C2's Alero Updates

[[ion] C2]

OFFICIAL BUILD THREAD
Instagram: @turboalero

Current peak power levels are:
636 whp
543 lb-ft


Most powerful and highest torque GM LD9.







CURRENT MODS


Exterior:
- ESR SR07 19x8.5 wheels, polished, clear Cerakoted
- Continental Extreme Contact Sport 255/35R19 tires
- Custom quad projector headlights with 5000K HIDs
- Painted Ford Dark Blue Pearl Metallic
- 25% VLT tint, 35% windshield

Interior:
- Evo VIII Recaro seats
- AEM CD-7F 7" display
- Sony XAV-AX7000 receiver
- 4x6/6x9 Pioneer speakers
- Rockford Fosgate Punch P1 12" loaded enclosure
- Halotron fire extinguisher
- Blue LED accent lighting

Powertrain:
- Garrett G35-900 turbocharger, 0.61 A/R turbine housing
- Custom tubular turbo manifold
- TiAL 44mm v-band wastegate
- Full 3.5" stainless exhaust
- Vibrant Ultra Quiet resonator
- Vibrant bottle style resonator
- Vibrant Streetpower muffler
- Custom intake manifold with velocity stacks
- 62mm bored/sleeved throttle body
- TiAl Q blow-off valve
- Garrett 900HP intercooler w/ATP end tanks
- ARP Custom Age 625+ head studs
- Cometic .051" MLS head gasket
- Eagle forged 4340 H-beam connecting rods
- Wiseco forged .020" overbore 9:1 pistons
- 200deg/.360" intake camshaft
- 200deg/.375" exhaust camshaft
- Crower valve springs
- AEM smart coils
- Scott's Performance Wires
- NGK 3690 spark plugs @ .022"
- PTFE core braided fuel lines (-8 feed, -6 drain)
- Killerglass upper radiator hose
- Custom aluminum coolant reservoir
- UMS custom catch can
- Ron Davis custom dual-pass radiator
- Link G4X XtremeX standalone EMS
- AEM flex fuel sensor
- AEM X-Series inline wideband sensor
- AEM 3.5 bar MAP sensor
- Zeitronix fuel and oil pressure sensors
- Mac Valve boost solenoid kit
- TI Automotive E5LM brushless fuel pump
- Turbosmart fuel pressure regulator
- Injector Dynamics ID1700X injectors
- Radium Engineering fuel filter

Brake/Suspension/Chassis:
- CTS-V front calipers w/14" rotors, Hawk HPS pads
- Grand Prix GXP rear calipers w/12" rotors, Bosch QuietCast pads
- KYB AGX struts
- Eibach springs
- eBay rear strut tower bar
- Speedbuilt front sway bar
- Speedbuilt rear sway bar

Drivetrain:
- Clutch Masters FX850 Super Single clutch and flywheel
- Quaife LSD
- Polyurethane transmission mount bushings




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Had to remove previous completed stages due to 10,000 character limit in posts.


IN-PROGRESS STAGE 8 (The Endgame)

DO FINAL TOUCHES ON CURRENT CAR:
✓ Radium fuel surge tank
✓ investigate clunk noise during hard braking and subsequent quick acceleration
✓ fix clutch pedal intermittently stopping halfway down
- 3D scan engine bay, fabricate 4" equivalent cross section intake tube

BUILD SPARE (STRONGER) ENGINE:
✓ get another LD9 long block
✓ Pauter rods (CHV-220-512-1450F) with ARP CA 625+ bolts
✓ ARP main studs
✓ JE forged 9:1 strutted pistons, FSR, lateral gas ports, heavy duty wrist pins, coatings, .010" over
✓ bearings
- mildly ported head (widen and clean up exhaust side)
- assemble engine

PREP NEW CHASSIS:
✓ get a manual rust-free Alero
- fabricate fender bars/bracing
- weld X brace between rear strut towers
- fabricate half cage
- custom subwoofer box in cabin of car
- vibration/sound dampen anything that makes noise inside
- replace carpet, custom headliner
- reupholster interior with gray/dark gray fabric, seats with Olds logo embroidered
- wrap steering wheel
- 3D scan car, mock up possible new bumpers and skirts, determine color to paint car

AWD CONVERSION:
✓ junkyard CR-V trans and transfer case
- engine/transmission adapter flange
- AKDBuilt RT4WD Billet Viscous Coupler
- gearDriven Honda AWD K-Series PPG SYNCHRO GEARBOX Manual Transmission with Quaife LSD
- Drag Cartel AWD K-Series transfer case & gear set
- Oldschool Capital OEM rebuilt Civic Wagon rear differential
- custom transmission mounts
- custom center driveshafts
- custom rear subframe
- custom front CV axles
- custom rear CV axles
- custom rear control arms or trailing/lateral link setup
- rear hubs (undecided from which vehicle, GM Epsilon?)
- K-Tuned TSX shifter KTD-TSX-AC2 and cables
- custom adjustable coilovers
- fuel tank/fuel cell
- revised exhaust routing
- RPS triple disc carbon clutch with flywheel pilot bearing accommodation

RUSTPROOF AND PAINT:
- add tow hook to front subframe where it is accessible through bumper opening
- ensure proper drainage in body to prevent future rust
- fully rustproof everything possible
- paint car (either slightly bluer metallic, or extremely metallic candy red, depending on bodywork and mockups)

TRANSFER ENGINE AND GOODIES OVER TO NEW CHASSIS:
- modify A/C using custom lines and Link ECU control
- fabricate new aluminum water outlet with additional bung for level sensor
- install/configure Casco Universal Coolant Level Sensor 2030100057
- install engine/trans, brakes, wheels, fuel system, etc.
- install polyurethane engine mount
- silver TiAl Q BOV
- wire tuck engine bay

MISC:
- add bellows to wastegate tube for easier installation and ensuring v-bands seal
- add ambient air temp sensor
- configure TPMS with AEM display
- Volk Racing TE37 Ultra M-Spec 19x8.5 ET+45, polished
- create custom carbon fiber front splitter
- Centerforce custom clutch that has smooth engagement but holds the power