It is not a thirdgen, but I post here a lot so I wantad to share what I have been doing with my Corvette.

As you probably know I take a lot of pictures

I bought a Holley Stealth Ram and it is about an inch too tall for the stock Corvette hood. I wanted to keep the stock hood and came up with this solution.

 

A comparison with a non modified HSR.








On the Corvette.

 

I also bought a Garrett GT40 and that is the reson for posting here.

 

And some header plumbing.

 

 

Looks good. How did you attach and seal the plenum to the intake base?


How did the SC Crossfire run? Going for a little more HP with this combo I guess...

 

I am going to weld the plenum to the base. I don't see any reson to ever take them apart in the future.

It ran good, good enough to break the th700. After rebuilding it twice, $1500 the second time using, I gave up and installed a 4L80E. I never got a time-slip but I think that it had performance to be in the 12th on the quarter. I ran the Vortech for 5 years and now I wanted to try something new.

Whe following movie is from last summer with the 4L80E and Vortech. I lost quite a bit 'off the line' performance with the long fist gear (2.48 compared to 3.07 on the th700) and the stock diesel turbine in the 4L80E. The rear has a 3.45.

According to the owner this go-cart can do 0-60mph in less than 3 seconds. I don't think that he was that quick.

http://gs455.no-ip.org/Onsdag2005070...r/PICT0158.AVI

 

What schedule els are you using? Is that schedule 40? How are you shaping the end of the els to match the shape of the exhaust ports? Did you build some sort of mold that you press around the pipe to make them form to that shape?

Also, where did you get those flanges and how thick are they?

Looks good..


Thanks,
-Matt

 

What is schedule 40?

I am using a hydraulic press. First I press the pipe to the right with. Then I insert it into a fixture to keep it from expanding when I press it square. It worked well with these pipes. You see the blue press in some of the pictures.

I got the flanges from a company here in Sweden. They are 10mm ( 0.4" ) thick.

 

Schedule 40 equates to a pipe wall thickness of about .140".

Basically, he is asking what is the wall thickness of the bends you are using.

 

The wall thickness is about 0.1"

 

Impressed, as always with your work..... Makes me wanna do trip up north to visit sometime....

/N.

(now you have planted a Turbo seed in my head...)

 

Very nice. Any more progress?

 

Not that much progress. I got the holes at the center ports closed. The next task is to get the final welding done on the headers as they are now when it is still easy to do. Then I will finish the piping on them.

 

I'm going to be building a set of turbo headers in the near future and I was wondering if anyone has any opinions on combining the two center ports like was done here... I think it will make for a cleaner/simplier overall look but does it have any performance implications?


Thanks,
-Matt

 

The first part is welded now.

 

Lookin' good. I was wondering how the header bolts would fit against the pipe in some earlier pictures. Now that they are welded it looks even more difficult. You must be using hex key (allen head) header bolts. Correct??

J

 

I have stage 8 locking bolts that I used with my hooker headers.



I am not sure if I want to use them or not. I will weld pipes to the bolt holes around the center ports. That is the way the stock exhaust was made.



With longer bolts they keep the tension better when heated. If I use long enough bolts I can use hex heads in all positions.

EDIT: Added some pictures.

 

Update.

This is what the headers look like now:

 

I also bought an intercooler. The core is 24" x 12" x 4".

 

you got some skills man thats for sure. How much boost you gonna push. Are you gonna custom chip it your self? That Vette is not a Z52 right? I looks like it's got the stock suspenstion and 16 inch wheels. also looks like you got the carcoal metalic paint.

I'd love to hear and see that thing runn when it's all done.

 

It is a 1984 with standard suspension. The front is almost as stiff as 1985 and later Z51. The rear is stiffer than 1985 and later Z51. I do have a set of 1985 Z51 springs that I got about a year ago but I am not in any hurry to install them.



The rims are stock 1986 16" wheels.
http://www.joby.se/corvette/div/corvette_wheels

It has been repainted black in 1995 by a previous owner. It is a lot of dust on the pant now. The stock color in probably Light Bronze Metallic.

About a year ago I installed a Haltech E6K instead of the GM ECM so i can tune while driving now.







I have a 2-bar MAP sensor that is good for 15 psi boost so that is the limit right now. If (when) I need more boost I kan replace it with a 3-bar MAP sensor.

 

Cool Very nice man your gonna have a really nice ride once your done

I've got the Z52 package, and I'm gonna get some z51 bilsten shocks when upgrading, my car rattles and bounces around to much.

 

On the Stealth Ram mod why didnt' you just shave the top of the intake runners on the base? Seems like that would be a lot easier that cutting up the plenum then having to weld it together?

 

A few resons.

I wanted to keep the full runer length.

By lowering more at the front you gain extra clearance for the TB and intake duct too.

More than 1" would have to be ground off to clear the Corvette hood. Then both the thredded holes for the plenum bolts and the fuel rail would be gone. It would probably cut a hole thru into the lifter valley between the runners too.

