Butchering a Bertone
Discussion
Started life as this
Then stripped of all dignity:
Once finished getting mashed up and ended up like this:
Along the way a few bits were slightly altered:
Final phase of destruction, to an otherwise perfectly good piece of Italian automotive history, is now almost complete:
Edited by CarreraLightweightRacing on Tuesday 27th October 07:58
To answer some of the questions, here is a little more detail; due to the depth and attention to detail with this car I’m just going to lightly skim over some of the design and construction pics, I would literally be here forever for the full breakdown. The car started life as a 1975 GT Junior 1600. The project started with a completely restored shell with all the other components in boxes. The early idea was to use the Alfa engine but this was ditched fairly early on. In search for a new powerhouse the F20C was chosen. Those who know a thing or two about NA engines will most probably know Honda's F20C engine held the record for producing the highest specific power output for any mass production naturally aspirated piston engine, at 123.5 HP/L, until Ferrari began production of the 458 Italia in 2010, which produced 124.5 HP/L. The F20C revs to 9000rpm, is unbelievably strong and reliable even at this level of tune. The engine was completely stripped down and rebuilt as new then some special track orientated modifications added, baffled sump etc. A completely unique custom fabricated ITB system was made, not only that it uses Formula1 engine type injection with the injectors housed within the trumpets; a true work of art as you’ll see from the pictures below. The car was mapped and running on E85 so it is a very green machine. In the current state of tune it is making around 265bhp and weighs just under 850kg. Some of the detail and lengths gone to really are somewhat crazy, 180mm wider track for instance… It really is a one-off in the truest sense.
The car has been through various stages of design and some aspects of the early work presented here may no longer be on the car. The pictures are roughly in time order. The final car is fully FIA compliant and certified so can be used in most race series. It has also been road registered which is some achievement. I am now in the process of dialling it back a little in an attempt to make it TUV compliant for registering in Germany.
Apologies in advance if you stumbled across this thread looking for deviated stitching
This is only a short summary but I’m sure that’s enough of my blabbering, I’ll let some pictures do the talking. Let the engineering porn commence!!!
The car has been through various stages of design and some aspects of the early work presented here may no longer be on the car. The pictures are roughly in time order. The final car is fully FIA compliant and certified so can be used in most race series. It has also been road registered which is some achievement. I am now in the process of dialling it back a little in an attempt to make it TUV compliant for registering in Germany.
Apologies in advance if you stumbled across this thread looking for deviated stitching
This is only a short summary but I’m sure that’s enough of my blabbering, I’ll let some pictures do the talking. Let the engineering porn commence!!!
Interior is now pretty much sorted in terms of NVH, test drive will confirm but a lot of attention has gone into sound proofing, carpeting, sliding seats, sealing, and basically making it a far more friendly place to be
Next up major changes to the bodywork and external appearance. Panel beating, welding, painting, wheels, new arches, new ground effect panels made, most crazy race-car aero and diffuser removed revealing the beautiful classic ‘Bertone’ lines:
After the mid section and diffuser were gone the car was left looking like this; front end still very agressive:
So decided to ditch the front end and make some new panels
Due to the F1 injector set-up not really being a solution for a road car (Difficult to start or idle when fuel is being squirted onto the face of a butterfly 20cm from the combustion chamber), I have had to completely redesign the injection and throttle system also the car is mapped for E85 fuel so the injectors also need to be changed for normal fuel. Lots of head scratching to find a workable solution but I’m lucky to have a dream workshop at work with every machine you could every think of, so a lathe and milling machine came in very handy for this phase:
Following the carbon airbox removal (4 hours alone due to inaccessible fasteners…) Started to take some measurements
Found some lovely short 440cc injectors only 38mm o-ring to o-ring. Due to all the redesign issues clearance was the biggest headache. I’m literally talking only 1mm or less is some instances between fuel rail and throttle linkages etc. Anyway what’s the first thing you do when you receive some lovely new car parts; chop them up of course, so straight onto the lathe they go
Next up I needed to fabricate some parts to relocate the throttle assembly so an inch thick slab of aircraft aluminium was put to good use
A few of the newly fabricated parts
Throttle assembly parts now made
In CLR fashion I decided they could do with trimming down somewhat
Throttle assembled
Other new parts modified/fabricated
Even made a loom mounting bracket out of titanium
Finally very close to resolving all the design issues now
Latest is the fuel system is complete.
