And the Fun Continues.....

[BlackJack]

This thread is a continuation of the old thread found here (http://www.aleromod.com/forums/showthread.php?t=11588)

Ok, I was having problems uploading the latest pics (too large) so I deleted them from the server and am starting over.

Next up, since the turbo install requires the battery to be located to the trunk, and NHRA requires a battery in a passenger compartment connected area to be sealed and vented to the outside, the next mod is complete. No more open battery in standard hold-downs.

http://i81.photobucket.com/albums/j202/qaddamage/myturbo/battery.jpg

after completing the battery install, I figured since I had the camera out, I'd get a side-by-side comparison of the new throttlebody vs. the stocker. Hell of a difference. The upper intake manifold is being built currently, and is full custom "barrel style". I haven't polished it yet though, that's next on the list. Also in this pic, you can see the huge MAF installed and fully operational. I know, the intake t-bolt clamps aren't on quite straight, but i'll tighten and straighten that up as soon as I get the turbo back in.

http://i81.photobucket.com/albums/j202/qaddamage/myturbo/throttlebody.jpg

[alerored04]

BJ what is the diameter of your new TB?

[BlackJack]

a little over 75mm

[alerored04]

damn, you are gonna knife edge it and polish it up then right?

[mustang_killer]

Dude, Thats just Jaw Dropping great.

[BlackJack]

thanks.......it's already knife-edged, I just have to polish it :)

[Trickyslick]

That is such a sweet Alero.

[ptrudel]

holy shit...i'm so anxious to see a real dyno/track run of this car....simply amazing man

[steve-o]

cant wait to see the finnished product!, althought projects like that are never finnished ;)

[battistoni21]

dammn blackjack i can't wait to see that finished

[sushko]

hey guys
should i get a supercharger or turbo but i have 80,000 miles on it
What should i do

[battistoni21]

uhhhh off topic rook

[BlackJack]

please post questions like that in a new thread or just click this link.
http://www.donkeypunchperformance.com/blackjacks_uploads/turbo_vs_sc.htm

[AlbinoMonkeyRat]

so...you're overcocking the V6? lol

[BlackJack]

nooooo, it's already "overcocked", and you're number 2 to notice out of the 3 months it's been there.....good job :)

[Coldfire]

Yeah I just want to fastforward to when this is done and see a vid of it at the track ;) Oh well, the anticipation will make it better when it's done :thumb:

Edit: BTW I see you've changed your signiature slightly...are you really planning on a custom hood?

[BlackJack]

ok, for the sake of consistency, I'll move the headers over to here, and shortly, a few more things to add.

http://i81.photobucket.com/albums/j202/qaddamage/myturbo/header2.jpg
http://i81.photobucket.com/albums/j202/qaddamage/myturbo/header1.jpg

[BlackJack]

Next up....P&P LIM. You can see it's been hogged out. I know, I know...I need to hit the whole thing with some degreaser...heh. Been burning the midnight oil getting this thing going. P&P heads are already installed, SI stainless valves, Manley 350# valve springs, molly pushrods, etc.

http://i81.photobucket.com/albums/j202/qaddamage/myturbo/enginelim.jpg

Painful, this is. Have to cut apart the injector harness and hand-wire in the new injectors. You can see the old stockers in the background (the little thin ones) versus the new 42.5# injectors installed in the rail. That's me assembling the clips in the pic.
http://i81.photobucket.com/albums/j202/qaddamage/myturbo/fuelrail.jpg

[Trickyslick]

Looking sweet would love to se it.

[ptrudel]

thats insane man....just keeps gettin better and better with every update...it's nice to see you're not stopping short on any of the details either...great work man, keep it up

[jackal2000]

the best will be when he shears his wheel studs at the track LOL


or did you upgrade those too???

[ptrudel]

hahaha yeah eh that'd be somethin to see :p

[strtrydr]

wow ... deffinitely should have made the trip this weekend :( would be a sight to see ... I'm plannin' on making the trip sometime soon.

[BlackJack]

thanks guys...lovin the motivation.

wow ... deffinitely should have made the trip this weekend :( would be a sight to see ... I'm plannin' on making the trip sometime soon.
Probably good that you didn't......as you can tell, I wouldn't have had much time to BS around :)

crossover pipe now tacked up on the mock-up engine...

http://i81.photobucket.com/albums/j202/qaddamage/myturbo/xover.jpg

[jturkey69]

is that a flex piece in there??...i hope you plan on using something a lil more lasting? It looks like flexpipe for the qwik fix exhaust? Maybe a stainless flex piece from an import

[BlackJack]

actually, it is a flex piece and intentionally. It will outlast a solid piece because of the weight of the turbo (it's larger than normal) will put stress on the welds in a solid pipe application even with a brace. So it will work perfectly.

[jturkey69]

i know its not supposed to be a solid piece...never said it was...but i did say that it will not last that long...meaning it will leak within 6 weeks to 6 months...take your pick....i meant to use a flex from an import car like a nissan stanza etc. with the woven braided flex made out of stainless

[BlackJack]

not sure on that one, but the guy that's making them has been designing his own turbo headers/exhaust for a few years now on several different vehicles. He recommends it, so I guess I'll have to find out the hard way :)

[BlackJack]

Headers are now shipped, and I just need to finalize the setup with deciding on placement for the wastegate, and get the oil return line piped into the oil pan. Then we're ready to roll. These pics are of it mounted on a mock-up engine and yeah, that's an older 4t60 transmission in the pics.

http://i81.photobucket.com/albums/j202/qaddamage/myturbo/PHOT0009.jpg
http://i81.photobucket.com/albums/j202/qaddamage/myturbo/PHOT0013.jpg

[battistoni21]

that looks soooo sick man......

