ma-car1159.jpg

External 300lph fuel pump with cradle
http://shrani.si/f/2M/9K/3gBL6EEc/ma-car1168.jpg

Some more exhaust parts
http://shrani.si/f/3d/4r/3CH6D6Xa/ma-car1167.jpg

Now we had all the parts, to make a custom 3" downpipe
http://shrani.si/f/Q/mS/27Ea5v6A/ma-car1173.jpg

This heat shield for the A/C compressor was in the way, so we removed it
http://shrani.si/f/3f/r9/1hWWESAi/ma-car1175.jpg

We've removed this lothttp://shrani.si/f/C/AZ/36tolKKX/ma-car1176.jpg
And installed this lot
http://shrani.si/f/e/13n/3iym0v33/ma-car1178.jpg

Everything installed, together with a brand new front O2 sensor and a wideband O2 sensor
http://shrani.si/f/j/Xk/i7Vv4jO/ma-car1186.jpg

http://shrani.si/f/2h/fH/10jcfVK0/ma-car1185.jpg

http://shrani.si/f/3f/47/3YZR270L/ma-car1184.jpg

We've also installed a bigger turbo of course! I had this unit on my previous AR145 V6TB, which had only done 5000km. The turbo was rebuilt completely before it went in the AR145, so it would have been a shame not to use it on this car. :) The turbo in question is a Mitsubishi TD05 Big16G (68mm compressor), where as the stock turbo is a tiny TD05-12B (58mm compressor). I know your DSM owners love that B16G turbo :Big Laugh:
http://shrani.si/f/3j/11N/2W8BGHbD/1/ma-car1181.jpg

On this turbo, we've also added a Forge Sierra Cosworth T3 wastegate actuator, which can hold 2bar of boost with ease (I've been running that much boost with this turbo before) :)
http://shrani.si/f/1H/tA/1wwgK0z4/ma-car1179.jpg

MAP sensor installed
http://shrani.si/f/1t/xl/41Ji9sO5/ma-car1192.jpg

Replaced connectors on all the sensors
http://shrani.si/f/1b/mZ/4K5Tynuo/ma-car1194.jpg

And a bit of tidying up the cables
http://shrani.si/f/2o/a5/3Dt6OIYu/ma-car1196.jpg

The engine was in this state after all that work
http://shrani.si/f/1/lG/4m5SBj9F/ma-car1191.jpg

To be continued...
'talla

johnnny 05-19-2014 12:15 PM

Man, that is one mean, detailed rebuild! Love the effort that went into it!

How does it run now?

peruccy 05-22-2014 03:01 PM

Thanks! Car runs very good now. But it still isn't the way I want it. I've got that tuning bug in me :)

Anyhu... back to the build. Wideband oxygen sensor & LC1 mounted and connected
http://shrani.si/f/2Y/VX/2veE7HHc/ma-car1198.jpg

Wiring went through the firewall
http://shrani.si/f/2i/mp/2nw43D3e/ma-car1200.jpg

Quite a few cables :)
http://shrani.si/f/1a/Xs/32E7VeWU/ma-car1201.jpg

There was no other place for the wires to go in the cabin, without taking the engine out, except under the windscreen
http://shrani.si/f/1D/vv/1sWpo4jw/ma-car1202.jpg

Just behind the passenger airbag
http://shrani.si/f/1r/Ou/4RHB9sbY/ma-car1203.jpg

I've also installed wires for three gauges, which were mounted on top of the dash (no other place for mounting in this car)
http://shrani.si/f/Q/sH/2ghfczWT/ma-car1204.jpg

Tidying up the wires
http://shrani.si/f/42/Zk/4tjovON/ma-car1205.jpg

Silicone around the hole, to prevent any water to come inside the cabin
http://shrani.si/f/2Q/kR/nruB3lw/ma-car1206.jpg

