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Unread 01-15-2007, 06:55 PM   #1
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Default Camaro IROC 5.7ltr Turbo

Well ive started taking part in these forums a bit and noticed the motoring section just now. This is the log from another forum that I thought I'd up here for you guys to gander at.

Ill just be porting the log over, so ignore the time frames etc in the posts.



Well the turbo build has been going for a couple of days now and since im doing a little dairy on another site id thought id put it here in case anyone gave half a *****. Firstly i thought id through up a quick pictorial time-line of the car...

Just got her;


Juiced;



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Unread 01-15-2007, 06:56 PM   #2
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New Wheels and interior;



New paint;


New stance;


Thats about it untill earlier today. Shes now OFFICIALLY in pieces getting the turbo treatment. I hope that while I'm working on it the parts i'm waiting for arrive as my window for this to be done is closing alot faster than im happy about. But it shouldn't be too long.... (fingers crossed)

Ill update with pics most days as the build progresses....

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Unread 01-15-2007, 06:56 PM   #3
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Well basicly the last 2 nights have simply been getting the headers off.

The passenger side was a snap, and came off in no time at all.



The drivers side became a big mission since I had no way of reaching the back 2 manifold bolds with the steering shaft in the way. So 3 bolts on the inside of the firewall, 2 under the dash and 1 onto the intermediate shaft and that was out of the way.



After pulling the shaft up a few inches access was a breeze and the manifold came right off.



I also pulled the intermediate shaft out as i have a newer one to put in but i also noticed my steering box was leaking. That combined with my sloppy steering has prompted me to replace the box. Can anyone tell me what box is used in RHD conversions or how to ID this one?

Tomorrow: Test fitting of headers (without spark plugs )

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Unread 01-15-2007, 06:57 PM   #4
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OK... day (night) 2 is done.

I got the rest ofthe exhausts system off and began the test fitting of the headers. Naturally, nothing quite fits.

Firstly, the drivers side header. This was always going to be the scary one since it needs to dodge the block, starter, brake lines and steering shaft. Oddly enough it fits better than anything else. I'm not 100% sure if it will clear the steering shaft fully untill i put it back in, but right now the only mod it needs is where the white dot is in this pic needs to be bashed/crushed in about 15mm as its fouling on the top of a LCA mount.

** EDIT: Turns out i marked it wrong. Its fouling further up on the collector and is actually hitting the cross memeber **



OK.. next. The turbo header. Firstly I could tell just visually that it wasnt going to fit my big ass turbo in without removing the heater blower, so off it came. Im a little worried since Ive heard of cars failing rego without a heater, even up here. Something to do with de-misting i guess. Anyway, I tore out all the hoses and controls ages ago so its gone too.

The header itself bolted straight on without any dramas and looked the goods. BUT.... 2 major problems are present.

1. My turbo is too big, and hits the strut tower.
2. The V-Band Neck on the turbo is so long, it half passes over the gap mad for the dump pipe.

Here you can see the mark on the paint where it hits.



This I HOPE I cant solve by taking the header in and getting the flage cut off, and a spacer/angle put under it to raise it slightly and tilt it back in towards the middle. That would solve problem number 1.

Problems number 2 is a little mor tricky as it involves a very difficult to shape dump-pipe. I had hoped to use 4" until i got underthe car, but in order to get the initail "S" bend i need to bring the pipe forward under the turbo ill have to imidiatly go the 3" and have some very sharp turns. ALmost crushed I fear.




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Unread 01-15-2007, 06:58 PM   #5
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These pics kind of show where its gonna have to go. I'm not too stressed about number 2 right now as I need to find out exaclty where the turbo is going to end up before I can fit anything.

Another drama I just noticed last night is the bolt pattern on the turbo (GT40) doesnt match the both pattern on the header flange or supplied gasket.



After tracing the bolt holes onto the turbo with the gasket as a template you can see the black marks that need to be drilled/machined out.

Finally, with the help of this lovely ASS....istant :moon: , I was able to get a shot of where its all gonna end up. Should be awsome. :beer:



Big Engine + Big Turbo + Hot Chick = Teh WINNAR!!!!

