The Right Stuff (Post # 122)

Illustration of the parts of The Alfatross' original exhaust
system. The parts in the upper right corner are the heat shields
that cover the generator, starter, and steering column. Another
heat shield covers the "siamesed" muffler or resonance chamber.
The system is supported by three sets of hangers. 

One of the big surprises in this restoration is how difficult it has been to replicate the exhaust system. Why bother? After all, it's something you can't even see most of the time and not usually judged in car shows. True, but even if exhaust systems aren't readily visible or judged they are an important part of how well the engine performs and how it SOUNDS. A car's exhaust note is its voice and as such, just as much a part of its character as is a person's voice.  

I was able to make a sketch with dimensions of the original exhaust system before it returned to earth and to save what was left of the header flanges. I could not help but marvel at how sophisticated and performance-oriented the surviving parts of the system were: Individual exhaust headers mated to double pipes running the entire length of the car with a siamesed  resonance chamber, a crossover pipe, and two sets of mufflers. 

The exhaust system starts with the beautifully-made 4-into-2 headers. To get a good look at them you have to first remove the aluminum shroud that ducts cool air to the headers when the car is moving.  The next thing you notice is how the steering column passes between the header pipes!  Then you note the aluminum heat shields covering the generator and starter and the asbestos shield wrapped around the steering column. Seems like overkill or even some kind of high-performance affectation. You don't appreciate how absolutely essential they are until you fire the engine up. Those pipes quickly reach 500+ degrees F, even at idle!






Until relatively recently original exhaust systems after the headers were typically made of mild steel with little thought given to corrosion protection, so they didn't last long. They lived out of sight under the car where they got bashed by things you thought you could drive over--but couldn't. The combination of heat, water vapor, and exhaust gasses guaranteed a nasty, brutish, and short life. 

As mentioned earlier in this never-ending blog, part of the Alfatross' exhaust system had already fallen off by the time I bought the car in 1969. I noticed it was unpleasantly LOUD and when I looked underneath, the entire system aft of the second set of mufflers was gone except for the hanger straps dangling forlornly in the breeze. What was left of the exhaust system followed suit during the 47 years The Alfatross patiently waited for its restoration. In 1995 I ordered a custom-made all-stainless exhaust system through Joost and Peter and that is the one now on the car. It looks and works well, but I'm sure it is louder that the original system, perhaps because it lacks the third stage muffler pair aft of the rear axle.

Jeff Robison and I installing the current exhaust system. It works well and is well-made of quality materials, but differs from the original system.

But I wanted something more authentic. Images of the original system, which was quite complex, may be found in period catalogs and I noticed that at least one of The Alfatross' restored siblings, *02056*, has a pretty good replica system. But where did it come from?

An illustration of the exhaust system for Alfa 1900 SS and TI models from a period catalog.

The long-awaited AFRA exhaust system finally arrives more than 9
months after being ordered and paid for.

Naturally, production of exhaust systems for Alfa 1900s ceased decades ago. One of the biggest suppliers of parts for old Alfas in Italy is AFRA, s.a.s. When I noticed that they offer a replica system I ordered one. That was nine months ago. After pestering them for 6 of those 9 months the gestation period finally bore fruit and the system arrived at my front door. Having been warned in advance by Giuseppe Maranghi and David Smith that I should not expect to be impressed, I was not crushingly disappointed when I unwrapped the package.  

Example of sloppy welding and damaged 
muffler neck on the AFRA system.

This is AFRA's idea of how to fabricate an exhaust system.
Each pipe is made up of at least six sections of tubing of
different diameters sloppily welded together--
looks like it has already been crashed! 

Even before trying to match it to The Alfatross I could see that the long wait was a waste of time. The system already on the car was far superior to what now lay before me: low-quality materials, pathetically poor welds, absence of a critical attachment point, flimsy gaskets, and crude bends. Four short sections of pipe were stainless but everything else was cheap mild steel. The system appears to have been fabricated in two different shops. The front half, painted black, is all mild steel. The critical bends between the header flanges and where the pipes straighten out were not created on a mandrel but made up by crudely welding many short sections together. The fabricators did not even attempt to recreate the "siamesed" first stage muffler or resonance chamber. The silver-coated back half consists of two pairs of off-the-shelf steel mufflers joined by stainless pipes. I might actually be able to use parts of the second section, but the first section is worthless! 

So I still don't have the right stuff--but I'm getting closer! I just learned from David Smith that Quicksilver Exhausts (http://www.quicksilverexhausts.com/1900-Ti-and-Super-Sprint---TWIN-Stainless-Steel-Exhaust-(1953-59)_ALFA%20ROMEO_915_productbulletin.htm) makes reproduction systems for the Alfa 1900 SS model and they look pretty good.  It comes in modules, making it easier to install and adjust the fit, is all stainless, costs just over $1,000, and arrives only 2 weeks after the order is placed! David already ordered a set for his car, *01947*.  If he is pleased with the quality of the system I may follow suit.  After all--"Third time's the charm"!