Making an adapter plate for the Porsche throttle body, out of an old intake manifold
http://shrani.si/f/27/BF/2tZytzxn/ma-car1207.jpg

Drilled holes
http://shrani.si/f/2P/ih/1ksqnGGb/ma-car1208.jpg

Test fit on the manifold
http://shrani.si/f/3z/v3/4MilCOzz/ma-car1209.jpg

And on the TB itself
http://shrani.si/f/2c/7G/1uDiZ2kL/ma-car1210.jpg

Putting everything together, to see if it fits. I had an old coupling hose laying around, so I could start the car
http://shrani.si/f/f/em/19d6FZ70/ma-car1211.jpg

http://shrani.si/f/3V/ju/4zTlWAeV/ma-car1213.jpg

Of course, there's always a problem with customization. TB is too wide, so the original expansion tank would not fit anymore...
http://shrani.si/f/9/Sl/2oWf1QUx/ma-car1212.jpg

The appropriate tank was from a Golf III, which is also one of the cheapest around :)
http://shrani.si/f/1n/Vm/39I7UQ1x/ma-car1214.jpg

Test fitting
http://shrani.si/f/36/fx/26RbDrsD/ma-car1219.jpg

Port matching on the TB
http://shrani.si/f/0/SA/UHBxK2D/ma-car1215.jpg

Enlarged intake manifold entrance
http://shrani.si/f/3Q/6p/2ez5NxoM/ma-car1216.jpg

I've enlarged the hole by 9mm...
http://shrani.si/f/2V/E1/3ciV2Z4y/ma-car1217.jpg

Some more port matching
http://shrani.si/f/42/dE/1E5ycQZd/ma-car1218.jpg

It looked like this before the very first start up with the new TB
http://shrani.si/f/2g/sR/3AWaU2SF/ma-car1220.jpg

And with mounted gauges. Some people would say they look "ricer", but frankly I don't care that much about that. I prefer function over esthetics :)all day long
http://shrani.si/f/D/fh/4zURk4cI/ma-car1225.jpg

To be continued...
'talla

peruccy 05-25-2014 06:16 AM

Moving on... Replaced rear subframe bushes
http://shrani.si/f/2S/nL/KKUfvDS/ma-car1226.jpg

Status before the first test drive
http://shrani.si/f/2q/qg/easHjqK/ma-car1227.jpg

After the shortest test drive... ever. This coupler hose sucks, so back to the drawing board
http://shrani.si/f/S/H5/HEwnaGF/ma-car1228.jpg

In the mean time, I've replaced all the bolt inserts around the engine bay
http://shrani.si/f/3U/Xx/3cOILfDK/ma-car1230.jpg

Because the bolts were becoming loose
http://shrani.si/f/2w/ql/2aDi1Keb/ma-car1231.jpg

Replaced drive belt lid
http://shrani.si/f/3k/x4/3elNhevX/ma-car1233.jpg

And pièce de résistance. Proper silicone hoses and clamps!http://shrani.si/f/i/QI/im5mzFr/ma-car1234.jpg

We had to modify the T-pipe for the dumpvalve
http://shrani.si/f/1M/Cs/2tdt26lW/ma-car1235.jpg

And weld on the nut for the intake air temp. sensor
http://shrani.si/f/2b/Ef/1icDbD34/ma-car1236.jpg

But we got the original expansion tank to fit, which is a great bonus, because it looks fairly stock now. The only thing that was in the way, was this bracket for the cover around the engine...
http://shrani.si/f/1h/3w/21Z65PXK/ma-car1237.jpg

Status before the second test drive. I had a good feeling this time :happy3:
http://shrani.si/f/1N/ZK/1KeZ3Nm0/ma-car1238.jpg

