Camaro 6.5L TD project

[Rafedial1]

Casey,

well I thought since the car will be used mainly for drag/roadtrack racing that the solid mounts would be the best way to put the power to the ground. I am having second thoughts though. The natural vibration of a diesel is much more considerable than a gasser. My clearances throughout the drivetrain are very close. I did not want to take the chance of any contact with the body through the torque motion of the engine. To counteract the vibration problem I used ALOT of Dynamat sound deadener throughout the car, it won't be enough though. I guess I am willing to live with the distraction, until I build the next one, which will be much more streetworthy and user-friendly.

To everybody:
Yes, if you would like a 6.5L turbo diesel 4th Gen Camaro/Firebird I will build you one. My plan is to build 10 of these, depending on demand. I am documenting every measurement and detail as I go along. There will be performance options among lots of other options for the buyer. Come by the shop if you would like.

[Rafedial1]

Merry Christmas all!!

Alright, the car is coming along nicely. Ran into a couple issues. Anyone's help is appreciated.

I am building my own COMPLETE exhaust system for the car starting with 6.2/6.5 N/A manifolds. Are the outlet sizes/flanges the same for the 6.5L Turbo and N/A manifolds?

Is it mandatory to have the exh. manifold-to-head surface machined flat for the best seal before installing?

I noticed the factory exhaust manifolds use a donut style cintered metal gasket that fits into the manifold. On the other side is a flare and a 3 hole collar/flange that keeps the whole assembly together. Well I found the gaskets for the manifold easily but I can find something to work for the other side.

I thought about using a fabricated 3/8" flat flange mated to the flat surface of the exhaust manifold and a universal style DIY gasket material. My concern is the surface area is very small and leaks/failures seem very easy. Any ideas? I checked Heath's high-flow crossover pipe kit and it looks very nice. But again, I am not sure the 6.5 turbo and N/A manifolds have the same outlet dimensions. Ohh and a little too much $$ for me to just cut up later. The reason I am using the 6.5/6.2 N/A manifolds is for the remote mount turbocharger.

Next issue. I got my hands on a ESS out of a 93 6.5 turbo truck. I am looking to somehow use it for a tach signal and as an input for the stand-alone TCI 4L80E transmission controller. I know this has been asked before, but where do I start? Does the OEM ESS output a digital or analog signal? Can it be translated for use in a tach like Autometer's Part #3788 diesel tach. I see Autometer calls for using some cheesy 2-pole magnet deal that I don't like at all. Could this tach just be hardwired to the ESS? How about some type of crank-triggered sensor mounted near the balancer? I don't want something that'll jump around or be inaccurate? Any help?

Sorry for the long post, I just wanted to make my situation understandable.



Cody

[Burning Oil]

One thing I know is the ESS has 8 pulses per revolution. I had to know that when I did my Cummins into Chevy swap. We hooked up the ESS to a scope and read the # of pulses. I used the GM TCM to control the
4L80E.

[Rafedial1]

Keepin' pace with the project. Here it is after final engine placement.

Working on all the plumbing for fuel system, trans cooler, engine oil cooler, radiator, exhaust is just mocked up for alignment (working on keeping it sealed, see last post). Trans mount is complete, driveshaft cut and done, rear suspension completed. Re-working brake lines, removed ABS. Interior is getting a full set of gauges including EGT, Boost, Trans temp. Front suspension is complete including moving steering rack and coupler. Upgraded entire brake system to full disk/disk 12" rotor LS1 F-body specs (from small single piston front/drum rear) to slow this mutt down.

In the picture you can see the oil pan does hang below the front K-member by about an inch. It will be protected by a reinforced skid plate.

Car will be completely rewired with a universal style Painless harness.

Check out my previous post to see some questions I have not yet answered.

Car will have no HVAC due to my concerns for nose weight. 50/50 would be nice!

Brackets, brackets......fabricating

[93GMCSierra]

Wow, looking pretty good, can't wait to see how you mount and setup the turbo.

[trbankii]

Pretty amazing how fast your project has come along. I wish I could move my projects along that well!

[Rafedial1]

Well I thought i would start the new year by making a resolution to quit smoking cigs. So far so good. Happy New Year!

Cracked open the valve body on the 80E for some help from Transgo. What a mess! Replaced with some new solenoids and Transgo hard parts and Delco filter. Trans fluid looked ok before dissassembly. Also got the Transgo valve actuator repair kit. Now working on TCI Controller wiring....

Went with a Wolfe Racecraft rollbar with pre-notched tubes for strength, racing rules. Car got some updated interior pieces, Hurst shifter linked to the 80E.

I have some experience with DC electrical wiring but not enough. It has been a major obstacle with this car. I was fortunate enough to find some help from a previous GM tech for his advice about my setup. but it's intimidating!

Ohh, and these posts are somehwat delayed.

