🔧 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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Turbocharged400sbc

3800 & 4T80E > ALL
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It matters. Just as fuel velocity and plumbing direction vs inj angle.

Had odd fueling on a 3800 with one modded oem rail plumbed at 100* turn to injectors baskets, and the other bank with 80*

Replumbed the rear rail so it was also 80. And it sure seemed to help.

I don't know ifvthats an issue with large bore rails but the factory stuff has fuel flowing fast as fuck vs one of my Fatman -8 or -10 rails.

Don't forget the oems figured out fuel pulsation was an issue in 99 with the "disk" type damper. The l26/32 have dampers with 4 times the surface area and volume. (L26 rails with the flat side rectangle tube, use atmospheric pressure and "oil canning" to do this. The l32 use a ss tube bladder inside each rail.
 

turtleman

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NHRA rules on fuel pressure regulator mounting are as follows:
  • Mounting regulators, fuel distribution "logs" or isolators, etc., within 6" forward of the flexplate or flywheel is not allowed.
  • Fuel pressure gauge isolators, with steel braided line, may be mounted on firewall.
  • Cool cans, fuel-distribution blocks, etc. must be located at least 6 inches forward of the flywheel/bellhousing area on rear-wheel-drive (RWD) vehicles, and on opposite side of flywheel/housing area on front-wheel drive (FWD) vehicles.
  • NHRA limits the amount of rubber hose in the fuel system to 12" total.

Looks like for FWD, the firewall on the passenger side is fine which is probably where I'll go.
 

v6buicks

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Tossed a 7.10 pushrod into the worst offending spot and got about 0.16" of preload so those are going to be too long. Good thing I only bought four. I guess I'll have to wait for those 7.05s which are still supposedly on track to come in early March. At least I know they will be the perfect size.

Since that was a bust, I finally got around to torquing the knock sensors down. 🤣

This is the kind of time I have to work on stuff now. 😓 Kid needs to get a wrench in his hand!
 
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v6buicks

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Wouldn't you need like a 7.050" if you are going for .060" preload? Unless I'm misunderstanding something, which is likely.
Yes. Those are the ones I'm waiting on. One head was exactly that with 7.00s. The other head is kinda wonky, and needs two sizes. These heads had to have been milled a decent amount considering I have rocker spacers too.
 
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v6buicks

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I have officially given up on Manley pushrods. My estimate for 7.05s got pushed back to August, so I'm returning all the ones I have and getting ZZPs.

It sucks because I kinda feel like I'm starting over. I'm not sure if I should try getting a full set of 7.05s and hoping they work or the goofy combo I was trying to make with Manley.
 

v6buicks

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All my orders have arrived and it's the weekend so it's finally time for some action.

Comp BBC roller rockers with the trunnions drilled and doweled for 3800s.
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Set of 8 NOS Comp replacement rockers soaking in ATF because the seller used 8 and never oiled them down. They all had some rust on them.
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I failed to read the detailed description so yeah.. it's only eight. Still a good deal.
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I used a 3-jaw puller to remove the arms.
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I can see how you need to be careful about aligning these because the dowels are not a press fit.
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Some how I managed to replace all the ugly rockers with brand new ones without spending hours searching for needle bearings and c-clips. I only replaced four, so I have four spares. Turbocharged400sbc Turbocharged400sbc turtleman turtleman if you need spares, let me know.

I'm going to try to finish blasting this knuckle, but then I'll be trying to finish the valve train assembly.
 

v6buicks

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Figured that one out quick. Judging by the witness marks on the pedestal shim, I'm shocked that these things clear the head without it. Unfortunately, I'm SOL unless I can get somebody to remake these sleeves just a smidge longer.
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I'll probably just ask whichever machine shop balances my flywheel to whip some up.

Also, are the rockers really supposed to be so... Rocked? I mean, just eyeballing the rollers it seems like they're making good contact with the valve and they work with stock pushrods, but jeez. This alignment looks really funky.
 

v6buicks

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Easy enough lathe job, you may have to get em hardened. Not sure on wear requirements.
If I go ahead with that I'll request it.

I actually listed them for sale. I feel like I got too good of a deal, and I'm actually really mad at myself for complicating this once again. If they sell for what I'm asking I'll throw stockers back in, hopefully toss in the pushrods I just bought, and move on. I'm tired of playing with valve train and spinning this unlubricated engine.
 

v6buicks

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Lol wow ... I managed to sell those rockers really fast and made a fair amount of money. I'm slightly bummed that I'm back to having stock rockers, but also super relieved to be rid of the headaches.

I can see why I already ran into talks about girdles. Those rockers are beefy, but there doesn't seem to be much use for it with such thin pedestals. Stability has to be questionable even with mild spring pressures.

Anyway, I somehow emptied all of my marketplace ain a matter of a week. 😳 That's another grand of car money. It might be time to finally get the TIG welder I've been lusting over for years now.
 

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