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Unread 01-15-2007, 06:59 PM   #6
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Heres the turd-blow



Specs (from memory);

GT40;
Comp wheel diam 82mm, 50 trim, 0.58 A/R
Turbine 77mm, 73 trim, 0.94 A/R

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Unread 01-15-2007, 07:00 PM   #7
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Day 3

Not much today unfortunatly. Took teh turbo-side header in to the machining shop for them to have a look. The up-shot is that they're gonna make an angled spacer to weld onto the current flange-face. The result is that the turbo is raised about 10mm and rotated back towards the motor.

My new worry is that the drivers side header is fouling too much on the cross member to be 'dinted in' enough. So now I have to look at possibly taking a small chunk out of the edge of the cross member, or almost totally re-making that header.


Weekend Update:

Well a fair bit managed to get done this weekend. Not too many pics since the parents took my camera to bali but a few phone ones to keep the masses happy.

The headers have all been tacked up to where they need to be and are in getting finished today. For the turbo header modification, instead of cutting up teh header to move the flange up and in, we made up and angled spacer that effectivly rolles the turbo back in towards the engine and gives my the clearance i need from teh strut tower. It ended up being a very expencive way to do it due to the labour involved but it turned out well. It DOES however look like some minor hood modifications will ahve to be made in order to keep everything covered, which is a shame but not really unexpected.

Since alot of the this weekend was wasted waiting for parts to be made/modified, i focused on a few other bits of the car that i wanted to work on. I finally got around to installing my new Superior Forged Axles from the states and I must say they fit alot more snug that my old stock ones and are definatly made to a higher standard and should hold together a fair bit better.

We test fitted my FMU, external fuel pump and surge tank and it all looks like it will fit well. I need to fabricate up a peice of steel to box off and enclose the rear boot 'hole' to close it off from the cabin so i can run fuel in and out of there, but thats no major drama.

I also managed to install the Energy Suspension polyurethane bushes for the front and rear swaybars. While I was looking at it all, i decided it would be a good time to start boxing some braces.

In no time at all we have boxed both the trailing arms and re-enforced the panhad rod with tubular steel.

Note: We here and Droopz Customz are all about workplace safety.







Everything we pulled off also got cleaned up and coated in a nice Volcano Orange to match the K-mac springs and its all starting to look fairly trick.

And one more for the sake of it...



That was about it for the weekend. Now we begin work on the intake piping and downpipe.

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Unread 01-15-2007, 07:01 PM   #8
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Finally gotthe camera back so here are a few pics of the weekends results.

Here shows the final colour of the boxed LCAs and also the shinny new Superior axles.



Here are a couple of pics of the finished turbo header, with its angled spacer plate. All still needs to be tidied up and such but it give you an idea of what was done.





This is a pic of the non turbo header. If you compare it to the pic further up in this thread, you can see how much it was modified to fit. Even as it is now, I may still have to 'oval' some parts of it to give it enough clearnace from the K member and starter motor once the engine torques.


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Unread 01-15-2007, 07:01 PM   #9
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Well, the latest is all from my good friends workshop at Rattla Racing. I needed an experianced exhaust fabricator and a hoist to get this little project into its closing stages.

Firstly, we have the awsome down pipe John made up for me. Its 3" mandrel bent from the turbo's V-clamp (even though it uses a 4" outlet, it would be unrealistic to try and fit 4" of pipe through everything...) The black pipe is the lower connection over to the other header, and the silver one is the bottom of the down-pipe.



Another shot of the downpipe but here you can see the braided line running from above the oil filter that will lead to a block for the turbo feed, oil pressure and oil temp.



Here are a couple of shots of the drivers side sub-frame connectors. Me and the old man welded them in while John was making the downpipe.




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Unread 01-15-2007, 07:02 PM   #10
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And one last shot of the whole lot so far. Boxed LCA's, boxed Panhard rod, poly bushes and SFCs.



Well that was it for today. With the exception of the silicone reducer I need to hook it up to the throttle body, she'll be bloody close to done my the end of the long weekend. All that left is plumbing the wastegate to the down pipe, tapping the sum for the oil return and thats about it. Stay tuned folks....

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