Made another little titanium mounting bracket for the rigid section of the fuel return pipe:
Which fits here:
Engine bay fuel lines new layout:
This picture gives a close up high-lighting the tight tolerance clearance issues referred to earlier:
Final assembly:
Next up major changes to the bodywork and external appearance. Panel beating, welding, painting, wheels, new arches, new ground effect panels made, most crazy race-car aero and diffuser removed revealing the beautiful classic ‘Bertone’ lines:
After the mid section and diffuser were gone the car was left looking like this; front end still very agressive:
So decided to ditch the front end and make some new panels
Due to the F1 injector set-up not really being a solution for a road car (Difficult to start or idle when fuel is being squirted onto the face of a butterfly 20cm from the combustion chamber), I have had to completely redesign the injection and throttle system also the car is mapped for E85 fuel so the injectors also need to be changed for normal fuel. Lots of head scratching to find a workable solution but I’m lucky to have a dream workshop at work with every machine you could every think of, so a lathe and milling machine came in very handy for this phase:
Following the carbon airbox removal (4 hours alone due to inaccessible fasteners…) Started to take some measurements
Found some lovely short 440cc injectors only 38mm o-ring to o-ring. Due to all the redesign issues clearance was the biggest headache. I’m literally talking only 1mm or less is some instances between fuel rail and throttle linkages etc. Anyway what’s the first thing you do when you receive some lovely new car parts; chop them up of course, so straight onto the lathe they go
Next up I needed to fabricate some parts to relocate the throttle assembly so an inch thick slab of aircraft aluminium was put to good use
A few of the newly fabricated parts
Throttle assembly parts now made
In CLR fashion I decided they could do with trimming down somewhat
Throttle assembled
Other new parts modified/fabricated
Even made a loom mounting bracket out of titanium
Finally very close to resolving all the design issues now
Latest is the fuel system is complete.
Made another little titanium mounting bracket for the rigid section of the fuel return pipe:
Which fits here:
Engine bay fuel lines new layout:
This picture gives a close up high-lighting the tight tolerance clearance issues referred to earlier:
Final assembly:
In answer to a few of the questions raised:
Many thanks for all the positive comments guys The car has been a project for the last 8 years, for which I've spent the last year going over the whole car and reworking many systems including, Fuel, ignition, suspension, wheels, steering, body work, interior, engine, aero, NVH... It is getting pretty close to finished now but I still have the monumental task of getting it through the TUV approval process. Should that fail, I shall be finding another country to register it in which is a little more friendly in this respect (The UK or Sweden for instance, where it is currently registered).
Mr.Jimbo said:
That's utterly awesome. I think I prefer the restomod (ish) look you've ended up at but no denying that the aero machine is something else.
What power is the engine running? Must be a healthy improvement over stock and a fair power to weight I'm guessing.
Thanks Jimbo, from memory the stock 1600 GT Junior develops 107bhp. This car is now pushing out 265bhp but I will dyno the car shortly to verify.What power is the engine running? Must be a healthy improvement over stock and a fair power to weight I'm guessing.
SturdyHSV said:
Oh that's excellent, I'm going to assume there is video of this...?
Once the car is fully resolved, I will look into some sort of video Jaaack said:
Now THAT is a seriously good way to p
s off the purists
Bet it's a right laugh. Love it.
Funny you mention this Jaaack, I thought the Porsche beards had it bad from when I ruined my 911 in similar fashion but the Alfistas are truly on another level s off the purists Bet it's a right laugh. Love it.
Superhoop said:
Is that an MX-5 or RX-8 rear diff assembly in the rear end?
