🔧 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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This build makes me want to find a clean 3.8/5 speed f-body. Thanks for sharing. Can’t wait for a video
Doooooo it!! I've definitely worked on mine more than I've driven it, but I think it'll be worth the effort.

The transmission thing is a turnoff for a lot of folks, but the reality is that you can have planty of fun with an M49 or 4l60e... Just not 1000hp fun. Lol

I'm going to try to be a pioneer with this. I've heard a lot stories about budget bolt-in T56 and Mustang T5 conversions but no hard evidence to back it up. Whenever I get a new body for this car I plan to Mustang T5 and 3800 swap our Volvo. It'll be well documented and I'm betting it can be done with all off-the-shelf parts.
 
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v6buicks

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The final piece of the puzzle 3-20.jpg

??????????????????????

Flywheel 3-20.jpg
Clutch installed 3-20.jpg


I'm so close, but this transmission does not go back in as easy as it comes out. It really just falls out once you shake it a little, but going back in? You have have to tilt the engine back a whole bunch which means undoing all the K-member bolts. :cautious: Apparently that's one thing that I couldn't remember from the last time I did this. The other thing I forgot is why I need to drain the fluid! I paid for that one. Oh well. I only wasted maybe 20 minutes trying to toss the transmission back up. As for the fluid, I'm guessing it's going to cost me a few towels. :oops:
Trans going in 3-20.jpg
She bleedin 3-20.jpg


My employer changed my working hours due to COVID-19, so I'm now working four tens as opposed to my regular eight hour shift Monday through Friday. I don't understand how TF that's supposed to help anybody since we will all still be together for forty hours per week. However, I'm still employed, so I'll keep my mouth shut! Anyway, the point is that I'm exhausted from waking up an hour earlier and working at least two hours longer. Hopefully I can sucker a buddy into helping me out soon. Bench pressing this T5 on my own with a floppy engine and tight block dowels isn't going to happen. Working with pals in the garage is not exactly CDC approved or socially acceptable though, so it might take some convincing..... What an era we're living in!
 

v6buicks

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No problems! My buddy was happy to help muscle this trans back in as long as I would help him do brake lines in his Civic this weekend. DONE. That's just his beater though. I'd bet that TCG would love his Power Tour Long Hauler. I'll try to take some pics when I'm over there.

I really wish that dropping the K-member wasn't necessary for re-installation of the T5. It's kind of a pain and so hard to remember to do when the trans just falls out upon removing the bell housing bolts! Oh well. The deed is done, and I can complete the rest of this stuff solo. I think I'll be cruising this weekend. :cool:
Transmission installed 4-20.jpg
 

v6buicks

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Does anybody know what it means to "catch a break"? I don't. As usual, my daily saw that the Camaro was about to leave the garage, so it said "MY TURN!"


I also got my pay cut by 10% starting tomorrow. :( I'm going to be in a world of hurt if this thing ends up needing an engine, but I'm pretty sure it's just a water pump. I still think that the Camaro is closer to daily status than the Volvo, so I'm still on track for weekend completion. However, don't expect any COVID-Gymkhana videos. Once again, the Camaro's duties have been demoted. :cautious: I really need a new car.
 

v6buicks

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Damn, that sucksssss. 100% rod knock and it has oil?
I say "knocking" as a sound description, but it's not a lower end issue. Worse case scenario is that I have a bad cam follower in which case the engine is still toast. It could also be a failing cam phaser, but I'm really betting it's just the water pump shaft bushing that's causing the water pump fins to slap the block. There's also a cringey metal-on-metal screaching. It all comes and goes.

What I know is that there is plenty of oil, plenty of oil pressure, and no glitter on the dip stick. That's a big relief. It's also puking coolant out the front of the engine, but it's hard to say where exactly. The water pump is timing belt driven so I'm guessing the issue is hidden behind the timing cover.

This is what I HATE about this car. There is never a warning. There's no limping the car home. When it breaks, it's dramatic AF.
 

v6buicks

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My dear friend, you need to own a Honda. IF it has timing belts it only needs them every 100k miles and if it doesn't, you just have to make sure it has oil. Literally all you have to do.
You speak the truth. I was younger and dumber when I bought this car. I had just graduated, got a good job, and wanted a flashy car to show all that off. It hasn't been a bad car overall (assuming my engine didn't just yeet itself) and it's actually pretty enjoyable to drive. I just could have been a more sensible.

A Honda would be a great replacement, but I also need a truck. Toyota Tacos seem to be the Honda of trucks these days. We'll see. With all that's going on, now is a terrible time to buy something if I can avoid it.
 