[Rafedial1]

Progress:

Plumbing completed
-fuel system sending and return
-trans cooler sending and return
-turbo oil sending and return
-radiator
-oil cooler sending and return

Wiring completed
-gauges, turn signals, headlights, brake lights, hazards
-windshield wipers

-Intercooler mounted

-Turbo mounted

-undercoating 1/2 done (Por15)

-switches for glows, fans, FSS, oil pump, vacuum pump done

Here are some progress pics.

Don't forget if you want one of these hand-built PM an offer!!

[Burning Oil]

Would love to see more pic's of the turbo. How are you returning oil to the engine?
How are you going to supply compressed air to the engine

[Rafedial1]

Would love to see more pic's of the turbo. How are you returning oil to the engine?
How are you going to supply compressed air to the engine

here's another pic of the turbocharger position.

I am returning the turbo oil to the engine with a gravity drain mated to an electric "scavenge" pump rated for oil temps over 200 deg F. Manually switched with warning indicator/redundancy.

The cold side/compressed air will be sent to the intercooler on the front of the car along the rocker panel and bottom of the car with 2.5" exhaust tubing, silicone couplers, and t-bolt clamps. Of course this has yet to be completed.

[93GMCSierra]

Wow, that is very cool. if that is going to be driven on the street though is the open air cleaner behind the rear wheels going to become a problem?
I know just for the track its fine.

Oh and with the distance you have to push the intake air will you need a higher psi boost?

[Rafedial1]

Wow, that is very cool. if that is going to be driven on the street though is the open air cleaner behind the rear wheels going to become a problem?
I know just for the track its fine.

Oh and with the distance you have to push the intake air will you need a higher psi boost?

The air cleaner and turbocharger are located where the fuel tank used to be, pretty high up in the chassis. Front my past experiences with F-body's none of the outside elements ever collect here. The filter will be getting and Outerwear (common on ATV's) to prevent any moisture from getting in. If needed i will fab up a shield to direct cool intake air and keep everything else out.

I appreciate any and all questions about the project. If you see something you would do different or that doesn't look right feel free to comment, I am always open to suggestion. Thanks.


Cody

[6.5 Detroit Diesel]

Man, if I had the money, this would be on my list. Looking awesome. What turbo are you running?

[Rafedial1]

Man, if I had the money, this would be on my list. Looking awesome. What turbo are you running?

Thanks Detroit!

The turbo is a HX35W from an '01 Dodge 24 valve H.O. truck. Picked it up really cheap with zero shaft play and no seals leaking.

The boost will be controlled by a Synapse 40 mm wastegate. Almost infinitely adjustable pressures, also picked up cheap, used. No diaphragm to wear out.

Will be starting off at 8 psi and working my way up till it puts a hole in the side of the block.

[6.5 Detroit Diesel]

Though highly not recommended, I have hit 24 psi a few times while towing.

[Rafedial1]

Well I thought i would start the new year by making a resolution to quit smoking cigs. So far so good.

Fail.......back to a pack a day.

[BigRabbitMan]

Fail.......back to a pack a day.

Don't worry about it, you can do this later - I did.

This project has rekindled my thoughts on my future conversion project of a Duramax into my FMC rear engined motor home. I have the LBZ in my garage. You are doing a very clean install and have been very resourceful in adapting things to fit and doing good metal work. I anxiously await the finished unit with lots of pictures.

[Rafedial1]

It's alive...

I just couldn't wait 'till I got it on the road.

Here's what went on in my head today. I had figured out the exhaust issues and fabbed up the wastegate plumbing. The oil was already going to the turbo and the scavenge pump was doing it's job. The cooling system was done, tightened up the clamps. The glow plugs wired, the FSS wired, starter wired, Tci trans controller 75% wired, gauges. Fuel sytem plumbed, fuel cell filled with some fuel and some additives, then primed the whole system. The trans cooler and system filled and flowing pressure. Tci programming done which includes many many calculations. Lub Specialist Oil Cooler tight and flowing. Serpentine belt system correct. Alternator wired and 95% total wiring completed. Oil primed, Baldwin filter. I sat and went over everthing in my head 100 times and was pretty confident she was ready.

So I thought I would crank her over and see if she would fire. And she did.....
http://s648.photobucket.com/albums/u...t=MOV01065.flv

[Rafedial1]

Don't worry about it, you can do this later - I did.

This project has rekindled my thoughts on my future conversion project of a Duramax into my FMC rear engined motor home. I have the LBZ in my garage. You are doing a very clean install and have been very resourceful in adapting things to fit and doing good metal work. I anxiously await the finished unit with lots of pictures.

Thanks for the compliments. Your project sounds interesting, can't wait to see it in progress! Good score on the LBZ engine too!


Cody

[trbankii]

So I thought I would crank her over and see if she would fire. And she did.....
http://s648.photobucket.com/albums/u...t=MOV01065.flv

Music to the ears!

That'll scare those kids at the stoplight in their Hondas with the coffee can mufflers!