Ghia engine swap

As I have decided to go the Alfa route, I have sourced this un-used adapter kit, which came from GB Engineering. It normally costs £204 but I got it from somebody that had changed their minds about the engine swap. It just needs a clean up.

I always seem to get asked for GB Engineering's details so here they are:

Tel: 01270 841081

They are based in Cheshire, no web site I'm afraid

The kit consists of an adapter plate, a new input shaft and an extension piece for the release bearing which wouldn't reach the Alfa pressure plate with the extra distance caused by the thickness of the adapter plate.

In the end, I found an identical engine to the one I had in the speedster. It will give a useful 120bhp...

It has been looked after until the car was written off after being rear-ended by a truck! You can tell by hte fact that it has had good quality consumables used on it.

Engine in place...

Alfa manifold cut down and welded to new flanges which replicate a type 4 engine, so many aftermarket exhausts can now be used.

I have a standard type 2 back box which has the standard side exit tail pipe missing. I'm thinking of relocating the pipe ot the rear of the box if this is possible, maybe two like a big bore stock VW system. I'll look into the the internals of the box first but I have seen this done before...

Finally got around to putting pics up!

Making a start with the cooling pipework was necessary to make sure I had space for it up front. Here you can see the copper pipework I have made up. As the radiator has no provision for a bleed point, I fitted one here. You can also just about make out the adjustable radiator cooling fan switch and controller

Rigid lines stop at the rear transmission cradle, I will join from there to the engine on either side with flexi hose.

Plumbing clips are used to fix the pipework to the bottom of the chassis.

Mid section is kept up high, no loss of ground clearance here.

Unfortunately with the inlet/outlet positions of this rad I have to cross over, not too much hassle though...

I have also just bought a second Alfa 33 1.7 8V engine off ebay. Only 62k miles on the clock to I couldn't not really! Just in case anything is wrong with the current one...

The rear luggage compartment is going to house the heating system.

It is based around a heater matrix I found new at a kit car show with a custom made fibreglass box. A type 2 (camper van) electric fan will suck heat through the matrix and blow down into the heater channels so it will come out of the stock outlets up front without the hassles of fitting the heater under the bonnet and taking up all that space.

I made a box around the matrix (seen in the background) and covered it in tape to make the fibreglass housing.

Here the matrix is fitted and the the heater pipes can be seen on the rear bulkhead. I added and extra air bleed here as it is a high spot.

The holes in the back are where the air is drawn into the heater box. This means that there will be some usable space in the rear.

I also made some metal tube bulkhead fittings that the fan pipe will fit to and then the insulated pipe underneath also joins. I'll add another pic when the paint is dry on all the parts. Just waiting for the carpet set before everythign can be finally fitted.

Radiator switch temperature controller mounted to side panel

To force all the air that comes in via the 'nostril' grills through the radiator I needed to fully duct the air. I made up two side panels out of sheet steel and welded captive nuts into them...

and these then mount to these flanges wither side of the radiator inside the nose. Looks neat too!

Heater just about finished. You can also see the new speakers I fitted on the rear shelf and the heavy duty wiring that just needs hooking up now.

Radiator internal cover installed after painting. Screwed in place with a foam gasket.

Here you can see the ducting between the heater in the picture above and the heater channel.

Engine install finished. I had to blank one of the exhaust tips off in the end and add baffling to the other one as it was so noisy. Still a bit of tidying to be done for the wiring but just about there... Bulkhead is being left as it's original paint...