Mike

69 Camaro 6.0 4L80E Twin Turbo

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Here is the next shop project for me.  It belongs to a friend from high school.  He bought the car 3 or 4 years ago as a plain jane green 69.  It spent a few years in paint jail getting a new coat of black.  Then it went to a small shop in KY where minitubs, Ridetech front and rear suspension, Moser fabricated 9" rear and Wilwood brakes were installed.   

He has also had a 6.0 built by Larry Sexton.  It's an iron block, stock crank, wiseco piston, forged rod, un-ported rectangle port heads, LJMS turbo cam etc.  The trans is a 4L80e built by Cameron Powers (crown vic).  It's got everything necessary for 1000hp.  He has a set of Comp 61mm? billet wheel turbos going on.

My job is to fab the turbo kit and exhaust.  Wire the Holley and the rest of the car.  Install vintage air.  Plumb brake lines and fuel lines.  Generally finish up the car.  He'll only need to have the interior installed when I'm done, but we may do that at my house too.

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I completely covered the car in "crash wrap".  I'm a bit uncomfortable working on a car with such fresh and nice black paint so I'm doing what I can to protect it.

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We are going to use manifolds instead of headers.  @JohnC do those manifolds look familiar?  We had three sets to try and John's 5th gen camaro manifolds came the closest to fitting.  I still have to notch them by the steering box and completely rework the "collector" end, but I think they will be nice after I smooth all the junk off them.

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66sprint6, Tino, mstrpth and 3 others like this

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NICE!  Super cool project and I agree with you on the paint deal, YIKES!  Looks like your covering all your bases by covering it like that!

Matt

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Niiiice car.   I use that wrap also. Word to the wise, pull it off every few months and re-apply. I left it on too long in a few places on the green coupe and it was hell getting it off. Never saw sunlight either, just became one with the paint. I think the spec is 90 days before needs to be removed, at least for the junk I used.

Mike likes this

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Thanks, I was curious about what might happen with time.  This paint is only a year old, so I'm concerned it is still curing and I thought I better keep an eye on it.

Ashley P likes this

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Not much has happened.  He's still ordering lots of parts so I can load up the engine compartment and build the turbo kit around it.

He bought the Holley accessory kit and that's on.  Waiting for the radiator,, fan, intercooler cores, brake booster brackets for a smaller booster, steering shaft flex joint and a few more small parts.

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66sprint6, Tino, Disney and 1 other like this

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Progress has been slow on the camaro.  We needed a lot more parts to start mocking everything up.  Pre-fabbed raidiator/fan assemblies are rediculously expensive.  So he bought a Be Cool radiator and a couple fans and I made the mounts and shroud.  Then the turbos could go in to build headers and downpipes.

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Tino, mstrpth and 66sprint6 like this

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That guy's gonna LOVE your work and how FAST his car is.....

 

....until you blow his doors off with your 4 door Caddy.  lol

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17 minutes ago, 66sprint6 said:

Wooow!  So the cast manifold to steel pipe joint will last?  If so that's incredible stuff!

Matt

That’s what everyone else says.  I’m undecided.  It welds decent but it’s not like mild steel.

13 minutes ago, Ashley P said:

That guy's gonna LOVE your work and how FAST his car is.....

 

....until you blow his doors off with your 4 door Caddy.  lol

This thing will eat my caddy up.  1000 less lbs and a couple hundred more hp.  He was here today and he likes it.

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It LOOKS amazing but I've always heard cast welded to exhaust pipe usually won't last.  Then I also see others do it and it seems to be fine.  If anyone can do it it's you!

Matt

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 I think it's an extreme test for sure...Mike, would you tell the process for that weld?  TIG I assume?  Any preheat, control cool down?  Filler metal = ?

Years ago I had a slip yoke leaking ATF, it was leaking around the "freeze plug" used to cap the splines.  I MIG welded it and the weld looked good, but about 20 seconds after welding I heard a "tink" and the weld had cracked all the way around!  lol  (I know that was the wrong way to do it, and I know you've put more thought/skill into than I did.)

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On 11/24/2018 at 10:41 PM, StreetnTrack said:

Nice!

Wish I could find my checkbook to cash in on some of my overtime pay to forge mine and boost it! :yum:

Sent from my iPhone using Tapatalk

Corrected. ^  :D 

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2 hours ago, Ashley P said:

 I think it's an extreme test for sure...Mike, would you tell the process for that weld?  TIG I assume?  Any preheat, control cool down?  Filler metal = ?

Years ago I had a slip yoke leaking ATF, it was leaking around the "freeze plug" used to cap the splines.  I MIG welded it and the weld looked good, but about 20 seconds after welding I heard a "tink" and the weld had cracked all the way around!  lol  (I know that was the wrong way to do it, and I know you've put more thought/skill into than I did.)

No special process.  Just tig it with 308l stainless filler.  Modern cast manifolds are apparently much cleaner than old stuff.  Or they are lower carbon content (steel), than they are like typical cast iron.

I’m going to add some bracing just in case, but it seems to weld pretty good.  But it’s not like a stainless to stainless joint.

Ashley P likes this

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What do you think about the different expansion rates of the cast vs steel pipe?  I'd fear that cast wouldn't grow with the steel at temp, plus when you add the pressure and vibration...  It seems like an uphill battle, but, you're a mountaineer and if it works it's SO worth it.  

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10 hours ago, Ashley P said:

What do you think about the different expansion rates of the cast vs steel pipe?  I'd fear that cast wouldn't grow with the steel at temp, plus when you add the pressure and vibration...  It seems like an uphill battle, but, you're a mountaineer and if it works it's SO worth it.  

Cast steel pipe and rolled or extruded steel pipe will expand and contract the same.  If I didn't make it clear above, this isn't exactly cast iron.  It's debatable what it is exactly, it's either cast steel or something very close to it.

This isn't new.  https://www.google.com/search?q=weld+LS+manifolds&rlz=1C1GCEU_enUS819US820&source=lnms&tbm=isch&sa=X&ved=0ahUKEwj2rqmVkvLeAhXLvVMKHUbXBc4Q_AUIDygC&biw=1920&bih=978&safe=active&ssui=on

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I know it welds like steel. I've welded on several factory LS manifolds and they do weld just like steel. I've done SS to manifold and MS to manifolds and both did very well. I haven't tried to support any weight through them, but I have no doubts it would hold just fine.

66sprint6 likes this

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