🔧 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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Part out?
1617233125722.png


I really wish I didn't just do that. That was a decent amount of work just for unsuccessful exploratory surgery.
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Correct me if I'm wrong. Is this the basic idea behind what's going on in the 3800 timing cover?
3800 timing cover oil diagram.png


If so, I'd either need to have some sort of failure in my sensor circuit or a physical blockage upstream of the timing cover.

Lucky for me, I have a factory service manual. The gauge does not quite work how I expected. High resistance or an open circuit makes the gauge fail high. WTF GM?! Oh well. I think it's a good idea to finally replace my timing chain tensioner anyway. Then I'll go look into the gauge wiring. I already know that my sensor pig tail is rotted to hell, so I might shoot the parts cannon in that direction.
 
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Rdrnnr

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I wish I could stay on mine for any amount of time and then when I do I end up doin other stuff than what I should be. Currently drilled out the window regulator rivets to replace the motor so now I gotta deal with that the pedal and gettin thru my firewall instead of pullin my trans or gettin my headers on
 
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v6buicks

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Not a lot of pictures were taken because I am going for time. This car needs to go back (mostly) together today. I am done picking my ass while waiting for parts, so I'm going to button some things up, push this bitch to the side, and bring the GN home. Tomorrow is my only chance to go to the storage barn before I start getting to busy. Here's where I was at before finally taking a break.
1617477259417.png

I just noticed that it looks like I pooped on the floor and rolled around in it. Oh well. I guess that's the perfect representation of my current sanity status. :LOL: Anyway. Things are going well for the most part. The rear cover is on and flush with the block's oil pan rail. The timing cover is installed with and looking pretty cleaner than I've ever seen it. The only things that really suck are the coolant elbows. I replaced them with aluminum because it was all I could get on short notice. What a scam. The orings are so small that installing the elbows without lube was like throwing a hot dog down a hallway. I ended up taking the orings from the used plastic elbows and using those instead. The fit was tighter, but still not what I wanted to feel. I have a feeling that I'm going be back here again in the near future. If I wasn't rushing, I would have measured and taken pics. The point is probably moot anyway. People love these elbows for some reason despite the $10 plastics being a superior part that only needs to be replaced every 15 years. ?‍♂️

Whatever. Maybe I'm not that smart anyway. I did in fact break my PS pulley installation bolt inside the pump shaft. Although the pulley is installed all the way, it's the last time it will be installed on that pump! The pump is original so replacing it really won't be the end of the world.
 

Rdrnnr

wannabe racecar builder
Nov 15, 2020
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Not a lot of pictures were taken because I am going for time. This car needs to go back (mostly) together today. I am done picking my ass while waiting for parts, so I'm going to button some things up, push this bitch to the side, and bring the GN home. Tomorrow is my only chance to go to the storage barn before I start getting to busy. Here's where I was at before finally taking a break.
View attachment 85116
I just noticed that it looks like I pooped on the floor and rolled around in it. Oh well. I guess that's the perfect representation of my current sanity status. [emoji38] Anyway. Things are going well for the most part. The rear cover is on and flush with the block's oil pan rail. The timing cover is installed with and looking pretty cleaner than I've ever seen it. The only things that really suck are the coolant elbows. I replaced them with aluminum because it was all I could get on short notice. What a scam. The orings are so small that installing the elbows without lube was like throwing a hot dog down a hallway. I ended up taking the orings from the used plastic elbows and using those instead. The fit was tighter, but still not what I wanted to feel. I have a feeling that I'm going be back here again in the near future. If I wasn't rushing, I would have measured and taken pics. The point is probably moot anyway. People love these elbows for some reason despite the $10 plastics being a superior part that only needs to be replaced every 15 years. [emoji2369]

Whatever. Maybe I'm not that smart anyway. I did in fact break my PS pulley installation bolt inside the pump shaft. Although the pulley is installed all the way, it's the last time it will be installed on that pump! The pump is original so replacing it really won't be the end of the world.
I don't like drilling the edges of the broken pieces of the plastic ones out so there's that. I throw a shitton of dielectric on em never had any issue. I'd rtv em but I don't wanna deal with gettin em back apart
 

v6buicks

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I don't like drilling the edges of the broken pieces of the plastic ones out so there's that. I throw a shitton of dielectric on em never had any issue. I'd rtv em but I don't wanna deal with gettin em back apart
I've always used a small saw blade to cut through them in two spots, pull a chunk out, and use a screwdriver the pury the rest out. If you have to do an early car with the cast in elbow, you'll find out that aluminum can make the task much more difficult. It's not worth arguing. I just don't think that the grass is necessarily greener.
 
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Rdrnnr

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I've always used a small saw blade to cut through them in two spots, pull a chunk out, and use a screwdriver the pury the rest out. If you have to do an early car with the cast in elbow, you'll find out that aluminum can make the task much more difficult. It's not worth arguing. I just don't think that the grass is necessarily greener.
I don't doubt that considering the aluminum truck wheels ive seen seized on cast hubs so that makes perfect sense from that side too. Plus dexcool. Time is hell on everything
 
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v6buicks

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Again. I was trying to hard to keep busy to take pictures of anything but the car is as together as I want it to be for now. The garage is looking cleaner than I've seen it in a couple years, and the car got washed in place. I'm thinking that the cover is going to go in it until I get the transmission. Until then, I'll make a windage tray for the pan, weld on a new bung, and drill the crank for bigger bolts which I decided to just go ahead and by from Summit. From there, all I will really NEED to do is finish the transmission conversion.
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Rdrnnr

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Nov 15, 2020
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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
View attachment 84783

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!
Going back to this did you figure out what the strip are? I'm gonna start puttin mine back together today and really don't wanna be back in here any more than necessary. Was there anything necessary to get the torque wrench out on? I was thinkin cover flywheel and converter bolts would be my biggest concern?

Kinda sad to see you rollin this one out back for a while it's been a tremendous help to my build as you've usually been right ahead of what I need to do
 
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Turbocharged400sbc

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if the kit was opoened someone tossed parts from another gasket kit in there.

im trying to rack my brain for the eengines that have the rear main cap exposed and requires sealing strips and guide dowels before the main is tightened and the rear main installed.

i wanna say some of the ferds were like that as well as mopar but my memory isnt what it used to be
 
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v6buicks

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Going back to this did you figure out what the strip are? I'm gonna start puttin mine back together today and really don't wanna be back in here any more than necessary. Was there anything necessary to get the torque wrench out on? I was thinkin cover flywheel and converter bolts would be my biggest concern?

Kinda sad to see you rollin this one out back for a while it's been a tremendous help to my build as you've usually been right ahead of what I need to do
I determined that Fel-Pro doesn't understand how our blocks and rear covers are shaped. The strips went to the trash can. Just be sure to get the alignment with the block rails close. I put all the bolts in finger tight which is enough to hold the cover in place. Then I used pry bar to move it where it needed to go.

Go figure. Jegs sent me tracking info for my flywheel bolts. ?‍♂️ Now I guess I'll have two sets. Maybe my transmission will come early too? We'll see. Realistically, I'm not going to be delaying the Camaro progress much. I'm really just getting the GN so that I'll quit worrying about driving the Camaro this summer. Now that I'll have a fun car to drive, I can focus on doing the Camaro correctly without cutting corners.
 
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Turbocharged400sbc

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slowly sneak up on snug for the rear cover esp near the water jacket and oil ports, 1/4 to half turns to keep you from squeezing it out and to let it slowly compress and conform.

i toss the gasket onto the package/carton and paint it with the super 300 brush , flip and paint, toss on.

be carefull, some of the "brush in cap" bristles can come free, i had to use side cutters to crimp mine down a bit more to hold em firmly
 
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Rdrnnr

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This was kinda my plan except I was gonna smear a lil black on both sides to hold it in place and then once bolts were in I was gonna try and shove it down from the top to seal against the pan. As for flywheel bolts I ordered new ones and got the wrong ones (they ended up bein for the old buick/Pontiac block) so I guess I'll use the old with some red loctite and hope for the best.

You guys are the best
 

Turbocharged400sbc

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Technically grade 8 5/16 - 18 bolts from the hardware store should work fine for you however usually the heads are a little tall so once you install and tighten them down you may need to check and make sure they clear the torque converter or you'll have to grind a little bit of the bolt heads for clearance.

If you are we using the factory torque to yield flywheel bolts check them by holding them up to a new or known good 5/16 18 and check for light coming through the thread profile between the two as that will definitely indicate whether one has stretched permanently. Also you'll feel it slightly get easier to tighten the moment before it snaps off and then you have to hurry to remove it before the red Loctite cures
 
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Rdrnnr

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Technically grade 8 5/16 - 18 bolts from the hardware store should work fine for you however usually the heads are a little tall so once you install and tighten them down you may need to check and make sure they clear the torque converter or you'll have to grind a little bit of the bolt heads for clearance.

If you are we using the factory torque to yield flywheel bolts check them by holding them up to a new or known good 5/16 18 and check for light coming through the thread profile between the two as that will definitely indicate whether one has stretched permanently. Also you'll feel it slightly get easier to tighten the moment before it snaps off and then you have to hurry to remove it before the red Loctite cures
Sounds about right. Bein a tire guy I'm pretty good at makin tight bolts loose really fast [emoji23]
 

Rdrnnr

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I actually never use Loctite on them I always use an ARP Lube.
I've put the arp bolts I use all the way up to 30 foot pounds. The stockers if I were call it something like 11 + 90 which if I work all ends up closer to 25. Don't hold me to that though
25 seems about right and your absolutely correct on using lube with any fastener now that I think about it.

Basic tire 101 is that you use a light oil rather than penetrating oil or antiseize because it increases the clamping force where the other two lessen it. Actual torque is only accurate with clean threads good fasteners and good lube to get it where it needs to be.

I always kinda considered it like a woman. You absolutely don't Ram it in dry.
 

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