having been through the exact same process I can tell you this...
swirl flap removal a great idea, I have had it don along with EGR delete and re-map. BUT if power is your aim, now the EGR is gone I would if I had the decision to make again replace with a brand new flapped mani...without exhaust crap going into the mani it should be fine to very high miles..that said failure does tend to be random. there is a direct correlation to mileage though.
I may consider going with a stock mani at the next cambelt as the flaps do give you a bit more low down power.
your stock clutch will absolutely give up as the torque produced at anything above around 190-195 BHP will take it out...options are a dimpled clutch that is fitted to the clover 170 or some kind of stage 2 dual friction clutch, larkspeed, CG motorpsorts or give Joel at JTD performance a shout...he is currently building a custom one for ALFADOIT check out his build thread here..https://www.alfaowner.com/Forum/alfa-...and-build.html
I have a stage one myself, the dimpled clover jobbie, it SHOULD be fine at the 210-215 I am planning but IS a weak point. TBH again if I had planned this a bit better I would have gone stage 2 initially. it having been done recently I have decided to limit the map to ''sensible'' to get my moneys worth out of the clutch. I may re-visit the map at a later date.
now to the FM intercooler, well I recently fitted one ...after about 30 mins of driving it developed boost leak which I tracked down to the cooler itself (it was a used one) but it WAS OK for a spell. enough time for me to work out that at the state of tune we are going for does not require an FMIC and in fact added lag to the turbo..I returned back to stock and all good again...we live in the UK even on the warmest days the stock cooler should be able to cope without getting heat soaked unless you are constantly blatting the car or tracking it.
I think an upgrade to the stock intercooler with a more efficient internal but same external sized SMIC may well be a better solution.. you are adding volume to your induction system with an FMIC due to the extra pipework and as I said at this state of tune the inlet temps are not the main issue. in my desire to eliminate Lag I will probably fit these.. Stainless steel turbo pipes and silicone couplers set for Alfa Romeo 1.9 and 2.4 JTD | Sport exhausts | Exhaust manifolds | Sport exhaust systems | Extreme-Tuning.bg
these will reduce lag further by eliminating the ballooning of hoses when the turbo spools up.
now onto the turbo, well I have spoken to Aide at AHM and he says 210BHP is easily achievable on the stock turbo and cooler on a HEALTHY ENGINE AND TURBO!, he is a well respected tuner and develops maps on a dyno for many others, NJS in pershore use AHM maps among others...the thing to consider is the age of your turbo and car. if its an old one with 100k plus on it I would get it refurbed and maybe take the time to hybridize it.
I currently have Tom at Turbo Dynamics making me a hybrid as we speak, I picked up a Garrett 777250-1 from a clover with 40k on the clock and he is upgrading thrust bearing,compressor wheel and various other bits to give me a ''bigger turbo''
bear in mind if you plan to upgrade the turbo a custom map will be required as any generic map will be designed to work with the stock turbo...when I fit my new turbo I will be going to Red dot racing for a map tweak to get the best out of it as it will be laggy on the current map even though it is pushing somewhere around the 190BHP mark.
depends what your aims are really..if you are chasing figures and power then stage two clutch,FMIC,hybrid turbo and custom re-map, straight through exhaust system water meth injection , 290 BHP is achievable...I am not sure I want that as reliability and day to day use may be compromised.
you can easily mismatch things by going FMIC with the wrong map or turbo and it will hurt performance, just make sure that whatever you do that things are designed to compliment each other rather than work against each other.
FMIC on stock car and map ..pointless. FMIC with hybrid COULD create more lag, would need to be custom mapped on a dyno. Hybrid turbo on a stock cooler at around 210 BHP..for my needs perfect with a clever map. any more than that an FMIC and a stage 2 clutch upgrade would be required.
here is what is possible with your engine
if like me reliability and driveability is more the aim then ,stock cooler, stage one clutch,and a hybrid turbo with a clever custom map avoiding torque spikes...I am aware that pushing much more will potentially push the transmission,injectors and MAF and MAP sensors to the limit of what they are designed...it can all be sorted but has a financial implication.
and finally there is no point in any of this without looking at the stock suspension and factory diff.
I have Bilstien B12 kit Eibach arb kit and a Quaife LSD, without these I would say a 190 BHP+GT would be un-drivable...or at least not much fun in anything but a straight line.
no point in all that power if you can't safely use it.
good luck with your project