Well spotted SH, tis indeed an MX5 torsen diff with a 4.77 final drive.shalmaneser said:
Do these have a steering box as standard? Would be interested to see how you've (presumably!) converted to a rack.
It has been fitted with a new Mk1 escort rack reworked with a higher ratiowoodnut67 said:
Phwooar! Do you watch Home Built by Jeff (Australian YouTuber) perchance? He's doing a Ferrari engined Alfa albeit a road car and I think your fabrication could show him a thing or two!
I've watched every video Jeff has made from when he first started out. He is incredibly talented with a great engineering mind and a diverse skillset from painting to welding to upholstery and everything in between. I'll give most things a go but have wide gaps in my fabrication knowhow. See 'Bad Obsession Motorsport' for real skill. Those boys are seriously talented. Many thanks for all the positive comments guys
The car has been a project for the last 8 years, for which I've spent the last year going over the whole car and reworking many systems including, Fuel, ignition, suspension, wheels, steering, body work, interior, engine, aero, NVH... It is getting pretty close to finished now but I still have the monumental task of getting it through the TUV approval process. Should that fail, I shall be finding another country to register it in which is a little more friendly in this respect (The UK or Sweden for instance, where it is currently registered). Apologies for all the pictures Henry, I realise for some, this level of destruction could cause life long injuries
Regarding a video, a prominent YouTube has expressed an interest in coming over in late summer to review the cars so we will draw up a plan of action for this shortly.
I’m actually over in the UK right now but unfortunately spending a little too much time with the NHS, I’ll send you a picture via WhatsApp but you’ve been warned not to open before breakfast!
Regarding a video, a prominent YouTube has expressed an interest in coming over in late summer to review the cars so we will draw up a plan of action for this shortly.
I’m actually over in the UK right now but unfortunately spending a little too much time with the NHS, I’ll send you a picture via WhatsApp but you’ve been warned not to open before breakfast!
Slippydiff said:
Not nearly enough pictures 
Get a video up smartish, or I'll have to post a link !!
Hope you're well Rich
Got your email thanks, I'll respond to it sometime this week.
I'm looking into learning video production and editing over the winter but in the meantime here are a couple of raw one-take no editing videos; one is a walkaround and quick overview, the other is an acceleration test:Get a video up smartish, or I'll have to post a link !!
Hope you're well Rich
Got your email thanks, I'll respond to it sometime this week.
https://www.youtube.com/watch?v=GFSfXRSirjQ
https://www.youtube.com/watch?v=QhbNhoioaVg
Apologies in advance for the crap quality, as mentioned above, I'm working on this for future videos
CedricN said:
Ive been following this build for years here in sweden, i didn't know where it went. Did you buy it from the builder in sweden or have it moved around? Nice to see its being continuously worked on and that it didn't disappear in someone's garage.
Hi Cedric, yes I bought the car from Bjorn. I saw the car and just had to have it. It was a 3200km drive with a trailer in one hit. I didn't even drive the car just loaded it up and drove home. It was an amazing achievement by Bjorn to get it to where it was, but quite simply it wasn't drivable for many reasons. A year since owning the car it is now just about fully resolved. I will still have to do all the testing and final set-up but the basic car is now one that starts, steers, is fully road compliant, mapped for normal fuel, NVH levels reduced... There is still a fair way to go but it has been a very interesting project to be involved in. But like any project of this magnitude, there are always things you want to improve. Over the winter I still have to complete the TUV process, I want to optimise fueling & ECU map, fit sliding windows, change the wheels and suspension set-up, fit ICV and cold start system, change diff (from 4.7:1 to 4.1:1 final drive), redesign of ARB's... I just can't wait to get the drive the thing.
CedricN said:
Ah, I see, totally understand why you needed that car . But yeah it was built like a race car, which seldom creates the best road car, its interesting to see your journey with roadifying the car. I would have though taking it through TÜV would be impossible,but it seems like its not with some work, the rules are very different compared to here though.
