Monday update

Bob got the ignition switch anti-theft bolt out! He removed the shroud on the steering column, used a Dremel tool to cut a grove in the bolt, and then unscrew it. Of course, the new ignition switch (from Alfaholics - https://www.alfaholics.com/parts/105-series/electrical/ignition-switch-late/) went in easy.

Barry sorted out the rear brake lines. This was one of those slow and frustrating tasks because the old rear-axel flex line was seized into the 3-way union. So we needed a replacement part from Classic Alfa (see http://classicalfa.com/products/BR048-REAR-AXLE-3-WAY-BRAKE-UNION.html) to finish the job.

Weekend update

Bob and Barry continued to work on the car through the week. They've got most of the wiring done, but ran into a snag removing the old ignition switch. We've decided to stop until we can figure out an easy way to remove the anti-theft bolt.

The new exhaust system from Classic Alfa arrived on Friday. Everything looks good and should be easy to installed.

I disassembled, cleaned and repainted the airbox this afternoon.

Veloce colour chart

Throttle linkage notes

Weekend update

Slow but steady progress.

All of the new coolant hoses are on. Supplied by Alfaholics.

The fan belt proved to be a challenge. At some point, this car had been upgraded to use an alternator, so the belt size is an unknown. After several trips to the local part stores, we found one that fits (34.6") and has the correct tension.

I thought the brake booster vacuum line looked new, but I was wrong. It started splitting and crumbling in my hands, so I replaced it with high pressure fuel injection hose. This is the same stuff I used on my Lotus Elan.

The alternator is back on. We also cleaned and reattached the ground strap.

We used a ceramic paint on the headers and reattached most of the exhaust system. For those of you who have been through this process on a GTV, hats off to you! It's a fun and painful job. Instead of using the original bolts, we substituted ones with a hex-head which made the job easier.

I gave the coolant reservoir a good cleaning. It is amazing how much casting sand makes its way into these! The lid and straps were also treated with a fresh coat of paint.

Finally, we trial fitted the carbs.

  

1750 fuel pump diagrams

A smart upgrade

I forgot to mention these in an earlier post. Alfaholics has designed and manufactured a rubber trim strip for the door handles - too keep water and nasty stuff out! Something all 105s should have had in the first place...

Alternator checks out

Barry took the alternator into a shop for testing. Everything looks good.

Alfa bolt torque specs

Always handy to have around. Taken from Centerline's website.

Engine in

Everything is finally together.

The secret to reinstalling the Nord engine in situ is to remove the engine mounts and jiggle the crank with a long wrench and socket. Everything will slip together with a neat click.

We also found the brake and clutch master / slave cylinders need replacing. The units are rusty, the seals are deteriorated, and they're wet with brake fluid. So, I ordered new units from Classic Alfa earlier in the week.

Engine install progress

The engine is back!

We rattled off a number of small jobs:

• Installed new engine mounts (Alfaholics HD)
• Mounted new Bosch Blue coil
• Mechanical fuel on
• Oil & temperature senders

Unfortunately, the engine and transmission did not go together on the first try. We tried a number of tricks, but it wasn't meant to be.

Stay tuned.