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My dear friend, you need to own a Honda. IF it has timing belts it only needs them every 100k miles and if it doesn't, you just have to make sure it has oil. Literally all you have to do.
Yup my wife had a 98 civic. She drove it for 4 years with a Blown head gasket. Oil all in the coolant and coolant in the exhaust. $800 car with 268k when The speedometer stopped working. I kept that shit topped off with used oil and whatever coolant or water and changed oil filters and it was still running when we dumped it off. Nothing else worked on it though. It was a tank and we purposely never maintained it and never sank a dime into it.
 

v6buicks

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My next vehicle is already kinda picked out. I just want to save up for a bigger down payment than I can afford right now. I want the capability to tow a car on an open trailer. I also want at least 20 mpgs going to and from work. It must run on 87. As much as I love the look of regular cab trucks, that's a big no-go for me. I want interior, and exterior cargo space. However, I won't do an extended cab either because I can't stand the look of them. I also want to spend less than $40k. That kinda narrows things down to a few possible options.

Now for the real kicker that's making all my car buddies' heads spin... I might end up selling one of my "toy" cars to help ease the pain of the purchase. I'll give you a hint. It sure as hell isn't going to be the Camaro.
 

v6buicks

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Somebody pinch me... It's happening!
Back on the ground 4-20.jpg

Damn! I have videos, but I'm once again having hosting issues. Thanks imgur... anybody like another free hosting site?

This thing runs like a scalded dog now! I don't need to change my turbo. The lag is very much acceptable now that its's no longer trying to boost the atmosphere. :LOL: I haven't even hit peak boost yet and I'm totally in love with everything I've done. The heat blows nice and warm, there's no draft from the holes in the floors, the carpet really quieted things down, and there's no more smoke or smells coming from under the hood! The new clutch is honestly super easy to drive so far though. That's not what I expected from an unsprung 6 puck. Maybe it will get grippier once it breaks in? I don't know.

I guess this is what happens when Russia is over producing oil this year and all the corn was destroyed by floods last year. Weird! Still cheap AF though.
E85 During COVID-19 4-20.jpg
 

v6buicks

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Thanks guys!

Business as usual. When one project is completed no time is wasted when moving on to the next one! I'm still standing behind my water pump theory. That's at least for sure where all the coolant has been leaking. As for the noise, I guess we'll find out as soon as I get the parts and install them.
Third timing belt 4-20.jpg


The Camaro's clutch now has 50 break-in miles on it. It seriously feels nothing like the car I was driving last year, and I mean that in only positive ways. I know I've said all of this already, but all the sounds being muffled by the carpet, the lack of exhaust fumes coming through the rusty floor, the oil smoke being caught by the catch tanks, and being able to feel boost earlier in the gears is absolutely amazing. I feel like I actually built something good! It feels even better that I didn't have to break the bank to get here either. Sure there's plenty of room for improvement, but I finally have a complete car that I would be happy driving for a long long time as-is!

I mentioned earlier how the clutch seemed too smooth. Now that it's starting to break in a little, I'm starting to notice how I need to rev match a little better. No worries! It's by no means uncomfortable, and I'm extremely excited to give it the business. It's going to be super grippy in a couple hundred miles, and a little feedback is going to help me learn how to drive. :LOL:

Not having a mini heart attack every time I roll the key and don't hear the fuel pump will be nice too. lol
Getting ice cream 4-20.jpg

Isn't my lifeless quarantined town so cute? lol
 

v6buicks

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I edited post #383. The sound works in the video now.

I wasn't feeling good about seeing this weird spot on the floor.
Coolant leak 4-20.jpg


...but then I took everything apart and found this disaster. It turns out that that the black on the floor was coolant seeping out of freshly machined aluminum. How on earth I didn't hear anything long ago is beyond me!


That should take care of my noise and leak, so I started putting everything back together. I should be done next weekend.

Why?

Because Volvo and their beloved torx!!!
Torx tentioner 4-20.jpeg

WHY WOULD YOU EVEN MAKE IT LIKE THAT?!

Here's a nice POV shot of failure
Fail POV 4-20.jpeg


Sometimes hitting your head with a breaker bar that just stripped out the tensioner after hours of smooth work and only ten minutes to go means taking a nap on the concrete floor. Pro hobo tip: Empty oil jugs make surprisingly comfy pillows. Embarrassing head bruise selfie ahead.
Fail nap time 4-20.jpeg


After learning that Volvo changed the design of this tensioner halfway through the model year, I spent the next hour trying to figure out which one to order. Then I found out that it might not arrive until Friday. Joys! At least the timing aligned perfectly with the Camaro project being ready to roll. Although I must say that it's a little tough to trust it being so fresh out of the garage!
 

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