Sloppy - Budget 1000HP Build - Built 6.2l - 4l80e swap - on3 turbo kit - Goal hit

[schul274]

I will use this forum to document my build. I started off with the goal of doing a "sloppy" or budget oriented build for 1000RWHP. My original goal was to do this for around 6 grand net (after selling my LSA, LS3, and TR6060).

Current status:

Break in has been completed, no issues there (oil looked great). Dyno'd a couple times on 93 and E85. Made 1001HP, ran out of turbo. Sheered converter bolts on they dyno, that took out the trans. Winter/spring of 19 building trans. Just took it out of storage.

Goals for this year are to get drivability dialed in. Would like to do a full exhaust with a cutout dump. Need to figure out cruise control.


New setup - built engine, 4l80e, on3 88mm





Details to new build:

Engine
Original Block (cracked): LS3 Al cast block - $800
2nd Engine Block: LY6 Iron Block - Bored to 4.065, decked, line honed - Bought engine whole, stripped it and parted out what I didn't need so it was $0, Machine work $1200
Rotating Assembly: LSX376 B15 rotating assembly - bought from someone who upgraded their LSX376 B15 to a stroker. Gapped rings to 1st ring-0.028 2nd ring-0.032 - $900
Cam: BTR stg 2 turbo cam (spec'd by BTR on the phone for auto car with 376 and pt88) - $650 for cam kit
Oil Pump: Melling high volume oil pump - $120
Studs: Speed master head and main studs (honed for main studs) - $200
Heads: 823s hand ported and valves lapped, decked by machine shop - $500 for heads, $300 for machine work
Valve Train: BTR hardened push rods, dual springs, needle bearing trunion upgrade on rockers - springs, push rods in cam kit, $130 for trunions
Motor Mounts: Prothane 7-518 motor mounts - $250
Other: Motion raceworks steam port, -10 AN fittings drilled and tapped into valve covers (1 per side), LS9 head gaskets, Underdrive pulley, ebay sheetmetal intake, TCI SFI 4l80e flexplate

Fuel
Injectors: originally bosch 210s, had tuning issues, then FIC 127lb - $1000
Fuel Pumps: Fore Precision tripple pump (not Fore innovations) - used of forum for $500
Regulator: Aeromotive 13139 boost referenced regulator-$200
Rails: came with intake - both fed with -8AN fuel lines, regulated after rails
Feed: -10AN
Return: -8AN
Flex fuel sensor: # 13577429 w/ ebay pig tail - power from coil, pinned into ECU - $30-40

Transmissions
Transmission: 220,000 mile 2wd 4l80-E from wrecked truck w/ transgo HD2 shift kit - $200 for trans $120 for HD2 kit
Converter: Precision 3500RPM stall triple disk converter - $1000
Converter bolts: Oriely's class 10.9 bolts (yeah right) now upgraded to ARP
Trans Pan: Ebay cast Al deep pan from TSI - modified and added temp sensor from TR6060 - $170
Controller: MSD Atomic TCM (recommended by RPM transmissions for 4l80e swaps on 5th gens) -$750
Cooler fittings: Ebay banjo fittings for a 90° and adapt to -6AN lines

I followed Dietcokes DIY for the 4l80 swap https://www.camaro5.com/forums/showthread.php?t=187548

Transmissions V2
See pages 3,4,5 for trans build.
Pulled apart the trans above
All new clutches, steels, bushings, seals, etc - 500
300m input and intermediate shaft - 400
Rollerized billet forward hub - 100
Rollerized case - 30
CK Performance bellhouse adapter plate - 500
Reid SFI bellhouse BH001 - 300

Total for the trans upgrades ~$1800

Turbo
Kit: on3 performance 2010-2015 camaro turbo kit ~$3000 w/ turbo upgrade
Turbo: On3 88mm journal cast turbo
Boost Controller: ebay one that didn't end up working at the dyno - would not recommend
Modifications to kit: 88mm turbo required bigger exhaust flange, just made short hood exit for now. Kit does not include a MAF bung, this was added as well. Had to grind one of the supports since it hit my steering column.

Tuning
Tuned at multiple boost levels, 93 and E85 - $2000

Total with other misc stuff ($3k-$4k) was ~$16k, sold my blower, engine, and trans for ~$8k, so net this was around an $8k build.

Next time I would skip building the engine because that is a giant rabbit hole for money. If you were to copy this, you should just by an LY6, gap the rings, cam, springs, gaskets, and make the same power.

Next Steps
Exhaust: goal is to have a full exhaust with a loud valve (boost) actuated fender exit, current driveability is okay, but it very loud and the police have let me know they don't think it is "cool"
Shifter: I'd like to get some momentary switches on my shifter. cant justify the really expensive shifters yet, so not sure what's next there.
Built trans: hoping to build a bullet proof 4l80e for ~$2k this winter
Aftermarket ECU: Considering going proEFI if I cannot get cruise to work
Turbo: would like to upgrade to a T6 turbo so that the car can do 1000HP without locking the converter


Pictures:

old setup - see budget lsa install
https://www.camaro5.com/forums/showthread.php?t=456603






teardown and buildup



















































































Minor setback











New block

























































if you buy on3, cut this brace, it will hit power steering





more clearance issues













new rad with relocated inlet

[blake-b]

Great work! I love seeing home garage builds like this.

[joshnmn]

Ditto. So jealous of your skills. Way to bust it out!

[BradySS]

I didnt think the on3 kit would work with an auto. I have a th400 and considered the kit until I read about autos not working. How close was that crossover pipe?

[schul274]

Originally Posted by BradySS

I didnt think the on3 kit would work with an auto. I have a th400 and considered the kit until I read about autos not working. How close was that crossover pipe?

I'll take a pic next time it's on jackstands, but there is plenty of room for the cross over.
The issue is the actual exhaust pipe from the downpipe. That is designed for manuals. I just didn't use it, because... you know... hood dump?

[FKNGRSY]

Awesome. love garage built cars. Keep it up!

[joshnmn]

Originally Posted by schul274

I'll take a pic next time it's on jackstands, but there is plenty of room for the cross over.
The issue is the actual exhaust pipe from the downpipe. That is designed for manuals. I just didn't use it, because... you know... hood dump?

[fif_gen_powa]

Nice job! In to see some numbers on that 88!

[farm rat]

Originally Posted by schul274

I'll take a pic next time it's on jackstands, but there is plenty of room for the cross over.
The issue is the actual exhaust pipe from the downpipe. That is designed for manuals. I just didn't use it, because... you know... hood dump?

Guessing you dont drive it in the rain

You know, those might be cool with diesel type flappers on them

[RealQuick]

Cool build!

[schul274]

Originally Posted by fif_gen_powa

Nice job! In to see some numbers on that 88!

Plan is to dyno on low boost this year. Probably wait until next spring to do high boost. Plan changes constantly.

[schul274]

Originally Posted by farm rat

Guessing you dont drive it in the rain

You know, those might be cool with diesel type flappers on them

Don't drive it much at all yet. Around the block, down the street. Once on the highway. I don't know how to tune, so drivability is pretty bad right now.

[schul274]

Originally Posted by BradySS

I didnt think the on3 kit would work with an auto. I have a th400 and considered the kit until I read about autos not working. How close was that crossover pipe?

Plenty of clearance.



I think the issue is the actual exhaust, it fits through here


some more general pictures of the underside


had to grind (maybe 1/8 inch) off the bell house a little for this side

[SSE 4 2SS]

Nice work going on... kudos... I’ll be following...