After a successful test drive, I made three daylight pics of the engine bay. I think is looks pretty much stock.
http://shrani.si/f/3O/11q/4Lueg2lo/ma-car1239.jpg

http://shrani.si/f/1D/64/1Qzp34Ua/ma-car1240.jpg

http://shrani.si/f/39/G1/Ub0RyOw/ma-car1241.jpg

Next on the list, was the remote central locking, which has failed on my car. I got a Chinese copy for silly money, and went to work on it
http://shrani.si/f/l/g9/4T05Ryq/ma-car1242.jpg

http://shrani.si/f/2P/Vt/4s5JKjJ/ma-car1243.jpg

In the mean time, I have also installed the original rear subs, which I got with the original amp. There were two versions which left the factory 1) 10 speaker system which had an amp & two parcel shelf subs 2) 8 speaker system without the amp & subs. Getting from #2 to #1 is quite a challenge, because complete wiring harnesses are next to impossible to come by, and making one from scratch is not so easy. Because Italians haven't left the harness in the car if it didn't have an amp... Two thumbs up for the Italians!
http://shrani.si/f/3x/1X/3Xym9Ges/ma-car1244.jpg

I've also received a front mount radiator for the chargecooler system
http://shrani.si/f/40/P0/4P0bXuz3/ma-car1245.jpg

Quite a big unit @ 597mm x 171mm x 70 mm
http://shrani.si/f/2w/oX/3i1gXn62/ma-car1246.jpg

I've also got a "repair set" for the gear shifter. These plastics wear out over time, and you don't get that smooth gear change feeling. It was cheap so I had to have it! I also found a company which makes a bush for the upper engine mount for 30€, while the OEM upper mount is 120€...
http://shrani.si/f/1q/BY/3uKaeC4h/ma-car1247.jpg

This is the culprit. 160usd for this... they must be mad!
http://shrani.si/f/2j/1a/4VXelhJf/ma-car1248.jpg

Bush was in a bad state, which was noticeable when doing hard acceleration. Engine was rocking back and forth too much for my liking
http://shrani.si/f/k/33/3b7O56E0/ma-car1249.jpg

http://shrani.si/f/1R/zf/Wc3Q9LF/ma-car1250.jpg

Fixed
http://shrani.si/f/3h/OR/2Opq700H/ma-car1251.jpg

http://shrani.si/f/1p/FP/oPsHwPY/ma-car1252.jpg

To be continued...
'talla

peruccy 06-01-2014 03:04 PM

Shifter repair set was next
http://shrani.si/f/2/UL/2KNzKGrb/ma-car1253.jpg

The whole mechanics is made out of plastic. Which wears over time. Now, I have crisp gear changes once more
http://shrani.si/f/2w/Ck/zl6LcgQ/ma-car1254.jpg

We also had to replace the brand new oil pressure sensor from an AR164, because it had switched polarities. So the pressure gauge would read from 8-0bar. So I got a replacement sensor for the RaidHP gauge. Now I have correct readings as it should be.
http://shrani.si/f/2T/tv/1TMvsNdT/ma-car1255.jpg

Now for the chargecooler system. I needed a filler neck with cap for my system. Since I couldn't purchase the only one I found on ebay, which was compact enough, because the seller didn't ship to my country, we had to make one from scratch. It's made from plastic and I think it turned out pretty good
http://shrani.si/f/3X/1R/3lZGijYU/ma-car1257.jpg

http://shrani.si/f/i/fS/h4Ng0ov/ma-car1258.jpg

We replaced the 1,4bar cap with a new 0,9bar cap. Since this system will never have such a high pressure, there was no need for the 1,4bar cap
http://shrani.si/f/1W/Tv/1SzXRiv3/ma-car1259.jpg

Then, I turned my attention to the original amp and parcel shelf woofers. As I have previously mentioned, to get an original wiring loom for this car, is next to impossible, since everyone want's this amp'ed 10 speaker system in their 166. So I had to make a wiring loom from scratch
http://shrani.si/f/G/6k/1hygyxnv/ma-car1260.jpg

All the wiring goes through the car's ICS unit. This unit controls everything from trip computer, fuel consumption, radio, navigation exc.
http://shrani.si/f/24/CX/FBssuco/ma-car1261.jpg

