🔧 BUILD LAME Turbo V6 Camaro

General Information

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!
1688935182526.png


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!

Cgge0Pb.jpg


uapwiw2.jpg


08tL6Rj.jpg


7zXNhuZ.jpg


PVLQyzg.jpg

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
I got the pan removed.
1617058465066.png


What do you think? Enough to cause a leak? I sure don't like it! It doesn't appear that I used any RTV either. I'll redo it with dots where the cover meets the block next time.
1617058675723.png


If that wasn't a leak, this is!
1617058811586.png


Redoing these gaskets will for sure solve the external leak problems. As for the internal coolant leaks, I'm going to leave the pan off for a day or two and see where the new puddle forms. It may not tell me anything, but you never know. I have my bets placed on the intake gaskets though. Who knows. Maybe I forgot to seal those coolant ports with RTV!
 

Rdrnnr

wannabe racecar builder
Nov 15, 2020
1,361
2,386
I got the pan removed.
View attachment 84633

What do you think? Enough to cause a leak? I sure don't like it! It doesn't appear that I used any RTV either. I'll redo it with dots where the cover meets the block next time.
View attachment 84634

If that wasn't a leak, this is!
View attachment 84635

Redoing these gaskets will for sure solve the external leak problems. As for the internal coolant leaks, I'm going to leave the pan off for a day or two and see where the new puddle forms. It may not tell me anything, but you never know. I have my bets placed on the intake gaskets though. Who knows. Maybe I forgot to seal those coolant ports with RTV!
Um what coolant ports [emoji15] the ones with the orings? I rtvd the upper instead of buyin a new gasket but the lower I thought just goop the corners?
 

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
Um what coolant ports [emoji15] the ones with the orings? I rtvd the upper instead of buyin a new gasket but the lower I thought just goop the corners?
I had mixed feelings about it, but I'm finding that it's common for people to smear RTV around the coolant ports on the heads and intakes.
 
  • Like
Reactions: Rdrnnr

Rdrnnr

wannabe racecar builder
Nov 15, 2020
1,361
2,386
My philosophy was always to let the gasket do the work in situations like that. We aren't dealing with shitty oring-less paper gaskets anymore. I never had problems in the past. This will be my first failed 3800 intake gasket job if that's actually the problem. [emoji2369]
Well, I guess im not into doin it on the lower either and I never have with an ls but I'm not scared to put the black stuff anywhere either. I'd be lying if I said there weren't some gaskets made with cardboard and black goop around here tho
 

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
Another thing I failed to mention was that I once again investigated better turbo drain locations. I put that bung where it is because it was easy to weld with the original pan on the car. :oops: When I got less sloppy and replaced the pan, I was still too lazy to change the location. Now that I've given it a better look.... I'm gonna keep it in the same spot. The truth is that there is no better place to put it without serious reconfiguration of the exhaust or a tubular k-member. There are a couple spot that could work but I would greatly sacrifice serviceability. No thanks.

What will help a lot with cleanliness and my draining issues will be to run an AN hard line from the pan to just a few inches in front of the crank pulley. From there I can weld a little bracket that ties in to one of the front oil pan bolts or something. It should ensure a downward slope to the pan and look a little less janky. To better ensure proper drain back, I can also make that tube a lot larger while keeping the hose the same size. We'll see.
 
  • Like
Reactions: Rdrnnr

Rdrnnr

wannabe racecar builder
Nov 15, 2020
1,361
2,386
I just had red heater hose comin off the bottom of mine with a barb fitting at the bottom of the turbo and into the oil level sensor location and it worked fine.

This time I'm gonna do it with 10an and make it look nice, got a little power steering cooler I was gonna put in it but now reading this I think I'm just gonna go straight back into the pan I don't wanna have drain problems when I've got a nice balanced turbo with a factory installed restrictor and all that
 

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
I just had red heater hose comin off the bottom of mine with a barb fitting at the bottom of the turbo and into the oil level sensor location and it worked fine.

This time I'm gonna do it with 10an and make it look nice, got a little power steering cooler I was gonna put in it but now reading this I think I'm just gonna go straight back into the pan I don't wanna have drain problems when I've got a nice balanced turbo with a factory installed restrictor and all that
I wish I could find pictures of how it was before. My abrupt cast 90 isn't doing me favors. A mandrel bent 90 hose barb to to -10 AN might do wonders.
 

Rdrnnr

wannabe racecar builder
Nov 15, 2020
1,361
2,386
I wish I could find pictures of how it was before. My abrupt cast 90 isn't doing me favors. A mandrel bent 90 hose barb to to -10 AN might do wonders.
Dude I had a brass 90 fitting like 3/4ish crossthreaded into the pan with some thread tape. No leaks no issues nothin. Maybe I got lucky idk? I also fed the camaro full of Rotella too so maybe that's it [emoji23]
 
  • Like
Reactions: v6buicks

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
Dude I had a brass 90 fitting like 3/4ish crossthreaded into the pan with some thread tape. No leaks no issues nothin. Maybe I got lucky idk? I also fed the camaro full of Rotella too so maybe that's it [emoji23]
Lol my turbo is junky but the big difference is that you have room for the bing on the passenger side. Mine's on the driver side, so the distance to travel is a lot longer and practically horizontal toward the end. Oil doesn't wanna flow sideways through a 90 without some pressure.

