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Old 04-01-2016, 01:22 AM   #1
_HeC_
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3500 5 speed turbo build

Thought I'd share my build over here

just a quick catch up, I have a 2003 Grand Am GT that I swapped a 3500/5spd into last year with some bolt on's. Put over 15,000kms on that setup


Bit of a budget build so using 2 front LX9(3500) manifolds with a custom crossover and a Borg Warner S300 turbo from a 7L CAT machine, I had bought a turbo crossover fabbed up for a 2nd gen J-body with a flipped UIM for dirt cheap which didn't work at all lol

so grabbed a new turbo flange and pretty much started over trying to hug the engine as close as I could to make way for a 3" downpipe

The red transmission cap should give you a good reference point for how much it moved

Got the turbo mounted and did a quick mock up, happy with how things are going so far but still lots to do before May...

Dropped my turbo off at Re-Speed to get the turbo outlet flange changed to a normal 3" V-band
before

after
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Old 04-01-2016, 01:25 AM   #2
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All mocked up

better view of how its all plumbed and getting it welded up


all done except for wastegate placement

3" turbo back, charge pipes, and wastegate plumbing arrived as well as my intercooler

Was hoping to get the DP passed the subframe but I couldn't remove/install it if it was any longer then what it is now


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Old 04-01-2016, 04:57 AM   #3
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Thumbs up


I like where this is going
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Old 04-01-2016, 08:53 PM   #4
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OSV coming soon!!!!!
 
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looking good Mike! Guess that means you won't make the season opener in Whitby on April 10th... I'm thinking of going down for it...
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Misty: 3400, S&S headers, TCE 65mm TB, CAI, 180* TStat, Milzy motor & tranny mount, 18" BOSS 328 & much more... going osv!!
Silver: 2.4L, 5 speed, GAGT seats, front & rear STB's, all red tails, led headlights, Magnaflow muffler, Milzy Motor mount, WAI, Cosmo short shifter; sold n missed
Tequila: 2.4L, GA interior swap, scrapped...
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Old 04-02-2016, 09:14 PM   #5
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Thanks guys and what season opener Tim? Obviously I'm no where near driving yet lol but hoping to be burning rubber May long weekend!
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Old 04-02-2016, 11:16 PM   #6
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OSV coming soon!!!!!
 
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I'll send you the link through Facebook... Used to be run by the gmco club but he folded it a year or so and another club took over the meets... It's held at the landmark cinema in Whitby at Thickson rd and the 401... Starts at like 5pm or sobering like that haha!
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Misty: 3400, S&S headers, TCE 65mm TB, CAI, 180* TStat, Milzy motor & tranny mount, 18" BOSS 328 & much more... going osv!!
Silver: 2.4L, 5 speed, GAGT seats, front & rear STB's, all red tails, led headlights, Magnaflow muffler, Milzy Motor mount, WAI, Cosmo short shifter; sold n missed
Tequila: 2.4L, GA interior swap, scrapped...
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Old 04-17-2016, 09:42 PM   #7
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TCE 1.25" phenolic intake spacers

Hood didn't close lol

the culprit

will clean this up later

mounted my intercooler as high as it would go between the crash bar...

this bump was getting in the way of going higher


much better!


charge pipes!



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Old 07-10-2016, 01:10 AM   #8
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Did you get this build finished? Because this is awesome.

What was the power like before with the NA 3500 and 5-speed?
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Old 07-10-2016, 12:23 PM   #9
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He's almost done... I'm bugging him to finish it by the end of July to bring it to the mini meet we're having lol
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Misty: 3400, S&S headers, TCE 65mm TB, CAI, 180* TStat, Milzy motor & tranny mount, 18" BOSS 328 & much more... going osv!!
Silver: 2.4L, 5 speed, GAGT seats, front & rear STB's, all red tails, led headlights, Magnaflow muffler, Milzy Motor mount, WAI, Cosmo short shifter; sold n missed
Tequila: 2.4L, GA interior swap, scrapped...
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Old 07-10-2016, 01:29 PM   #10
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Ya still working away on it, hopefully soon! The manual V6 was a blast to drive N/A, hit the track twice and got 14.4@103mph I believe(traction issues)

heres some updates I haven't posted yet

So I spent some time finishing off my last charge pipe and came up with this contraption



which put my MAF down here


Not even 24hrs later and I chopped off half of that charge pipe and started from scratch though lol but happier with the placement of things, I'll grab some pics later when it's not so dark in the garage
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Old 07-10-2016, 01:30 PM   #11
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This should be better, might still mess with a small section of the charge pipe by the TB bracket


Decided to get a new wastegate to get a much smaller design and v-bands, also went with 44mm VS the 38mm Emusa


Going to be sitting something like this, still need to cut that pipe down a bit
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Old 07-10-2016, 01:31 PM   #12
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Might as well update this I guess, it at least give me a nice "journal" of my build lol

Got my drive train out a little while ago

Inspected my "stage 3" ebay clutch and rather happy with it after 16,000+kms with no proper break in and beating the shit out of it

drilled my pan for oil drain, thought I could get away with a nut and loctite but not enough thread showing


So dropped it off at a local shop that I use for my TIG welding(Re-Speed) and some beauty cars out front

Last year I lost my steering rack tabs.... NOT this year or anytime soon lol 1/8" plate on both sides

Lifted fuse box 1" and relocated wires from the front out the back

last year I had some TERRIBLE traction issues the 2 times i hit the track... Got a closer look at my poly rear mount and damn?

New one is here so little fire with the old lol

GTP 36# inectors/connections and my PCM flashed for them thanks to Scott!

ohh and got myself a WOT-Box for some 2-step launch control and no lift shift
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Old 10-15-2016, 12:46 PM   #13
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very impressive and well documented build here. I like what youve done.
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Old 10-16-2016, 09:15 PM   #14
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Thanks man, guess this needs some updating as the car is driving...

https://www.youtube.com/watch?v=KgG87WFq6VI

3" downpipe, wanted it to be 1 piece but wasn't happening


Girlfriend painting all the exhaust parts with some POR-20 heat paint


Some heat management




Quick clean to make sure no debris was inside


Notch for oil return


Screamer pipe

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Old 10-16-2016, 09:16 PM   #15
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Words can't describe how much I ****ing love this thing! Lol





Quick driving video
https://m.youtube.com/watch?v=cWxD0UAkkOw
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Old 10-23-2016, 12:13 AM   #16
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awesome. Car looks great, sounds fantastic!
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Old 11-08-2016, 02:02 PM   #17
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Sounds like a beast, nice work!
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