I found the wiring diagram online, and went to work. It took me 3 days to complete this task... And I must say, it makes one hell of a difference in sound quality. But I will definitely not be doing this task any time soon! It was a real pain in the :emotions33:
http://shrani.si/f/2k/Ws/wYmTV0H/ma-car1262.jpg

I got the electric water pump and flexible wire hoses
http://shrani.si/f/1b/CU/I1gIlLg/ma-car1271.jpg

We've also replaced the temperature switch, because my previous one had corrosion on all the contacts
http://shrani.si/f/1h/xS/2cIDZRmq/ma-car1272.jpg

We've also made our own gasket for the Porsche throttle body. Previous one we made, was from a thin paper. And it didn't last very long, because I got a vacuum leak after a month. So I got this Elring gasket kit, which has various thicknesses for various applications. Now I have no more leaks
http://shrani.si/f/G/jc/2JPAPyU7/ma-car1273.jpg

Brand new 0,9bar cap and two brackets for the CC filler neck
http://shrani.si/f/k/5m/2LLrpuiI/ma-car1274.jpg

Then I got 3" silicone elbows, pipes and W2 clamps for the CC system
http://shrani.si/f/1f/fs/azQK6QI/ma-car1275.jpg

We have also replaced the old fuel pressure regulator. Since I plan on using bigger injectors and an external fuel pump, I want the whole system to be 110%
http://shrani.si/f/2f/dC/11iCiHht/ma-car1276.jpg

And finally, the installation of the chargecooler system
http://shrani.si/f/42/kk/1uzfE9Zf/ma-car1277.jpg

Good thing I got an almost identical size cooler than stock. And even this one just barely fits
http://shrani.si/f/2k/bE/4E8YU6Xa/ma-car1278.jpg

It's a tight squeeze
http://shrani.si/f/1c/mD/1X60mQnN/ma-car1279.jpg

Home made bracket for the filler neck
http://shrani.si/f/3b/Jj/2WYqLkuG/ma-car1280.jpg

Turbo pipes installed
http://shrani.si/f/1t/5h/2q7aBhFZ/ma-car1281.jpg

Upper pipes were next
http://shrani.si/f/3G/xZ/3siYpTZe/ma-car1282.jpg

Just enough room for everything to fit
http://shrani.si/f/3q/xN/1Nf15QGY/ma-car1283.jpg

Front radiator for the CC was also installed with home made brackets
http://shrani.si/f/3x/Lr/BwpiJao/ma-car1284.jpg

This is how it looked nearly finished
http://shrani.si/f/2B/X/wVMicK3/ma-car1285.jpg

Very tight squeeze between the coil and intake pipe
http://shrani.si/f/3f/lc/1KYX2O0T/ma-car1286.jpg

We had to remove the original airbox and air filter, because it was just to big. So I got an universal one, which had the correct ID and was reasonably sized
http://shrani.si/f/J/bt/3kohIXmp/ma-car1287.jpg

It fits, barely
http://shrani.si/f/1V/58/4RaEU58M/ma-car1288.jpg

Now all I need, is an intake funnel which would go in front of the universal air filter, so I would have cold air intake. That's next on the list...
http://shrani.si/f/29/yA/3YHk4Yg4/ma-car1289.jpg

And finished
http://shrani.si/f/3W/Ze/3ej9qZcg/ma-car1290.jpg

Of course, there is always something to do on a car. One of my upper steering arms had play, so we replaced both sides. And my front brakes didn't perform as they should, so we overhauled all four brake calipers, just to be on the safe side. And to top it off, I got the best dot4 brake fluid I could find
http://shrani.si/f/1Z/QT/31r4XCT8/ma-car1291.jpg

And that's it. This is the current state my car is in. It pulls really well with this CC system. Dumpvalve makes one helluva noise! Me like :Rock on:

And now, I will save money to get bigger fuel lines, bigger injectors, and a custom chip. I already have an external 300lph fuel pump and cradle. So, until next time...

