🔧 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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01bluesnake

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Well fuck. No I haven't. I had been wondering how that was supposed to work too. I wonder if I still have the old lifters on the bench.

Yeah, its a little funky trying to get stuff like that figured out. I put mine in a vice, and use a dial indicator to measure how much im moving it. Once im at the spot, say .060" ill throw a few small welds to keep it there. After that, throw it back in the motor, grab an adjustable push rod, and find the sweet spot on the tip of the valve with a marker, like you already did, and should be spot on.
 
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v6buicks

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Yeah, its a little funky trying to get stuff like that figured out. I put mine in a vice, and use a dial indicator to measure how much im moving it. Once im at the spot, say .060" ill throw a few small welds to keep it there. After that, throw it back in the motor, grab an adjustable push rod, and find the sweet spot on the tip of the valve with a marker, like you already did, and should be spot on.
So you would want the lifter fully pumped up right? Could I achieve 0 lash on the rocker, measure the preload, and just add that much to my adjustable pushrod? I mean it's probably not as good as making a tool, but I would think it gets you close enough.
 
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bs009

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So you would want the lifter fully pumped up right? Could I achieve 0 lash on the rocker, measure the preload, and just add that much to my adjustable pushrod? I mean it's probably not as good as making a tool, but I would think it gets you close enough.
That's exactly how I measured mine. dial indicator on the valve set to 0 lash, measured to account for 0.050" of preload on the lifter.
 
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GTPpower

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I measured them at zero lash, then just added how much preload I wanted to that length.

I measured each rod 3 times, rotating the engine over a couple times in-between each measurement. Then, took the average for each one.

I ordered mine straight from Manton and received them in less than a week iirc. They custom make them however you want. Mine are 5/16" and I'm on 150# springs and a xpz.
 
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01bluesnake

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So you would want the lifter fully pumped up right? Could I achieve 0 lash on the rocker, measure the preload, and just add that much to my adjustable pushrod? I mean it's probably not as good as making a tool, but I would think it gets you close enough.

Yeah, theres a few ways you can do it. If your using test springs on the valves, which are extremely light, a pumped up lifter will be fine, but i wouldnt do it that way if leaving the normal spring in the head. With anything other then test springs, the lifter will want to collapse, or move down as your trying to cycle the engine over since theres no oil pressure to keep it pumped up. Its my preference to lock the lifter at a pre set pre load, this way i can get a true measurement on length, at my needed pre load, and get a feel how tight or loose the push rod is since the hydraulic portion is now an error removed. Its easy to get a reading on the valve tip this way too.
 
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sktchy

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I measured them at zero lash, then just added how much preload I wanted to that length.

I measured each rod 3 times, rotating the engine over a couple times in-between each measurement. Then, took the average for each one.
This. You can use a cut pushrod and a chunk of fuel line if you really want to
 
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v6buicks

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Okay. I'm with everyone now. Given that I was at a turn and a quarter between 0 lash and the torque spec I'm probably better off getting a longer rod anyway. I have test springs though, so that's another way I can verify. I'll try a couple different things in the morning.

Thanks everyone!
 

v6buicks

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I am having such a bad time. I wasn't looking forward to figuring all this out, but I didn't think it would be this difficult either.

I bought this ZZP adjustable pushrod years ago and hadn't used it until now. Only they could mess up something this simple. The threads are very loose and they didn't put a lock nut on it. No matter how careful you are, the tip will turn and the length will not stay consistent. Now I get to make the POS work so that I can move on.

It's not threaded all the way, so I did that as best as I could.
1000005934.jpg

Threads are shit, but I was going for speed. This tool might go in the trash when I'm done with it.
1000005935.jpg

Then I searched around for a 1/4-20 nut. 7.05" is as short as I can make the tool which is convenient but also the reason why it will go in the garbage. Lol
1000005936.jpg

Then I removed a valve spring and put the dummy spring in. That was a waste because the lifter still compresses before the dummy spring.
Sad No Way GIF by Shaw Brothers

Soooo I guess I'll try to just measure the amount of travel these lifters have, determine how much preload I want to put on them, add the remaining travel to my pushrod, and recheck? I think that's the only way without buying a single lifter to jam full of washers or weld up.
 