Its still in the registry here, which is odd if it has been exported. It looks like it was registered with a K20A2, or at least thats what the papers say
.. There might have been some issues with the power to weight ratio which is limited when you register a modified car.
Getting it through the TUV in Germany is practically impossible as all material spec and build standards have to be documented and approved. But where there is a will there's a way. You are correct it is still on Swedish plates until I can get it through the TUV. The reason for the engine fitted in the Swedish papers is also as you mention (the F20C and K20A2 are identical on the outside . But yeah it was built like a race car, which seldom creates the best road car, its interesting to see your journey with roadifying the car. I would have though taking it through TÜV would be impossible,but it seems like its not with some work, the rules are very different compared to here though.Its still in the registry here, which is odd if it has been exported. It looks like it was registered with a K20A2, or at least thats what the papers say
.. There might have been some issues with the power to weight ratio which is limited when you register a modified car. ). If it was just a case of converting a race car to a road car it would have been relatively simple. If you just take the front axle as an example, the tyres rubbed in the arches, the steering rack gaiters did not have chassis clearance, I could not apply more than 60% steering lock as the wheels would make contact with the lower wishbone, Anti-roll Bar, steering rods, caster arms and even the brake calipers. It needed a complete redesign to make work. This is just one example system of many that needed completely changing. Here are a few pics to clarify:
In this picture the caster arm hits the wheel in the original config. Also the yellow ARB blade and the steering tie rod also then made contact once I'd resolved the castor arm issue:
In order to get the castor arm clearance I basically had to remove 85mm from the arm then reweld together the new shorter arms.
Castor arm chopped then welded
You can see before and after lengths here:
The aft mounting points I then moved forward 20mm and inboard 65mm
New flanges made to move the mounting point:
Painted and test fitted:
This just relates to one component. As mentioned above I then had to come up with similar solutions for the ARB, brake caliper, steering rod, tyre clearance...
Geeks, Julian, Richard-390, Court_S & RichTT, many thanks for the positive feedback
Sf_Manta said:
This is exactly what i love, classic looks with modern performance 
I've got an Opel Manta stashed away (soon to move to new storage till I've got my own house) and this is exactly the plans for , though I'm planning to put some carpet in just for a bit of NVH reduction.
Please keep this updated!
I remember my Dad having an Manta GTE when I was younger, great cars. All the best with the house move and future project I've got an Opel Manta stashed away (soon to move to new storage till I've got my own house) and this is exactly the plans for , though I'm planning to put some carpet in just for a bit of NVH reduction.
Please keep this updated!
BEN99W said:
What a great project. Love the engineering integrity and the varied ingredients.
I really liked your videos too: unspoilt by unnecessary intros, music, ads or bleating for subscribers.
Enjoy it.
Ben
If truth be told Ben, I haven't quite mastered the whole video/youtube thing yet. If I do try to make a more proper go of it, I have no plans on it going in the direction you mention. I'm in the process of trying to get a bit of guidance for the video production/editing... My aim is to create a channel with the following content:I really liked your videos too: unspoilt by unnecessary intros, music, ads or bleating for subscribers.
Enjoy it.
Ben
-Guides/top-tips for custom work and fixes on cars
-Build project videos
-Road trips and adventures around Europe with the current cars I have (mostly custom made): CLR996, Alfa, Spyder, E30 trackcar and S1-Elise. Lots of great roads on my door step but mainly plan to focus on Germany, France, Italy, Spain.
-Trackday and driving related videos: NBR, Spa and Hockenheim are my local tracks
-Manufacturing processes and factory visits: Wheel forging, fabrication, fuel farm... that sort of thing
-Video car tuner workshops such as Manthey Racing, ECU mapping/rolling road, gearbox/diff overhaul...
The flavour of video I am interested in are the likes of the Henry Catchpole, Jethro Bovingdon, Harry's Garage, Tyrells Classic workshop and Retro Power. So these types of videos are I would try to deliver. I'm not in anyway inclined to be in video and want to focus on the cars, driving, roadtrips and car related adventure side. I'm naturally an introvert so it may be difficult for my type of character to make anything remotely watchable but I'm hoping the subject matter more than makes up for my shortcomings.