'talla

johnnny 06-02-2014 02:09 PM

Do you know where you're doing your chip? How much do they cost in Slovenia? And what happened to Trabant? :)

peruccy 06-03-2014 11:46 AM

I'm still deciding where to get the car chip tuned. Prices for a custom chip with a dyno in Slovenia are from 500€ - 1000€. Depends on the ECU, and how much work goes in to it. And since I have the rarest of ECU's, Bosch Motronic ME2.1, which was only in an AR166 from 1998-2003, with no upgrades or anything, I think I am in for a nice bill... I've seen many people give up on these ECU's, because they are damn hard to work on. It was an Alfa prototype ECU, which can memorize and adapt to various engine changes by itself. Also, it has multiple injections per cycle, which for it's time in a normal saloon, was almost unheard of. But they gave up on it after a few years. Confirmation about it's ability to adapt by itself was when I replaced the old altitude sensor with a MAP sensor. First one tells the ECU an approximate intake pressure via the preset value of the altitude, while the MAP sensor reads pressure directly via a vacuum hose from the intake manifold. Another thing was, when I added a bigger turbo and opened up the boost. ECU adapted to these changes instantly, without a chip tune. My AFR readings are spot on with this setup: 14,4-14,8 @ idle and 13,2 @ WOT..

Trabant is still in development. First I want my daily driver to be complete, and then we will focus all our attention on the Trabant. We have until May next year to complete it. I wish to participate in our annual drag race event here in Slovenia.

Shaggy 06-09-2014 01:53 AM

Keep up the posting on this. Love the detailed pics you are adding!

johnnny 06-09-2014 08:10 AM

I think SM chiptuning would do a custom chip for 600 (550 if you put on their decal), that could be worth a trip to Croatia (or Bosnia, Serbia, if you have someone to visit there), but I don't have a personal experience with them, so I can't say for sure how good they are. Maybe the best option would actually be not to chip, and if the need arises, go a Megasquirt way?

Hope you're making photos of the Trabant build! Aiming to pit it against monster Fica from Croatia or absolutely mental Yugo from Bosnia?

peruccy 06-14-2014 09:13 AM

@Shaggy: Thanks! I will post updates as they happen...

@johnnny: I still have time to decide which tuner it will be. Thanks for the info though, I will count them in for sure.
As for the Trabant, I have some pics of the build so far, but as I have mentioned before, it is still in development. As soon as the 166 is done, my attention goes to the Trabant. But the car will definitely not be a record breaker. I will use stock internals for starters. I only plan on doing minor engine mods to it, because first I want to see what I can achieve with a set budget, before I start spending silly money on it. Mods I plan on doing are: head porting, FMIC, bigger exhaust, bigger injectors & pump, custom chip and maybe a bigger intake system. And that's about it... I am relying on the silly weight of the car, to make it at least half competitive. By my calculations, with a V6 engine and a roll cage, together with a lighter hood, thin plexi glass all around, removed unnecessary weight, different rear subframe (the heaviest piece on the car), slicks, and a bucket seat... I hope I will get the car to 650kg (1300lbs)... And with the mods I want to do to the engine, I am hoping for 260-280hp. So for a starting project, it should suffice...

peruccy 06-23-2014 04:06 AM

I found another thing I can change on my car. MAF housing will be uprated...

Stock = 70mm
http://shrani.si/f/2r/nR/m4NqZMi/ma-car1295.jpg

Not so stock = 82mm
http://shrani.si/f/2n/w4/3LTru7zo/ma-car1296.jpg

In the meantime, I will replace the pipes that go to the turbo inlet to the same diameter as the MAF housing. So it will go from 63mm to 90mm
http://shrani.si/f/2F/Cz/2PNQBGV7/ma-car1297.jpg

'talla


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