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AO COTY Winner 2017
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Discussion Starter #1
Hello from Serbia.
After six turbulent months, it appears to be the right time for me to present my project to you. It's nothing new, or something you haven't seen before, but still, I'm really proud of it.
I have gone down the road that James(jbsmith1) and Pete (Clogz) have taken before. Before i say anything or insert an image, I really need to thank Pete for unselfish help throughout this ordeal. He was always more than happy to answer all the questions i had. Pete, you're da man! I know that James is not active on the forum anymore, but thanks for all the knowledge shared.
The car in question is '07. Brera, 2.4 with 210hp...originally :) It was in decent enough condition when I got hold of it, and I never planned on doing any modifications to the engine, or even suspension at the time. These are from the day I first got the car and few artistic ones from a few months after that:
 

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AO COTY Winner 2017
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296 Posts
Discussion Starter #2 (Edited)
There were few things that annoyed me, for example some damage on alu trim. I googled "brera interior" wanting to buy a new alu trim and then just fit some Prodrives...that was all I wanted. Somehow, landed on James's thread and started reading...big mistake. To shorten it, I've spent several days just reading on his and Pete's threads. I now know that i was doomed from the get go.
Next thing I knew, I was bugging Pete for an advice and started on the project.
First things first...turbo...
It was Adam and TDi Turbos that did their magic and supplied me with GTB2260VK hybrid that was simple plug and play option. I've opted against VKLR one to avoid oil and water pipes fitting(for the time being).
Adam also provided the pictures. :)
 

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AO COTY Winner 2017
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296 Posts
Discussion Starter #3
While turbo merging took place, i was busy getting all other parts:
KW Variant 3
Prodrive 8C alloys 19''
Michelin Pilot Super Sport 235/40 ZR19 Y96
Tarox Sport Japan rear discs
Tarox Strada 112 rear pads
Phaeton Front Discs 365mm
AP Racing CP5575-804S4R2
Ferodo DS2500 Front pads
Goodridge braided hoses
Quaife LSD
Sachs Performance Clutch
AIRTEC FMIC 600x400mm 60mm core
Mocal oil cooler
PowerFlex all around
Novitec front diffuser
+ some more parts that i won't be fitting, like front Tarox discs and PerformanceFriction pads.
 

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AO COTY Winner 2017
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296 Posts
Discussion Starter #4 (Edited)
Everything except that FMIC was plug and play, or so I thought... :)
We started on the car...and did a good job when everything is taken into account. It took us two weeks to fit most of the things and finish all major hardware installation...from turbo and FMIC to PowerFlex and LSD . At the time, coilovers and few other items were not installed. This was part one finished...
 

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AO COTY Winner 2017
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296 Posts
Discussion Starter #5 (Edited)
While this was taking place, mapping needed to be secured. I have contacted Gregor, known around here as TribesMan :) . Not only that he knows thing or two about mapping, he actually knew everything i have asked. And i ask a lot of questions...mostly dumb ones, but even so, he provided all the answers. For all of the knowledge, and all the patience, i take my hat off.
I had requested a map that will create a car for daily use, but one that won't be ashamed on the track also. That is what I got...
It was a bit bumpy, since I had only road to create logs. No dyno, and more important, no experience whatsoever on my side. My first log runs produced more problems than information. First, clamps i used were not even close to the ones i needed, and then my custom made hose was impaled on AC compressor and blew. That was a minor sat back. Soon i got new hoses and some T clamps, and was back on the road creating logs.
 

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AO COTY Winner 2017
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Discussion Starter #6
Around that time I started to get annoyed with the black smoke at the exhaust in high revs and when I gun it. Not much smoke, but enough to prevent me from enjoying the car completely. Since we did quite a lot of work, and there was more on the way, I decided to take the car to get custom exhaust fitted, and after that to take the car to Alfa Romeo garage. I needed to have intake manifold cleaned, coilovers fitted and car completely checked.
This created more problems. After exhaust was fitted and intake cleaned, smoke was still there, even worse than before, but I've also experienced power loss in high revs. I've created new set of logs, everything was the same, except 0.7 slower time to 4500rpm. Gregor suspected some kind of air leak, and again, he was right...
I got the car with EGR blanked and DPF removed, but it seems that EGR part was not done properly. Blanking plate was poorly made, and leaked all over. Once we did that, smoke that appear when I sink the pedal was gone...for a while.
 

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AO COTY Winner 2017
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Discussion Starter #7
Around this time, i decided to have the car detailed...and then some. Even tho mechanically everything was not perfect, I wanted it to look as good as it can...
 

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AO COTY Winner 2017
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AO COTY Winner 2017
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296 Posts
Discussion Starter #9
While beautifying was going on, decision was made to de-swirl intake manifold. I got one from 2.4 166, cleaned it, painted it and installed it.

After that, smoke was almost gone. I did few more log runs, just to check where we are, and even tho there are few more things planed, Gregor created another map. That was the one. Finally, car run like it should from the beginning and if I was normal person, I'd give it a rest here...So, here are things planned for the near future(next couple of weeks)...
1. Thermal wrapping - turbo, exhaust and some piping in engine bay
2. Installing APs, since those are still sitting in my room
3. Fitting custom stainless IC hoses (this would have been finished by now if ASH have not been so unprofessional)
4. Engine and injector cleaning
5. Installing engine guard
6. Moving oil cooler away from FMIC

Plus few cosmetic improvements...

That's it for now...there should be more soon :beer:
 

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AO COTY Winner 2017
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296 Posts
Discussion Starter #16
Wow, that is dedication. Great work, a credit to you!
Thanks, it has been a battle so far, but driving this beauty makes everything worth it

Post up a video of the sound ;)
Will do. I just need to record it properly. I am really proud of the sound it makes over 2300 RPM
 

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Congratulations and welcome to the club.
 

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Wonderful car,

Would be nice to see it in flesh next time I past trough Serbia :)
 

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AO COTY Winner 2017
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296 Posts
Discussion Starter #20
Congratulations and welcome to the club.
Thank you sir. It's great club to be in :)

Looking awesome. The interior looks great in gloss black was that painted?
It was painted. Picture doesn't give it justice, it really looks stunning. I'm not big fan of shiny and glossy stuff, but once it was on, it looked perfect.

Wonderful car,

Would be nice to see it in flesh next time I past trough Serbia :)
Thank you. Please, just PM next time you go trough and we'll arrange something for sure

A new toy arrived yesterday :) It'll be fun fitting it
 

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