It was not that difficult to doo. I could probably modify another intake over a weekend. With a cnc milling machine most of the plenum modification could be dome in a few minutes.

It seems to be plenty of room to do the welding.

I wanted to do something different.

 

The inner cooler tubing running throw the wheel well, thats gonnna be getting a little hott not much is it gonna cause any issues? I think it looks pretty cool.

BTW just wondering why not a super charger , just seeem like a big head ache with the turbo setup. I Know you can get some real pwoer with your turbo setup but it seems like a monster project. What kinda motor you got in it, it's not the stock block thats for sure. whats this thing gonna be pushing once all done

 

At 15 psi boost the charge air temp is going to rise about 40F. The pipe is going to get hot, but not hot enough to become a problem.

I bought a Vortech supercharger in 2000 so I have had one for five years now. I broke the rear axle and installed a Dana44 from a manual Corvette. I broke the th700 too many times and decided that I wanted something stronger. Last year I replaced the th700 with a 4L80E and a TCI T-Com comtroller.

The Corvette is a street car and I had been thingking about converting to turbo for some time. The good thing is that you can have full boost over a much wider RPM range, not just at max RPM. The bad thing is exhaust heat and lag.

As I said I have used the supercharger for five years and it ts time to try something different.

I am a bit worried about the engine. It is the stock 350 short block. It is balanced and has ARP bolts, but crank, rods and pistons are still stock. I have a different cam, AFR 190 heads and now the HSR intake too.

 

A few more pictures:

Pipe from turbo to intercooler. 2.5" that increases to 3" before the last bend.







Pipe from intercooler back to the engine.



And a few more with the air filer on the turbo.

 

More pictures ...

 

And some on the welded intake.

 

The headers.

 

Looking good man. I want to undertake a turbo project on my 91 corvette, but I don't have the nerve that you do, lol.

 

Maybe I'm not seeing this right, but are the headers just connected together with a flex coupling? Where does the exhaust go?

 

This is ****ing sick, awesome work there Joby!

 

Up and into the turbo.

 

Yeah but where does it go from the turbo wheres the down pipe

 

It is still looking good. Do you have any pics of where you put the oil return drain fitting on the pan (if you got to that part yet)? TIG welding between the tunnel rams must have been a pain. The intake came out very nice.

Is that an Ebay IC? How do you like the quality of it? Those look like "light blue" injectors. Are they Peak-and-Hold or Saturated? Who makes them? I haven't seen light blue ones like that before.

 

I have not built the downpipe yet. It is going back from the turbo and down at the rear of the engine. On thise pictures you see the that it is plenty of room for it where the frame turns out behind the front wheel. That is also the reson that the #8 exhaust pipe is going down instead of up like the others.

 

The oil return is going to the fuel pump block off plate. It is not done yet.
The IC is a 'china' copy that I bought here in Sweden. It looks fine to me.
I got the injectors when I bought another intake and I did not know what whey were at the time. I measured them and they are about 120 lbs/hr peak and hold.

This is the intake I got with the injectors and regulator.

 

120 P&H. Are you running SEFI to deal with the small idle and cruise pulse widths? Maybe megasquirt alternate batch mode. That would make them sort of look like 60#/hrs to the engine. Still a lot of injector though. I am guessing sub 1ms idle pulse widths. Probably in the .75ms range.

 

I know that they are on the big side but I have them so I am going to try them. I have a Haltech E6K in the Corvette.

 

I think going bigger on injectors is better. That should work just fine if the ECM can do somewhat of a SEFI firing of the injectors.

 

Downpipe and wastegate.

 

I realize that you Wanted something different. I have a buddy with a 1984 c4 and a stealth ram. He milled the fins off of the top, and milled the base where the plenum mounts by a inch. No fitment problems.

 

Some more progress this weekend.

 

Hey,

Whats the total height from china wall of:

TPI setup on C4
HSR in stock form
You're HSR

??

Thanks!

-- Joe
----------
Hrmm.. interesting...

I like joby's idea of welding the top but i'd still probably mill the base.

-- oe

 

TPI is identical on Corvette and Camaro but I don't have any measurements.

I measured my modified intake today.





The front is less than 22 cm ( 8.6" ).
The rear is 25 cm ( 9.9" ).

edit ...

Stock HSR is 10" high front and rear.
TPI is 10" at the rear and 8" at the front.









http://www.eecis.udel.edu/~davis/z28...0524TPIheight/

http://www.eecis.udel.edu/~davis/z28...724stealthram/

 

Three more pictures of the TIG-welded exhaust.

 

Thats one heck of a clean shop floor. Wish mine was like that

Looking good man. You gonna wrap them or ?

 

Man, one of these days I’m going to sit down and get a good look at the ‘vette motor mounts, I can’t seem to figure out how some of the stuff that clears on a vette actually clears…

What kind of pipe/tube is that? It almost looks like its all sch 10 or so plumbing stuff…