Here's the problem: there isn't enough room for three pedals between
that starter solenoid and the kick panel.
Closer view, showing the badly positioned solenoid, and the quite
bulky motor, with it's cast iron snout/baseplate. Steel plate sits at back
of block, between block and bellhousing.
Here's the product of about a weeks worth of evening tinkering.
Was donated a Bosch starter from a V6 Vauxhall by a friend. Solenoid sits
above, the starter is also smaller diameter, gaining torque from a planetary
gearset inside the alloy housing. The pinion in this starter had 9 teeth,
the Alfa one (luckily also Bosch) had 8. The pinion from the old
starter was modified to fit, by shortening the carrier and grinding a new
circlip groove. Side of the nose part was trimmed away to allow the motor
to be rotated as far as possible to gain the most foot clearance.
Luckily the starter needed to be spaced back by 3/8 inch, allowing
these adaptor plates to be cut out and welded to the steel intermediate
plate. A chunk of the rear of the block was cut and filed away to allow
clearance for the upper bolt of the starter. luckily there were no bolt
holes in the area. Plates were drilled and tapped 10mm for the starter
and 8mm on the old starter bolt locations to allow more attachment points
for the bellhousing.
View from the front shows the improvement. A lot of work, but if
I hadn't been able to pull this one off, the Alfa motor would not have
been feasible for this project.
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