01bluesnake

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I am having such a bad time. I wasn't looking forward to figuring all this out, but I didn't think it would be this difficult either.

I bought this ZZP adjustable pushrod years ago and hadn't used it until now. Only they could mess up something this simple. The threads are very loose and they didn't put a lock nut on it. No matter how careful you are, the tip will turn and the length will not stay consistent. Now I get to make the POS work so that I can move on.

It's not threaded all the way, so I did that as best as I could.
View attachment 192610
Threads are shit, but I was going for speed. This tool might go in the trash when I'm done with it.View attachment 192613
Then I searched around for a 1/4-20 nut. 7.05" is as short as I can make the tool which is convenient but also the reason why it will go in the garbage. Lol
View attachment 192614
Then I removed a valve spring and put the dummy spring in. That was a waste because the lifter still compresses before the dummy spring.
Sad No Way GIF by Shaw Brothers

Soooo I guess I'll try to just measure the amount of travel these lifters have, determine how much preload I want to put on them, add the remaining travel to my pushrod, and recheck? I think that's the only way without buying a single lifter to jam full of washers or weld up.

That sucks to see on the adj pushrod, can't say ive ever had that happen. Yeah, best bet is to just weld a spare lifter locked in either zero, or preload position. Like mentioned above, could always JB weld it too, but i can't say i've did it that way before.
 
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v6buicks

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Okay. I'm with everyone now. Given that I was at a turn and a quarter between 0 lash and the torque spec I'm probably better off getting a longer rod anyway. I have test springs though, so that's another way I can verify. I'll try a couple different things in the morning.

Thanks everyone!
Apparently my thinking here was backwards. My preload with 7.00" pushrods was about perfect. If I wanted less preload (less turns to torque spec) then I'd need SHORTER pushrods. Oops again.


I'm really losing my confidence in my ability to finish the car right now. I held off on sending my parts back to Summit, but if they happen to be the right size I won't know how to proceed. Do I grind reliefs on the rockers? Shim the pedestals and start all over?
 

v6buicks

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I've determined that my 7.00" pushrods are fine. They give a solid amount of preload without going overboard for the type of lifters I have, and changing the geometry to fix the retainer clearance is probably going to have adverse affects. The spring retainer clearance issue seems to be a disagreement with the rocker itself. I believe it would be solved with the Yella Terras, just because that's what Intense sells. I can't guarantee it though. Given the cost of that gamble, I'd rather try grinding the bottoms of my stock rockers a bit. I'm not sure how good of an idea that is on a hollow steel piece like ours though.


turtleman turtleman what was your remedy?

As for the head gasket, I'm just going to have to cut it up. I don't know how to do this with any elegance now that I've already installed the head though. I'm hoping I can get snips in there.
1000005949.jpg
 
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v6buicks

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Face valve stems if they are too tall from vsr.
Oof. I really don't wanna do that, but I think I see the value. I'm assuming that even if the retainer stays in the same spot, facing the valve tips could pivot the rocker enough to gain clearance from the vsr. I wish I could do that without removing the heads and sending them out.
Composit hg pushrod holes can be readily ovaled with a long large Phillips screwdriver and a flathead to force it sideways to open the hg pushrod triangles.

If those were MLS you'd have to grind em lol
I like this idea. That'll work!
Be aware that often it's the head casting flash that will rub pushrods, esp larger pushrods or inward moved pushrods (moded 1.8/1.9 rockers)
I hope that doesn't come into play, but I guess we'll find out soon.
 
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turtleman

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I changed to zzp rockers which I'd say have a little bit more clearance at the retainer area but the bigger thing that helped was switching to zzp retainers. Those moved the spring hight down like .050 compared to the retainers that were in there. The installed hight with the zzp's were about 1.780" and they just have a really low profile in general
 
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