🔧 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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Mr_Roboto

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You got to a point where it boosted its self apart. :rofl:

Glad to hear you at least got some power from it. Having a restrictive inlet will increase your air charge heating and reduce turbo efficiency. The next question's going to be if you can turn it up or not. I thought you were hitting a wall boost wise, it's likely it went away now. Totally worth futzing with at some point.

It reminds me a lot of Turbo Mustangs where you'd hear about some rando guy cutting the Flowmaster off his build and gaining 40 at the tire. Ahh the olden days.

Sucks to hear about the ring blow by. I was hoping it would go away.
 
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Mr_Roboto

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That's nuts that an air filter was that restrictive. That honestly might be why my HX35 sucked so bad for me, it had a really small filter to fit in the spot it was in. I'd like to see K&N start putting HP numbers on their filters now lol
I will say I was looking on their web site and that drove me absolutely batshit. At least CFM or filter material area would be awesome for people like us who are trying to do things well beyond what a drop in panel filter does.
 

v6buicks

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Just got inside from taking stuff apart, but it's too damn hot. I might go back out and do the compression test when I cool off.

All plugs look the same, but I kinda expected that given that the E will wash oil away. These are starting to look kinda gross and dirty though, so it's probably time to change again.
PXL_20220828_230456514.jpg

PXL_20220828_230643943.jpg

PXL_20220828_230757754.MP.jpg

See what I mean?

The catch can was full of water and corn casserole as usual. Very little to no oil.
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On an unrelated (to the issue at hand) note, I started removing the coil wires so that I access the injector clips and noticed something really stupid.

How? Why? The. FUCK.
 

v6buicks

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All those horsepowers. May be time to hit that with the MIG a bit. Couldn't be in more of a pain in the dick spot to get to though. Out of all the shit on this I wouldn't want banging around too......
It's a cast aluminum bracket. I've sorta wanted to move the coils anyway, but I also kinda wanted to wait until I could convert to Holley and CNP
 

Mr_Roboto

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No filter on his. I still think it's because of the super thin adapter hat he made. He's probably boosting the snot out of that hat but not the pipes or engine. Hence, the insane heat he felt too!

There is some truth to that, maybe hitting the boost/exhausts with a FLIR will show him stuff he didn't see otherwise. They're a bit spendy even to rent but Home Depot rents them.
 

Turbocharged400sbc

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K&N dies their oil red so it's easy to apply a light even coat you are not looking to get it wet you are looking to get it lightly moist with oil. It doesn't take much for it to soak into the cotton.

Do not over oil and regularly clean your maf sensor filament until it's pretty well cleaned of excess oil by "large amounts of airflow to high rpm" or just go to the modern dry synthetic media and spend a little more
 
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Turbocharged400sbc

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Just curious but how is your PCV deleted on that? The f-body intake has some weird passages that you may need to take into account blocking off since you may possibly be pressurizing the crankcase through the factory throttle body because there's a fresh air feed from the throttle body through the upper intake and then through the lower intake
 
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v6buicks

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Just curious but how is your PCV deleted on that? The f-body intake has some weird passages that you may need to take into account blocking off since you may possibly be pressurizing the crankcase through the factory throttle body because there's a fresh air feed from the throttle body through the upper intake and then through the lower intake
OG PCV plugged full of JB Weld
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And throttle body passage pipe plugged.
IMG_20200312_173130.jpg

That solved all my "blow by" issues a couple years ago.

Compression test results are in and exactly what I expected. Nothing noticable. Further investigation needed.
PXL_20220829_004517323.MP.jpg
 

v6buicks

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Yeah but what about the passage in the lower intake? You could still be blowing pressurized air at the paper upper lower gasket in her face

If I recall it's right next to one of the port runners.
I can't remember what all is going on down there. I think the hole next to cylinder 2 is the throttle passage hole and the one next to 6 is the PCV passage?
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I'm starting to wonder if the "corn casserole" in my breather hose is completely gumming up my catch can baffles. Maybe the oil is so broken down by the alcohol that I'd never know how much of each is in there.

For what it's worth, that tub of gross water I emptied had accumulated in under 1000 miles. That seems like a lot, but I know it's not mostly oil.
 

Mr_Roboto

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Dunno if you saw this or not. Keep in mind it's stock heads too. If you do math on this engine without the cam it was making 115hp. With the cam extrapolating this I think he was nearer 160hp.

I'd bet the cam he used would net you 90HP at 15PSI and more at 20.

I was also just thinking about this, your CI/cylinder is the same as a 5.0L basically so you could likely use that as a point of reference in terms of picking a cam too.
 
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v6buicks

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Dunno if you saw this or not. Keep in mind it's stock heads too. If you do math on this engine without the cam it was making 115hp. With the cam extrapolating this I think he was nearer 160hp.

I'd bet the cam he used would net you 90HP at 15PSI and more at 20.

I was also just thinking about this, your CI/cylinder is the same as a 5.0L basically so you could likely use that as a point of reference in terms of picking a cam too.

I saw it, but it was long before I was in this predicament. I'll definitely need to re-watch!

My leak down tester is supposed to arrive today. Not gonna lie though. I don't see the results sparking any motivation. Life has been dragging me down a bit, and even the will to do "the fun stuff" like pulling the engine for heads, cam, and clutch swap is fading away.

Somebody buy me a shop and lift please. lol
 

Mr_Roboto

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I'm wanting to head swap my 258 to a 4.0 head, thinking damn the cam just do it. I'm really just trying to rub in that it's only one head to swap not two. ?

Seriously though, stuff comes and goes. Just drive it and bask in your success so far. The weather (at least in Wisconsin where I am) is awesome in the evenings, even without A/C you should be enjoying yourself.
 
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v6buicks

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I'm wanting to head swap my 258 to a 4.0 head, thinking damn the cam just do it. I'm really just trying to rub in that it's only one head to swap not two. ?

Seriously though, stuff comes and goes. Just drive it and bask in your success so far. The weather (at least in Wisconsin where I am) is awesome in the evenings, even without A/C you should be enjoying yourself.
haha and that head is in the center of an engine bay sitting straight up.

I really should, and I totally would if it weren't for whatever the hell is causing smoke. I have a hard time living with stuff like that. I guess if the leak down shows no issues, I can blame the turbo and be happy again. If not, I'll have to make some judgment calls, and possibly gambles.
 

v6buicks

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Wouldn't he need to block the catch can off in order for that to work where the crankcase isn't sealed anymore?
In that case, I think you would be guaranteed to develop a problem you didn't used to have. I don't wanna do more crank seals!

Gauge on the dipstick will reveal a wild crank case tornado that may not be getting dissipated by the hole in one valve cover. At least I think that's the idea.
 
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