🔧 BUILD LAME Turbo V6 Camaro

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Hello! Welcome to the shit show! I am updating this post in 2021 to explain what new readers are about to witness. If I knew that this thread and build were going to explode into what it is today, I would have started it out a lot different.

This car was (and still is) a basket case. The whole inspiration for starting this project was to start learning how to modify engines in a car that I didn't like. That way, if and when I screwed up, I wouldn't be ruining a nice car. It spiraled out of control from the first moment that I felt boost. I loved what I had created, but it took a ton of work to get to where I was. As soon as I got the car running nicely I was always saying "I'm going to fix______, and THEN I'll just enjoy driving it." You know the drill. Drive, break, fix, repeat! Before I knew it, I enjoyed driving and working on this turd more than the nice car I was trying to preserve!

The point is that the focus of this thread shifts A LOT. To complicate matters, I never have just one ongoing project open at a time. I listed some thread contents with links below. I will update this as new milestones or big updates happen. Just know that even if you click on the shortcut, you may have to scroll past other project posts to reveal the outcome. There are also some mini-projects and very helpful advice from other members in between, so read the whole dang thing if you want!

2018-2019
1. A late introduction
2. Discovering how a PCV works (and plugging it)
3. Custom grill for intercooler
4. Fuel pump trap door
5. Learning that I'll never learn anything from my goofy wide band gauge
6. Deleting AC completely, but retaining heat
2020
7. Low profile heater hose fittings
8. Deleting an air bag without setting a light on the dash
9. Starting a second round of floor repairs
10. ABS delete and line lock installation
- A separate thread for the electrons
11. Installing catch cans with nice brackets (Way overkill)
12. Figuring out the "blow by" problem once and for all (F-body intake plug)
13. Second clutch job, first rear cover job, and preliminary transmission swap research
14. Floors are "done", and Interior is installed.
15. I don't know how to tune, but this wide band might help.
16. Poly trans mount. Yeah, it actually deserves a link.
17. I waved the tuning white flag. Dyno Brian sets me straight!
18. T5 Pro5.0 shifter
19. New shifter was too much fun. OG T5 explodes, and my transmission conversion ideas start to get serious.
-TKX conversion
-TKX swap official write-up
20. Reconfiguring my exhaust for a quieter and less leaky future
21. I'm not done enjoying this car for the year, so I install a $100 T5 instead of a bulletproof conversion. SPOILER ALERT: It only lasts two months.
22. Minor repairs/updates that make the car livable (lighting, stereo, speedometer re-zero, and a clutch master cylinder that actually does it's job!)
23. Wheels and addressing rust again since I got time!
2021
24. Custom center caps
25. 1.9 roller rockers and LS6 springs
26. CAI V2.0
27. TKX is delayed so it's time to address the little annoyances.
-OE pan is junk. Dorman pan gets hot rodded
28. TKX is still delayed, so I install just one poly engine mount and beef up my flimsy turbo drain plumbing
29. TKX does NOT ship the following Monday. Flywheel bolts upgraded to ARP M10 x 1.0
30. When you're on a Chinese garbage budget, you better be ready to work harder. (Oil drain fitting hot rodding)
31. Finally repairing the oil sender pig tail, replacing the other engine mount, and test fitting the TKX.
32. Finally addressing rear brake lines while I wait for more transmission parts.
33. Modifying an ICM for a WOT box
34. Dash gets re-instrumented so that diagnostics become possible.
35. N2MB WOT box
36. Porked crank key. PSA: Be careful installing your balancer!
37. Car runs great after plug change, but the rear main seal needs to be changed again.
38. BURNOUT! Also, I kinda bought a cam.
39. Turbo drain finale (better be) and full exhaust commenced
2022
40. Downpipe V3 and BMR strut tower brace
41. Panhard bar and relocation for bro truck exhaust
42. Muffler, driveshaft, torque arm, and giving up smoking.
43. First trip to the GS Nationals (feat. time slip)
44. The very custom AC project is born
45. New dyno results (up 50 hp!)
46. Exhaust hanger repair before Michigan/S.S. Badger/Wisconsin trip
47. Sizing a better turbo
48. Painting but still not installing the IS3 heads and Monster clutch unboxing
49. Firewall brace
50. New ECM
2023
51. Out of storage and SC engine buy failure #3
52. Modified double roller and spitballing crankcase evac ideas
53. Completing the rear suspension. UMI rear control arms.
54. Cracked headers and L32 swap begins
55. My newest L32 was trash. I'm upgrading the L36 instead
56. Side project: The ultimate-ish intake manifold takes shape


Now back to 2018!
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Now that this car is running and driving, I figured I would start a thread dedicated to all the questions I’m about to pummel this group with. This is the first time I've really built anything to move quicker than stock, so I'm hoping to learn a lot from you guys before I make unnecessary mistakes. I also have a thread in the Turbobuick.com 3800 section, but I'm not getting as much input there due to a lack of audience. Here goes nothing...

The car I have is a 2002 Camaro with only ONE factory option (rear window defogger). The story supposedly goes that my buddy's dad was looking forever for a new Camaro because he never buys anything for a penny more than the best deal. He almost ran out of time as this was the final model year for the F-body, and '03s were already on the market. The dealer from which he found this car bought it for the sole purpose of being able to advertise "Brand new Camaros for under $10k", so this was the one he took home.

Fast forward to 2018. The car was structurally a wreck from living in the rust belt, but has a great interior, okay black paint, a third pedal, a 3800 (which is a plus in my book), and a lot of sentimental value since I remember riding in it when it was brand new. My buddy’s dad handed me the keys in hopes that I would enjoy it and make it a race car. To be honest, I don’t care for F-bodies, but I couldn't resist this one for the reasons above despite knowing that the floors were in desperate need of existing again.

I already had my dream car which is a 1986 Buick Regal Grand National. As much as I love that car, I like it the way it is in fairly stock form and modifying Buicks has gotten terribly expensive anyway. I figured a black 3800 Camaro could easily fulfill my childhood dreams of racing a badass turbo Buick V6 car while being on a budget, so here I am.

The car is now equipped with:
-6765 ebay turbo
-Precision PW40 wastegate
-Custom turbo exhaust utilizing a stock Camaro and FWD manifolds
-Air to air ebay intercooler
-AEM 50-1200 fuel pump
-Siemens Deka 80# fuel injectors
-Open 3” downpipe
-Custom 3” charge pipes
-Intense mail order tune
-Very ugly but functional upright radiator conversion (the core support was all just rust anyway) :dunno:
-Custom space saving AC delete without bypass pulley
-Midwest Chassis bumper support modified to mount my intercooler
-Spec Stage 1 clutch kit

The car is far from refined and has a lot of little issues to sort out, but I will leave the first post as sort of an introduction to that. I hope you enjoy hearing about it. It’s been fun to build!

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v6buicks

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Moving along ?
Any chance I have to make an ounce of progress, I take it. It's been an unhealthy obsession the last week or so. I should be excited as hell to be meeting some friends at Power Tour today, but I'm kinda not. I just want to finish the Camaro. ☹ I'm sure my attitude will change once I'm there though. I love the cars that this event brings.
 
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v6buicks

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I know that now is not the time to be screwing around with stuff that don't involve the transmission, but I got really excited to do the bs009 special on my ICM since I happened to have a spare. The trouble is that I think the spare is from a 3100 or 3400 car. It looks nothing like his does under the cover and I know the 3800 ICMs do not share PNs with the 60 degrees. Oh well. I don't know how they're different, but I'd hate to cause silly problems. I'll just have to modify the one that's already on the car whenever I actually buy a WOT box. No pro-activity for me.
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In terms of getting this car on the road, it stormed really hard so I was unable to get a lot done. I did get the cross member 100% finished though.
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You can't even tell which holes I made. Damn I'm good. :LOL:
 

v6buicks

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I thrashed last night. Now I'm too sore to move, but the amount of progress I made was worth the pain.

I painted and relocated the custom bolt. I needed to re lock the HTOB so that one hose was on top and the other on the bottom. Before, they were on each side which was going to be impossible to bleed and impossible to route outside the bell without kinks. The sleeve is also held on by RTV to prevent it from spinning.
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I also drilled, painted, and pushed grommets into the bulkhead plate.
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After once again dialing in the bearing height and checking pilot engagement, the trans was ready for final install. I struggled with this for over an hour. Those offset dowel pins put the bell in a bit of a bind that makes installation a bit tricky even without a transmission attached to it. I hope to god that I have this right because I'm going to be crushed if this mofo makes noise after all this.
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I pulled the whole clutch assembly off again to realiign the disc a little better. That ended up helping a ton. The new bolt hole for the trans mount ended up aligning fine, but I didn't make the the socket access hole wide enough. This meant getting in there with a carbide bit on my die grinder. Doing this overhead friggen sucks. ?
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Then I dialed in the shifter handle plate. I drilled/tapped two new holes a little closer to the dash and bent it a little more. I will need to trim part of the console so that it clears in reverse though. I don't like doing stuff like that, but it's a small price to pay. I think I nailed the handle length though!
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Just so I could knock one last thing off the list before bed, I got the bulkhead installed. I think it turned out nice!
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I may be sore, but I plan to continue my progress once I'm done with my coffee.
 

v6buicks

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Thanks! We're moving along. Paint on the shift handle bracket is drying, the flywheel cover is installed, and the floor boot is in process. I might have trouble with this. Luckily, the TKX shifter has its own dust cover unlike the Pro5.0 shifter for the T5. However, I might need to do a similar cut in the boot because the stock one will not allow for movement where I need it.

