ZL1 #140 starting mods

[1st Gen Forever]

Updated Oct 17, 2012
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Here it is folks. The chart!...

Blue is stock, Red is modified. This is an amazing combo!

Read the whole thread to see what I did to it.
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End Oct 17, 2012 Update
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Over the last couple months, I've been compiling a plan to modify my ZL1 bumping the power by a healthy amount while still maintaining daily drive ability on pump gas. Initially I was going to do pulleys, CAI, and a better heat exchanger getting it done in time to drive the car from AZ to Camaro5 Fest in Aug. At this point, the project has grown substantially. I have my blower in transit to KD Innovations for porting and my new headers in transit to Swain Tech for their White Lightning exhaust coating while my ZL1 sits in my garage torn down. I probably won't make Camaro5 Fest but in this thread, I'll document my project for others that may be interested.

So here's what I've done this week:

First I took the ZL1 to Loud Pedal Motorsports in Tempe, AZ for a baseline run. Our weather here is very poor for making power. It was 97*F, 28.9 in-Hg, and 16% humidity. The density altitude was 5073 feet. Here is a pic of my ZL1 on the dyno and the uncorrected results for the baseline.



After the baseline dyno run, in my own garage at home, I started the teardown. With the way the engine sits under the cowl and the fact that I don't have the means to lower the engine out the bottom of the car, I ended up removing the wipers, plastic coverings from the cowl, and drilling holes in the metal bottom of the cowl to access the 6 rear bolts of the inter-cooler.




Next steps will be to install KD Innovations heat exchanger up front.

[typhoidfvr]

Ouch! I just can't see myself drilling into my new ZL1 (if I owned one), but hey, it's your car...do want you want!

[1st Gen Forever]

Originally Posted by typhoidfvr

Ouch! I just can't see myself drilling into my new ZL1 (if I owned one), but hey, it's your car...do want you want!

It's all good. They won't be visible when it's back together and I'll plug them with removable plugs for future disassembly. Greatest risk is capturing the metal filings so they don't get where they shouldn't.

[evolve]

Great first mod (cooling)!! Heat definitely takes a toll on a PD car.

[DanSS24]

subscribed...

[DangerZL1]

I wasn't aware all the bolts weren't accessible without dropping the engine. Thanks for taking the time to document your build. I'm sure I'll learn a lot more from your upcoming posts. Are you considering using a higher capacity IC pump? Any idea how much power porting the blower is worth?

[1st Gen Forever]

Originally Posted by DangerZL1

I wasn't aware all the bolts weren't accessible without dropping the engine. Thanks for taking the time to document your build. I'm sure I'll learn a lot more from your upcoming posts. Are you considering using a higher capacity IC pump? Any idea how much power porting the blower is worth?

Not sure on the power gains from the ported blower alone. There's a thread started by KD Innovations on results of their car and they're the ones doing my porting...
http://www.camaro5.com/forums/showthread.php?t=230648

I am considering a higher capacity IC pump. I actually have a whole list of parts that I originally broke into two phases only because of cost but now I'm considering doing it all at once to avoid having the car down twice. It's too much fun to drive to have it up on ramps in the garage!

[DangerZL1]

I think you're taking the best approach and doing most of your mods at one time. I say most because something else will hit the market as soon as youre almost finished. A lot of the parts I like are sold by different vendors and some have just come out. The pump will be a big bang for the buck especially where you live.

[ADM PERFORMANCE]

Originally Posted by typhoidfvr

Ouch! I just can't see myself drilling into my new ZL1 (if I owned one), but hey, it's your car...do want you want!

Its all good if the owner of the car does it this way,But steer clear from shops that cant figure it out edgewise.

BTW-You can get them out without dropping the cradle like GM suggest.

[DangerZL1]

Is there another way besides drilling holes or dropping the cradle?

[1st Gen Forever]

Originally Posted by DangerZL1

Is there another way besides drilling holes or dropping the cradle?

+1

I'd be curious to not only know what the 3rd way is to get them out but how are you going to properly torque the bolts with a torque wrench when going back together without the holes or dropping the cradle?

BTW- This is the type of plug I'm going to close the holes with:

[ADM PERFORMANCE]

Originally Posted by 1st Gen Forever

+1

I'd be curious to not only know what the 3rd way is to get them out but how are you going to properly torque the bolts with a torque wrench when going back together without the holes or dropping the cradle?

BTW- This is the type of plug I'm going to close the holes with:

Secret set of tools

Only use on the back ones.

1/4 snap on swivel,1/4 deep craftsman socket,6" extension


Once again I said it was OK if an owner does this to his car.

[Sack Rat 2SS]

It is my understanding that on the Cadillac CTS-V, same blower different top, there is room in back to remove the rear bolts without droping sub frame or any other mods. Lucky Caddie owners.

[1st Gen Forever]

More work this weekend. I pulled the front fascia off to see how the new KD Innovations heat exchanger fits in there. It's not permanent yet as I'm pretty sure I'm going to do the cam and heads now rather than waiting so I'm going to have to pull the radiator and A/C to install the cam.

Stock HX before removal:


Difference between stock and KDi HX. 3/4" vs 4" thick:


KDi HX installed: