🔧 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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bs009

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I've had to replace valve stem seals on every series 2 3800 I've had so far except for my 2002 Regal (low miles still). That would be my guess for where your oil is coming from if it's not the turbo. It's a real pita to do in the car but if you're putting new heads on anyway then you're all set if that's all it is haha!
 
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sktchy

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I've had to replace valve stem seals on every series 2 3800 I've had so far except for my 2002 Regal (low miles still). That would be my guess for where your oil is coming from if it's not the turbo. It's a real pita to do in the car but if you're putting new heads on anyway then you're all set if that's all it is haha!
This is a good thought but wouldn't that be more of a warm up kinda of thing than an all the time deal? Just going off experience with 5.7 tbi valve seals from around the same era,, I haven't actually had an issue with them in one of these yet
 

bs009

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This is a good thought but wouldn't that be more of a warm up kinda of thing than an all the time deal? Just going off experience with 5.7 tbi valve seals from around the same era,, I haven't actually had an issue with them in one of these yet
For me it was really noticeable after idling and getting moving again. My first 99 Regal would blow pretty big clouds of smoke after every stop sign and stop light even on long drives until I replaced them.
My last engine in the Grand Prix was a little more random with it but that might've still been the turbo slightly leaking. It would do it usually when the turbo is spooling down after a rev or a hard pull even with a plugged pcv. Otherwise it wasn't really noticeable that I remember
 
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Turbocharged400sbc

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If you chooch a center section a restrictor can keep you from losing a lot of oil pressure...

Two small or restrictive of a filter I would think would also contribute to sucking oil past the shaft seal.

Do you have confirmation that's fresh oil from the last drives AKA you had cleaned out everything of oil previously?

I have a similar spot on the left and right side of my screen on the Cressida from the way the air flows through the curve in front of the screen. I'm guessing that's just the way that your water in your water slide is flowing... is leaving a small dead area down there that doesn't get blown clean by high velocity air
 

v6buicks

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This is good conversation. Thanks guys.

I have a massive K&N from the GNs ATR scoop that I could oil up and try. It just sucks that I'd likely need to put it on a couple 3" elbows.
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Maybe I should try running the car down a clean road without a filter and see if it smokes? It really does only seem to happen after fucking around, so the filter idea makes sense to me.
 
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v6buicks

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One reason I'm so hopeful for this is because I think this is the biggest turbo I've ever seen with a 3" compressor inlet and turbine outlet. An already small bell could be making my filter a choke point. I'm just surprised, because I didn't think this filter was small at all. Any larger turbo seems to have a 4" inlet and a 3.5" turbine outlet though. Maybe that should be telling me something.
 

Mr_Roboto

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The other option is to stick a vacuum gauge on it and see if you're pulling vacuum pre turbo and go do a run. You'd have to figure that out it would likely be a small hole somewhere in the rubber that you'd RTV up afterwards. If you were all fancy you could install one of these.

https://www.amazon.com/dp/B0014BI1KA/?tag=tcg21-20

Also, I'm pretty sure my Turbonetics T66 has a 4" inlet.
 
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v6buicks

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The other option is to stick a vacuum gauge on it and see if you're pulling vacuum pre turbo and go do a run. You'd have to figure that out it would likely be a small hole somewhere in the rubber that you'd RTV up afterwards. If you were all fancy you could install one of these.

https://www.amazon.com/dp/B0014BI1KA/?tag=tcg21-20

Also, I'm pretty sure my Turbonetics T66 has a 4" inlet.
OO! I was looking at that and didn't think it would help until I clicked on your link and saw the reset button. So I take it it holds the highest reading until you press the reset? I'm totally buying one. Hopefully there's enough room on the plastic end cap to install one. I used to have one from an old truck hanging around, but I almost guarantee that I threw it away by now.
 
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sktchy

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One reason I'm so hopeful for this is because I think this is the biggest turbo I've ever seen with a 3" compressor inlet and turbine outlet. An already small bell could be making my filter a choke point. I'm just surprised, because I didn't think this filter was small at all. Any larger turbo seems to have a 4" inlet and a 3.5" turbine outlet though. Maybe that should be telling me something.
So, the "inlet size" really doesn't determine anything other than what filter you run on it. The opening in it is still going to be determined by the size of the wheel. It's basically just more material smoothed down. I'm sure there's more to it than that and maybe some change in airflow characteristics but my .50 ar 67mm housing with 3" inlet actually has a bigger opening in the center than my 62mm .70 ar housing with a 4"
 

v6buicks

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Ope
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It's definitely collapsed a few times because this wrinkled section is pretty weak. Considering the type of pipe I had prior to the filter being mounted straight on the turbo, I'd say this is a prime suspect. The old pipe would have collapsed and created an unfiltered leak well before the filter would collapse. I really never had cool weather with this setup until I started seeing smoke either. I have high hopes that a bigger or no filter will be the fix.
 
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sktchy

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I went to a spectre 9616 on my car most due to the fact that it fits in the space and being somethin like 6x8 inches it has a whole lot more surface area than the shortly filter I had on before. Its probably still not sufficient but it's a cheap improvement and doesn't have the stupid metal center cap to worry about that sucking into the turbo
 

v6buicks

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I went to a spectre 9616 on my car most due to the fact that it fits in the space and being somethin like 6x8 inches it has a whole lot more surface area than the shortly filter I had on before. Its probably still not sufficient but it's a cheap improvement and doesn't have the stupid metal center cap to worry about that sucking into the turbo
I'm just gonna use that uge K&N with some elbows to make it fit. That outta be plenty. Lol
 
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v6buicks

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I managed to make the big mofo fit vertically with only one elbow.
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Better not hit too big of bumps! ? This thing hangs lowwwww.
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I'm gonna put the charge pipe back on tomorrow and go for some drives. If it doesn't smoke then great. The filter maintenance gauge is going to take a week to show up, and I don't feel like waiting for sound results that long. Regardless of the results, I won't be rocking this ugly setup for long. It's too dang ugly! I don't really want to go filterless either considering that I drive this thing all over the place. We'll see. Hopefully I learn something soon.
 
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sktchy

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I feel that. I hate that mine sits as low as it does but at the same time havin a pretty straight shot out of the downpipe has to be a somewhat good thing. I'd imagine cartuning put a little more effort into r and d than what the Amazon pipes have. I always did wanna throw a couple v bands in a set of those and hang the turbo on the bottom side of them though
 

v6buicks

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Do yourself a favor and watch your AFRs on your tune when hammering on it as well. Not sure there will be any changes but a bit of extra awareness may do you well just in case it leans out some.
Good point. I've always ran this car with a filter about that size even on the dyno. She's used to that restriction. I'll keep an eye on it tonight when I go for a test drive.

Anybody know anything about K&N maintenance? This thing probably needs it according to K&N, but I've never used one.
 
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v6buicks

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Tonight was fun, and it started out with a small present from ebay.

For those who don't know F-bodies, they're flimsy piles of shit. Therefore, if you slam on the brakes a lot of your pedal effort goes I to the firewall instead of the master cylinder. Here's what I mean.

So I installed this nice powder coated bracket to stop the movement. How it works is pretty self-explanatory, but the installation is kind of a bitch. As the instructions said, "patience is required." I'm just excited that somebody made one that clears a BMR strut tower brace.
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Then I put the charge pipe back on and went for a drive. As soon as I gave it a some throttle and shifted, I could tell it sounded a lot different! When I found some open road, I made some boost, and blew the charge pipe and boost reference hose off. The boost reference never comes off so that was exciting. The charge tube blew off with enough force to dent itself on the street though. ?
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I limped home boostless and secured everything a little tighter than before. The goofy offset silicone reducer I use to connect the turbo to the pipe needs to go, and the charge pipe needs to be modified so that it actually fits right. For now, test drive #2.
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This son of a bitch pulls even harder now! It spools faster and seems a lot more consistent. Most importantly. It didn't smoke all night. ?

I want to hold off taking it apart now. It would be nice to take it to the work car show in September as well as another test and tune if I can find a cool Wednesday evening that I'm actually available. For the track I'll just remove the filter.
 

sktchy

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That makes alot of sense after figuring out how bad my previous filter was holding me back. Glad to see things are lookin up!

Sucks about the charge pipe though, hit the connections with a lil clear permatex spray seal leak repair and tighten the hell out of the clamps, i call it the "eff it spray" because I'm pretty sure it's designed to stop leaks from the outside but the stuff is more or less like a hit it and quit it and it's one of my favorites being a fleet mechanic thats job is to "fix it so it doesnt do it again but do it as cheap as possible"

Side note: my cars probably never been more famous as when I blew the intercooler boots tryin to keep up with GTPpower GTPpower ?
 

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