Project: Blue Alero

[[ion] C2]

Originally Posted by tw0123

Lol it's so tall... are you putting in a short shifter? Mine feels much more responsive with the shorter throws...

i know i used 225/50R17 tires so they're a bit taller. i'd need to get different spacers and probably go back to a 45 series tire to lower it any more because it already rubs on turns and suspension travel. minor things to change in the future.

ya i have a short shifter and will install it when i feel like it. i want to drive it as is first when everything works before fooking it up

supposedly you have to modify shit with the shifter to make it fit I hear, people have to dremel out things or have issues getting it into certain gears. right now the stock shifter is the smoothest one i've ever handled and I can shift pretty damn quick with it. 450HP will keep it responsive enough for now.

[tw0123]

I can atest to that ... it's a bit stiff to get into first and was a bitch to get in lol... i used a sharpie on the cables to ensure they were still lined up properly... the reverse clip is also notorious for tearing the boot as it's tight to grab reverse...

[[ion] C2]

Accidentally started a fire.



RIP DieHard. Guess I'm using the Super Start piece of crap that came with the new Alero for now.

(I accidentally switched the power and ground for the starter, so when I went to connect the battery it was a little violent.)
I triple checked everything else over the build, so no worries about anything else. Never had any problems connecting the power/grounds before, didn't realize how easy it is to switch them.

[[ion] C2]

• wired HIDs
• battery successfully installed
• wrote tune to PCM
• installed fire extinguisher
• installed rear strut bar

Left to do:

• weld exhaust together, screw in O2 sensors
• bleed clutch

More snow coming tomorrow again. -___- I want to drive this thing.

[fisdad]

So close!!! I can't wait to see it at the assho meetup this spring.

[xXManwhoreXx]

I wanna see that projector cutoff againt the side of a building or something... looks really nice!

[[ion] C2]

There. Good as new. Just gotta throw on some JB Weld.



I want to put a 3" v-band on so I can disconnect and dump it, but this was free and quick so 2" at the stock piping was it.



Hilarious to see a v-band on the stock resonator.



Mmmm.





Bled the clutch, it works. Started it up a few times, worked fine. Fuel leak at the FPR. I apparently forgot an o-ring on the return line or something. I'll fix that tomorrow. It also has an exhaust leak at the 3" v-band on the downpipe because the flange was warped to shit when it was welded. I said it would leak. V-band flanges seal flat to flat. He said it wouldn't because the clamp would flatten it out (yeah okay ). Whattaya know, it ticks and leaks there.

So tomorrow I'll fix the fuel leak issue and hopefully drive it around and verify it's good. And hopefully confirming that the leak is at that v-band and having a new one welded better.

[sleepyalero]

3" is optimal for these when boosted.

[[ion] C2]

I know. 3" open downpipe seemed to work really well. I'll probably make a full stainless 3" exhaust using a 3" turbo muffler soon enough.

[sleepyalero]

Good choice

[[ion] C2]

• fixed fuel rail leak (was missing return line o-ring)
• added exhaust hanger to eliminate stupid clunking

Alternator wiring is screwed up, easily remedied tomorrow.
Didn't find the source of my fluid leak yet, but will tomorrow.
They're gonna weld on a new v-band flange to replace the warped one.

I drove the car around a bit today. Feels really good. Clutch is smooth. Turbo sounds nice. It's gonna be quick. Sure will be fun to drive.

[[ion] C2]

• fixed alternator issue
• fixed exhaust leaks
• identified fluid leak and solution

This is what's been leaking all these years. An engine plug with teflon tape. I picked up some good liquid thread sealant and will reinstall the plug this afternoon and let it cure until I drive it next Monday.



I also will cut off this stud down to the nut because it is way too tight with the v-band clamp in the middle of my downpipe and will cause rattling/clunking with any engine movement.

[xXManwhoreXx]

So close

[[ion] C2]

I cut off the stud, and that oil plug was the source of my mysterious oil leak all along. Wow. I tightened it and it completely stopped.

I think it's ready to drive for real now. I don't want to take it home unless everything is perfect though.

I'm making the shop weld the new v-band flange on because there's still a leak, I guarantee it. No one thinks it's significant or they say "it's so miniscule..." no it's not, as I drive it's loud and annoying as shit. I know what an exhaust leak at a flange sounds like, and I can't stand it.

Of course we're getting dumped on with snow. No driving til Monday-ish I'd say. I need to verify the clutch is actually working the way it should. I thought it was but when I was playing with the pedal today it felt different... idk we couldn't get it to really bleed much at all. It was very strange.

[[ion] C2]

Minor tasks completed today:

• re-bled the clutch just to make sure it's good
• audio tuned back up the way i like it

New v-band should be installed today, and hopefully when I drive the car around Monday (weather permitting) everything will seem OK and I'll take the car home and do some minor tuning in the next week or so after I break in the clutch some.

Some HD videos will come soon.

[guiguilandry]

KEEP UP THE GOOD WORK BUDDY !!!!!!!
tell me how your clutch is holding up too... I tried 2 differents brands on mine and never I was able to get all the power to the ground they always slips like a mofo...
SPEC stage 3+
and
Clutchmasters Stage 4...

[[ion] C2]

Camera phone doesn't get proper coloration. It's pure white with a tinge of blue on the edge.
Haven't adjusted the headlights yet either. My buddy is going to adjust the passenger side one a few degrees to make it level.





Car is fun to drive. Can't wait for the snow to be gone.

[[ion] C2]

also a video

[S8track16]

Seeing all the pictures in the thread, it makes me want a trunk without a spoiler.

[xXManwhoreXx]

I know the feels