I'm only actually concerned about it because I removed the drain hose from the pan last night, and it dumped all over me. Since the engine hasn't been started in weeks, that means it can't be draining very well.
 

Rdrnnr

wannabe racecar builder
Nov 15, 2020
1,361
2,386
Lol my turbo is junky but the big difference is that you have room for the bing on the passenger side. Mine's on the driver side, so the distance to travel is a lot longer and practically horizontal toward the end. Oil doesn't wanna flow sideways through a 90 without some pressure.

I'm only actually concerned about it because I removed the drain hose from the pan last night, and it dumped all over me. Since the engine hasn't been started in weeks, that means it can't be draining very well.
 

Rdrnnr

wannabe racecar builder
Nov 15, 2020
1,361
2,386
Oops. Mine ran down to the driver's side and I'm pretty sure it horizintalled like that too? Maybe I was havin issues but there really was much oil in the hot side when I took it off either. Camaro also only had like 20 or 30 psi of oil pressure on idle tho and idk if it ever really saw much more than that. Maybe its just the 15w40s a lil harder to flow lol
 
  • Like
Reactions: v6buicks

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
Oops. Mine ran down to the driver's side and I'm pretty sure it horizintalled like that too? Maybe I was havin issues but there really was much oil in the hot side when I took it off either. Camaro also only had like 20 or 30 psi of oil pressure on idle tho and idk if it ever really saw much more than that. Maybe its just the 15w40s a lil harder to flow lol
Huh I thought you were the one I talked to with the bung on the other side. Yeah, my oil pressure is outrageous. ? Idk what my problem is there. The S3 spring makes it 90 at high idle. I'm gonna put the S2 spring back in whenever I remember.
 
  • Like
Reactions: Rdrnnr

Rdrnnr

wannabe racecar builder
Nov 15, 2020
1,361
2,386
Huh I thought you were the one I talked to with the bung on the other side. Yeah, my oil pressure is outrageous. [emoji23] Idk what my problem is there. The S3 spring makes it 90 at high idle. I'm gonna put the S2 spring back in whenever I remember.
I'll put a hundo on that bein where your problem is rather than the drain. I may see the same with this birds idle psi being 60+
 

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
Perhaps I need to pull my tee again to see if some tape got lodged in there. If not, I'll pull the timing cover as soon as I'm done with the million other things I said I need to do. CRAP I need to make a new to-do list.

EDIT: The tee can't be what's plugged if a blockage is what's causing a high pressure scenario. It would have to be something further up stream.... Damn
 
  • Like
Reactions: Rdrnnr

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
Finally you can see what I'm talking about.
PXL_20210330_204636134.jpg


Then I pulled the rear cover.
PXL_20210330_205645877.jpg


Sorry for the sunlight messing up the pictures. Although the seal doesn't line up perfectly. I don't see any reason why it would be mixing coolant with oil.
PXL_20210330_205653647.jpg


Oh well...

I didn't realize that the flywheel bolt holes didn't go through to the crankcase either. I was planning to redrill them now, but I'm for sure going to wait until it's resealed now.
 
  • Like
Reactions: Rdrnnr

Rdrnnr

wannabe racecar builder
Nov 15, 2020
1,361
2,386
Do not use RTV lookup Permatex super 300 it's also sometimes referred to as Aviation sealer it's more appropriate for what we need.
Aviation sealer seems like somethin I'd be into. Body shop buddy recently turned me on to panel bond and I tend to use that in places I really shouldn't get away with it [emoji23]
 

v6buicks

TCG Elite Member
TCG Premium
Oct 22, 2018
6,369
15,814
Franklin, IN
Real Name
Jon
I'm probably about to get shit for choosing Fel-Pro. Oh well. I was feeling ultra lazy and dumpy yesterday despite the gorgeous weather. Waiting for my parts to slowly funnel through the Suez Canal or whatever the hell is going on is really demotivating. Hopefully putting a few parts back on the car and seeing it go the other direction will help.

What's the low down with these pins and rubber strips? I've seen them in product descriptions, but never actually got them in my kit before. Reading the instructions on the package only makes me more confused because it doesn't seem applicable to the 3800. Also, I wish I had that crank seal install tool when I did this last time. lol
1617194489194.png


I was thinking about what Turbocharged400sbc Turbocharged400sbc was saying in regards to my oil blockage... That's probably got something to do with my rocker tips chirping. I guess the front cover is coming off too!
 
  • Like
Reactions: Rdrnnr

Thread Info