not if you don't look at it

keep the corrections coming.. Thanks.

Headers suck

especially when the EGR fitting on the passenger side is in the wrong spot.

 

You're in luck....no EGR on a C5

 

Good luck with the build. I'll guess 400/380

 

Looking good.

 

Looks like everything is coming along. No matter what the numbers are, you are going to love having the extra power. Keep it up!

 

yea I guess that's an air injection tube... wrong gas wrong direction

 

Good to see you yesterday Mitch even though you are uglier then ever. I will admit my friend you are doing a hell of a job. I wish you luck on this. I could have never tackled this task. Replacing my transmission right now is a pain in its self.

 

Well, if you ever need help checking your transmission fluid levels, give me a call

 

It's been awhile since I updated this thread.

I had a couple of hiccups related to the AIR injection tube location as well as not having O2 extensions. Because nothing is availible locally - the mail order process added weeks to the project.

After I finally received the 2001 AIR injection pipes - I found that I had to take the manifold off (yet again) to get the thing back there. I was hoping I could fish it through but gave up after a short period. Took the manifold back off and installed the AIR injection pipe.

Here we are with the steering system back in:


And the throttle body:


And the cooling system and AC condensor:


And the hood installed:


So I'm pretty much done. There's no photos of the exhaust system under the car. There's plenty of photos of that on this web site anyway.

It fired off without hesitation! The long tubes combined with the corsa pace car catback is LOUD. Anything over 2000 rpm and you have to raise your voice to have a conversation. In 6th on the highway, you can hear the exhaust - but it's not bad. I don't think it's obnoxious enough to warrant going to a Ti system. The car is currently running rich and the odor is annoying. That should be tuned out pretty easily. The cam lope with the stock tune is barely perceptable - but there.

Tuning: Got in touch with Force Fed locally and talked to their tuner guy. He took a look at the parts that went in and immediately told me the stock injectors are too small. I was scheduled for Monday - but I doubt I'll find injectors in time. He recommended 36# bosch injectors. p/n: 0 280 155 868 or 0 280 155 811.

 

One more thing - I forgot the lock to lock turning of the steering system to bleed out the power steering. Took a day to get the bubbles out and had weird steering sensations (occasionally stiff wheel). The instructions were to go lock to lock a bunch of times while the wheels were off the ground.

 

Poor car. It went back together, just as filthy as it came apart. What a shame.

 

She's a daily driver/track car. no garage queen. Actually the yellow one doesn't even get the garage

The condensor and radiator are much cleaner. The pressure wash from the back side = a shovel full of dirt and rock on the driveway.

 

A warm afternoon,a bottle of simple green and a garden hose will clean things up nicely.

I'm cleaning mine as I go and it's quite a job I must say. Mine had a front seal leak for who knows how long. But the front and sides of the engine had at least 1/4" of accumulated oil and dirt on them. Lot's of brake clean. I bought a case of it.

Ron

 

404 whp is my guess

 

I took the car up to Billy at Force Fed Performance in Roseville for a tune. I updated the injectors from 24# to 36# per his request before I went up there. The stock tune hated the 36# injectors of course.

The O2 sensors were not working and he found that the fuse had blown and continued to blow. One of the front O2 sensors must have grounded out on a header pipe.

He said he could still tune it - but I'd have to come back after the O2 thing was squared away to double check it.

It took a couple hours - but the results are fantastic. Peak HP is great - but the drivability is back. I can lug the car from 800 rpm without issue all the way to 6500.

I'll post the dyno as soon as he emails it to me.

Result: 412 hp

The dyno from before is a different model - so it's not completely apples to apples.

So - 80 HP for all that work and money.

Cost Breakdown:
$50 pre dyno
$25 cam specification
$420 custom cam grind
$470 243 heads (used)
$144 PAC 1218 springs
$60 TrickFlow 7.425 push rods (used)
$375 gaskets, head bolts, LS7 lifters, trays, pulley bolt, LS2 timing chain
$55 new AC tensioner
~$100 Fluids
$40 AC recharge
$221 LS6 Intake (used)
$24 Intake gaskets
$136 36# Bosch Injectors (used)
$20 scotchbrite
$600 Headers/Cats/X-Pipe (used)
$66 O2 Extensions (expedited shipping)
$579 LS7 Clutch/PP/Flywheel, LS6 TO bearing, pilot bearing
$45 2001 Air injection tube
$50 crank harmonic balancer
$50 new belts
$3830

 

Great job Mitch!
I bet that extra 80 hp feels pretty good!
Ron

 

Great job on the DIY. How much torque did you make?

 

torque was 379.

 

Awesome end product brother.

 

Thanks man!

O2 sensor: the front driver side sensor plug had melted against the header. Not terribly bad - but to the point that one of the internal metal connectors had grounded out against the header. Look up - there's the factory clip to hold the wires away from the exhaust. Completely unused Pull the harness away from the exhaust and attach to the clip. All better.

I'm sure there's a reference to not using a manual in there somewhere. Hopefully Lucky will point it out. Probably something about not using old O2 sensors too.

After living with it for a week - it's a transformed car. Both in performance and sound. It's awfully loud with the corsa pace car pipes. Thinking about the Z06 Ti's.