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How to build a single turbo second gen camaro ** updated 6/14/09**
Old 01-06-2008, 03:11 PM   #1
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How to build a single turbo second gen camaro ** updated 6/14/09**

here is what the car was before i got a brilliant idea


here was the brilliant idea


had to get the exhaust housing coated, didn't want it to rust


then i had to polish the big idea (special thanks to andrewF for the polishing skills)


then it was finished


Nitrous setup would have been way cheaper to keep


so back it into the new garage and take it apart


stick the turbo in and see where it will fit


we played with a lot of options














We planned to put the turbo on the passenger side somewhere, then we started on the header building, figuring the headers will be harder to make and we can move the turbo around to mate to the headers would be easier.

I ordered a chris alstons make your own header kit out of mild steel.
I knew i wanted to use stainless, but i didn't want to be messing up on expensive stainless tubing so i would make it out of MS and then i can tweak it and play around to get the design down before messing with the stainless parts



started off pretty easy










making the last tube fit

everything is just tac welded to make it easier to bend or separate

another angle

here is both headers



so after doing that i started with the stainless
you can see the makeshift band saw we used to cut the tubing it actually worked out so well!!


always be careful when working with power tools


table where i made the headers


deburring all the edges



inside and outside


checking clearances since it will be tig welded no gaps


tack tigging the first piece


getting the second pipe ready


fusion welding on the collectors


preparing for the collector to go on, the hardest part of the header construction









let the welding begin



finished product
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Old 01-06-2008, 03:27 PM   #2
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the turbo is capable of 1400hp so i needed to build an engine that would be too.

I went back and forth between small and big block

i ended up going with a small block



start with a good block


nice aluminum heads








ordered 10 custom CP pistons



Kryptonite crankshaft




a good crank and good pistons need good rods



$700 rod bolts


typical piston wrist pin on the left and mine on the right


some teflon coated bearings


making sure the piston clears the counter weight
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Old 01-06-2008, 03:30 PM   #3
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Damn how long did it take to build those things?
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Old 01-06-2008, 03:49 PM   #4
J.T.
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damn! very nice work on the headers...
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Old 01-06-2008, 04:31 PM   #5
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Those headers look sick Rob.... I bow to you.........
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Old 01-06-2008, 05:52 PM   #6
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Sick indeed. Anyone who can fill using tig is my hero!
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Old 01-06-2008, 08:35 PM   #7
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Quote:
Originally Posted by bowtiewins
Sick indeed. Anyone who can fill using tig is my hero!
At your service.
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Old 02-26-2008, 11:44 PM   #8
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So as i assemble the engine, i relize i need to construct an intercooling system

So going back and forth between air to air and air to water, i decide to go with an air-air as i actually plan on road driving the car, and the extra weight and plumbing and tubing is not worth it to me at this point.

So i pick up the precision catalog and look up their biggest intercooler core they offer, and i start to measure....... yup it SHOUUUUUULD fit, it will be close though

About 2 weeks later and $700 lighter it arrives



Now lets stick it where it goes and lets see what i have to cut in order to make it fit...













Ok fuck it lets put the end tanks on and see if it fits.....
this is pre assembly


this is pre welding



this is all tacked up



finished product



Now of course comes the time where it has to fit or im going air to water



fits like a glove!!!

there is clearance when assembled, their is no supports on the front end so its sagging against the intercooler



TIGHT FIT!!!!


a look to where the tube goes and passes threw the bumper and fender supports


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Old 02-27-2008, 12:04 AM   #9
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So now i had to figure out what to do for an intake manifold.

Only one company at the time (their might be more now) made a off the shelf efi intake, it was made by edelbrock, and it was based off a victor intake, which i thought would limit my hp cause of the older style intake.

So i bought a Super victor intake.



Some fuel rails, and some fuel rail bungs



now just to figure out how to get it all installed.

I sent it off to a guy back east, and he proceeded to do all the modifications to the intake and to build me an elbow also.


Here is the intake on the mill getting the holes for the bungs drilled



right before welding



right after welding


now to mount the fuel rails




pic if the elbow that points towards the driver side headlamp at a 45* angle




pic with injectors



Inside shot of the runner


Intake meet engine



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Old 02-27-2008, 12:43 AM   #10
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now to figure a way to mount the this big 83# turbo

I didnt want to support it off the headers, and have the g forces stressing out the stainless headers....


So i came up with this idea.....





basically the turbo is 100% supported weight wise on this 1/4 steel bracket that is welded to the frame in a U shape. i can remove all of the piping and the turbo stays supported in the car... kinda ingenious if you ask me

Now time to make a crossover for the headers to merge into the turbo.
This was actually the easiest part of the whole process..





Weld the pipes up and smooth the transition up... i spent like 2 hours porting this section..


this hole is for the wastegate
add some v band flanges for quick removal


Installed








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Old 02-27-2008, 12:55 AM   #11
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Old 02-27-2008, 12:59 AM   #12
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so where are we at now...........

we are building the engine, intake manifold is complete, elbow is built, intercooler is done and mounted, turbo is mounted, headers are built, crossover is done.

Ahh time for the downpipe.....

So the turbo has a 5" outlet so i wanted to keep that for a while and not restrict it down so quickly. I figure if they made it with a 5" outlet, there is a reason for it.

So i purchased some bulk 5" tubing and 90* elbows in bulk and went to down.

I first start with a piece that had a slight maybe 10-15* bend in it, and tacked it to the vband on the output side of the turbo.



here is the jack holding up the other mating pipe


here is the pipe tacked up



Here is a view looking into the fender showing the route of the downpipe.


It was hard to get it to clear the hood springs, tire and suspension travel, but i got it


here is the pic of the downpipe out of the car
The tab is for support against the frame, so the downpipe is supported
the path the exhaust takes is it starts on the outside of the frame, going straight towards the firewall, then 90* towards the ground, then 90* in towards the engine, then 90* more towards the rear of the car.



So i ground down all the welds so when i had it ceramic coated it would look smoother and that worked out really well


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Old 02-27-2008, 06:46 AM   #13
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awesome build bro...love it!
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Old 02-27-2008, 09:54 PM   #14
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Nice buildup Rob!

You wrote that when you wanted to get your manifold injector bungs and fuel rails welded in you weren't sure where to have the work done. Mike over at Enterprise Motorsports could have done all of that and alot more. Also he has wicked tig welding skills on aluminum. stainless, titanium, whatever and his fabrication skills are incredible. just ask our big baller friend bowman because mike did 95% of the fabrication for daves next "project"
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Old 03-04-2008, 08:12 AM   #15
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Your car is badass Rob... I didn't realize they were yours at first, but I studied your header pictures when I built mine....

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