Edited by CarreraLightweightRacing on Monday 19th October 22:53
Pixel Pusher said:
Terrific effort Pixel Pusher, I don't have such a magic wand or any idea how to fix my terrible pictures, so thank you 
I have literally jut got in from a quick session on the VLN circuit (NBR GP+Nordschleife) today, so a few more circuit shots for your pleasure.
P5BNij said:
Still enjoying this thread immensely but apologies for a slight diversion away from the Bertone beauty with a question about the 996 below it.... I think I asked you about this before elsewhere but don't recall your answer - what diameter and width are those gorgeous Fuchs and did they fit straight onto the existing 996 hubs...? It is without a doubt the best looking 996 I've ever seen 
Hi P5BNij, the wheels are genuine Fuchs in the following sizes. These will fit straight onto a 996 however please note I have altered all my suspension with fully customised components effectively pushing the front hubs out 26mm each and the rears 18mm each. So on a stock 996 they would be quite a weak offset but your could easily fit spacers to fix that. Really happy you like the car, another picture for you below 7Jx17 ET55 with 215/45r17 CUP2's 7.5kg each
9Jx17 ET55 with 255/40r17 CUP2's 7.95kg each
Paul S4 said:
Incredible build and attention to detail is awesome.
I am not a genuine Alfisti ( not now, but my last 2 cars were Alfa 156s !!) and I did a few track days with my last one at Croft in North East England...
I can understand the rationale behind putting that engine in.....
But....and of course this is only IMHO.....!!!
To me it is not an Alfa without an Alfa engine....or at least an Italian one !
I realise that the power to weight is better with the Honda engine, but surely a race tuned Busso V6 of something from the 'Alfa back catalogue' would be more appropriate.
I am aware that I am going to get criticism for this, but that is just IMO !
The 105 is one of my favourite all time cars, in fact I built a Tamiya model a few years ago.
Great thread by the. way.
Hi Paul, you are not the first and will certainly not be the last to ask. I can fully understand and appreciate your feelings as Alfaholics do some great things using the Alfa back catalogue for their engines. This engine was primarily chosen as the F20C engine held the record for producing the highest specific power output for any mass production naturally aspirated piston engine, at 123.5 HP/L, until Ferrari began production of the 458 Italia in 2010, which produced 124.5 HP/L. It revs to 9000rpm and is unbelievably strong and reliable. The car was originally designed to be a race car, so a brand new crate F20C was fitted as it will simply take all you can throw at it and just laugh at your feeble effort. They really are a very strong and special engine, hence it winning engine of the year for 5 consecutive years. A Busso would also be a wonderful choice but they just can't take the abuse. If you came and for a drive in this car and heard the noise it makes you would fully understand I am not a genuine Alfisti ( not now, but my last 2 cars were Alfa 156s !!) and I did a few track days with my last one at Croft in North East England...
I can understand the rationale behind putting that engine in.....
But....and of course this is only IMHO.....!!!
To me it is not an Alfa without an Alfa engine....or at least an Italian one !
I realise that the power to weight is better with the Honda engine, but surely a race tuned Busso V6 of something from the 'Alfa back catalogue' would be more appropriate.
I am aware that I am going to get criticism for this, but that is just IMO !
The 105 is one of my favourite all time cars, in fact I built a Tamiya model a few years ago.
Great thread by the. way.
Also some F20C's have been tuned to 1200BHP. 
RC1807 said:
Intrigued as to how / why your cars are all registered in different areas, countries, even.
They are all registered in Germany where I live apart from the Alfa*. The WIL and BKS prefix is for the local region and I have the choice of either as they recently added BKS as an option. - Regarding the Alfa, the TUV in Germany is a very difficult process (a bit like the SVA in the UK just dialed up by a whole order of magnitude). My next TUV appointment is the 11th November, when it should hopefully be sorted. It will then also have a local plate, WIL-DI15 is what I have in mind
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