Here's the new stock T56 boot I got with a hole for the shifter handle. See what I mean? Too close to the outer edge of the accordion.
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I'm think cut a big hole for the whole shifter to pop through and turn the accordion inside out. It won't be the greatest seal, but it's better than nothing.
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v6buicks

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I basically said fuck the boot. There's no way to do it nicely with the parts I have, and there's no way that I'm going to wait for an aftermarket thing to show up. I drove this car for a while without a boot when the car didn't have an interior in it. Nothing ever seemed to fly up that far anyway. Someday I'll do it nicer, but today is not that day.
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Everything is done except for the clutch hose, oil, and setting my pinion angle. Friggen wild.
 

v6buicks

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Done yet?
So damn close. I'm waiting on my clutch line and trans fluid to be shipped. It's so friggen miserable outside that I don't know if I'd really want to drive this thing. We drove the 240 about 20 minutes today with weak AC and hated it. I can't imagine not having it at all.
 
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v6buicks

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I ain't scared to say that I am full vagina in terms of my climate control. Sure, I'll survive without it, but I won't necessarily enjoy it. The only thing getting me outside to work on this stuff now is determination, a box fan, shade, and having a pool directly behind the garage. :LOL:

It feels wrong to not work on the car when I have a wide open Sunday, so I tried to set my pinion angle. Oops. The UMI torque arm relocation kit doesn't come with a bushing. I ordered one on Amazon and then sat wondering what to do next. I was going to fuck with the boost controller and some other wiring bits, but noticed a concerning puddle on the floor.

It wasn't that I hadn't already noticed it. I kinda just chose to ignore my rusty axle brake lines for the past two years. I've had the tubing, the calipers already had new speed bleeders, and the hoses were new too. Time to knock it out.
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I don't know why I didn't do this years ago. It was about a three hour job. Speed bleeders are amazing.
 
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v6buicks

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Better you than me. I always hate doing brake lines, and I swear every project car I ever get needs them done.
Out of my ten cars, six have received extensive brake work. By that, I mean master cylinders, hard lines, proportioning valves, and rust problems. The Camaro has had everything brake related replaced EXCEPT for the pedal, calipers, pads, and rotors. Lol

I've grown to hate brake fluid, but I've gotten good at bending and flaring lines. :cautious:
 

Mr_Roboto

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Out of my ten cars, six have received extensive brake work. By that, I mean master cylinders, hard lines, proportioning valves, and rust problems. The Camaro has had everything brake related replaced EXCEPT for the pedal, calipers, pads, and rotors. Lol

I've grown to hate brake fluid, but I've gotten good at bending and flaring lines. :cautious:

I've definitely gotten better at it over the years, did the trans lines in the Fastro. Still decidedly not super happy about them but they're way better than anything I've done in the past. I want to get some of that cuppo-nickel stuff I've always heard good things but it's always been out when I try to get it.
 

v6buicks

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I've definitely gotten better at it over the years, did the trans lines in the Fastro. Still decidedly not super happy about them but they're way better than anything I've done in the past. I want to get some of that cuppo-nickel stuff I've always heard good things but it's always been out when I try to get it.
It's a game changer for sure. After seeing for how poorly the pre-bent stainless stuff tends to fit, I won't be messing with that crap anymore. The pre-flared stuff at the parts stores are nice in a pinch, but I hate that it still rusts. I bought a long roll of the Ni-Cu on Amazon or Summit for pretty cheap. No regrets. Having this ultra expensive straightener tool is a big help too though. I'm not bragging. It was a dumb thing to buy for how little it gets used. lol
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sktchy

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It's a game changer for sure. After seeing for how poorly the pre-bent stainless stuff tends to fit, I won't be messing with that crap anymore. The pre-flared stuff at the parts stores are nice in a pinch, but I hate that it still rusts. I bought a long roll of the Ni-Cu on Amazon or Summit for pretty cheap. No regrets. Having this ultra expensive straightener tool is a big help too though. I'm not bragging. It was a dumb thing to buy for how little it gets used. lol
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I'm still eating my ass over the expensive tool in the corner of my shop that hardly ever gets used but it's still pretty awesome to have when a guy gets to use it.
 

v6buicks

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I'm still eating my ass over the expensive tool in the corner of my shop that hardly ever gets used but it's still pretty awesome to have when a guy gets to use it.
Haha I could only imagine the kind of shenanigans that would happen here in Indiana if a friend or I had a dyno. It would probably never go unused.
 
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