[mustang_killer]

Holy F**K, thats all I can say...... Wow.

[jturkey69]

do we have that much room for the downpipe??

[BlackJack]

hope so, it was test fit into a GA since he didn't have an alero to go by when tacking them up. lets pray :)

btw jturkey....I didn't mean to sound like a dick before. I sometimes leave out the details behind what I'm thinking. I dont think those headers would be a good idea for N/A due to runner diameters and final merged diameter. I think a little more flow restriction would be better suited to the scavanging effect on an N/A application. I may be wrong, but I'm pretty sure a smaller diameter setup would be better for the non-turbo apps. That on top of...if I were making a header setup for N/A I would re-think the routing all together to prevent too much of a U-turn. that's why the GP's use a "U-bend delete" pipe.

[jturkey69]

i agree, well the front bank would work..LOL, the guy did an awesome job, what size are the primaries?...it looks to be a 3" dp, and the clamps are first rate. i feel sorry for the trans, then after that is built, then it would be the tires...BTW, how familiar are you getting with the tuner

[BlackJack]

heh, me too.....I've purchased a tranny that I think will hold quite a bit longer than my original, but we'll see.

I'm getting decent with the tuner so far. The concept isn't foreign to me, but some of the modifiers for the base tables can get tricky, especially if your engine is governed by more than two fuel modifying criteria at a time.

[strtrydr]

^Still amazed everytime I look at the progress on your car!

Now we can see how good you have gotten with the PT :)

[Trickyslick]

Your car is so figgin sweet. Got to see it sometime.

[BlackJack]

not like I dont live nearly around the corner from you two....it's what....less than an hour from Tucson, and maybe 2 to 3 hours from Phoenix?

[burg03]

well you are close to the,but you are faaaaaaar away from me

[billytheman1188]

Hmm u probably get this all the time blackjack, but when do u think you will be finished with the car????? and when are u getting that on a track?

And u expect to have around 450hp?? i think thats what u said on another thread. Oh and do u have any pics of your whole car....i wanna see that shitlol

[battistoni21]

its crazy, i read from the beginning to here, and im amazed by all the process you've made.... good job man

[BlackJack]

Hmm u probably get this all the time blackjack, but when do u think you will be finished with the car????? and when are u getting that on a track?

And u expect to have around 450hp?? i think thats what u said on another thread. Oh and do u have any pics of your whole car....i wanna see that shitlol

I have to be honest, there will never be any such thing as "finished with the car". I'll probably always be upgrading, tuning, tweaking, modifying, until there is just no more speed to be had out of it in a street-legal state.

I expect that the engine will be capable of putting out 450hp and hold it, but I dont expect the transmission (the modified 4t45) to be able to hold for long. The transmission that will save the day will be the 4t65 once I get ready to tweak it all the way out, which I expect to happen next year. I'm letting ZZP handle all the details on that one, and it might even include a 4th gear delete.

[billytheman1188]

Yea i knew u would say that, cause i know there isnt an end. but when do u think u will have that thing out on the track......cause i wanna know what it runs

[BlackJack]

I'm estimating a month out. I still have two weeks worth of fitment, adjustment, additional welding, etc., then I estimate more time beyond that for a very cautious tuning process. It would be easy to tune on a 5-6psi slap-on kit, but we're starting this out at 12psi (wastegate spring) and working it gradually up to 15-18psi range.

The track is also more than 1,000 ft elevation from where I'm building this, so that will take some extra time also. Nothing would suck worse than getting it all tuned correctly, then take it to the track and blow it to pieces. Sorry for the delays, but I'm not in any rush, which should prevent some costly errors.

[Trickyslick]

Any pics of the whole car...

[billytheman1188]

Yea i know what your sayin, better to take your time and do everything right then rush it. After all the work your puttin in u dont wanna fuck it up, that would suck. What kind of car do u drive while workin on the alero?

[BlackJack]

heh, sorry....I was busy and checked this thread then got called away and forgot to reply.

What kind of car do u drive while workin on the alero?
I drive the Alero while working on the Alero. I've been doing this as strategically as possible so that the car is never down for longer than a weekend.

[Orion]

BlackJack, what have you done to the car to lighten it's overall weight. THe Alero seems to be a freaking lead sled. And we all know the more power and the less weight you have the faster the car will be overall. What have to you done to the interior, exterior, Rims, Tires, extra to better your times in the long run?

[BlackJack]

first order of business is to see how fast we can get it running without stripping it down (full street trim). Then little by little, the power/luxury items are going bye-bye, starting with power seats, windows, ditching the A/C, power steering replaced with standard rack and pinion, etc. Eventually I'll have the interior components modified into quick-release/remove so that I can easily convert it from street to strip without losing all the daily comforts. We have extreme temperature variances here especially during fall and spring. It can easily go from a 95 degree day to a 40 degree night in one 24-hour span, so I'm not exactly eager to permanently remove everything. Lots of things will have to go away though to make way for the 12 point cage. I just have to be selective.

[HazMatt24]

any chance you are gonna have the car at HIN next weekend?

[BlackJack]

Not a chance in HELL.

1) I've still got extensive tuning to do and work the boost up as far as I can get it.
2) I HATE import cars.
3) I not into whores.
4) because of #'s 1-3, there's no reason to go.