Boosted 2200 Build - Page 12 - Boost Forum

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Re: Boosted 2200 Build
Wednesday, August 14, 2013 6:54 PM
FYI on that aeromotive fpr:

On mine I had to take the black part off and rotate it 90* because the vac nipple was hitting the intake manifold. This is with 80lb siemens injectors and factory rail/manifold. It's worth rotating cause it's easy and it'll save you pulling it off a few times like it forced me to do lol.




"A car just isn't a car without a little blood, sweat, and beers." -- Shadowfire

Re: Boosted 2200 Build
Thursday, August 15, 2013 4:53 AM
Matt: I noticed that too. There was not enough room for the fitting so I ended up rotating it as well.

All, I'm really taking my time with everything and making sure everything is 100%. I don't want to rush things but it is killing me looking at the motor on a stand. Do it right the first time was the mentality while doing this build and I know when it's all together it will be what I want.


XtremE2200CaV: The Build has Begun
http://www.cardomain.com/ride/3864109/2001-chevrolet-cavalier-sedan-4d
Re: Boosted 2200 Build
Thursday, August 15, 2013 5:36 AM
Nothing wrong with doing it right!

What about pcv? I had a superfluous amount of blow by with my setup for some reason, I ended up putting on 2 ports that go to a catch can that pull vacuum from a block I have attached to the brake booster (regulated with a check valve too) and 2 more ports on the cover one goes to the turbo inlet and one has a filter that's just a vent. That should keep it under vac at all times (once it hits boost it should pull from the turbo inlet and the check valve at the brake booster port should stop it from charging the crankcase)

I was pushing about a quart of oil out of every hole in the block every couple of days, it was bad. I also think the pressure lead to premature turbo failure but that might not have been related.

Personally I suggest putting a few ports in the valve cover but I don't remember if you mentioned anything for pcv. I didn't plan for it and it was the most irritating thing to diagnose ever.






"A car just isn't a car without a little blood, sweat, and beers." -- Shadowfire
Re: Boosted 2200 Build
Thursday, August 15, 2013 10:26 AM
For PCV, I welded 2x 1/2' NPT couplers to my VC, then ran 2x -12AN lines to catch cans, then from the catch cans, 2x -12AN to the intake side of the turbo.
You will always have low pressure or vacuum in the crankcase.
The higher the boost, the more scavenging capabilities you will have.
You can check my profile for pictures.
Re: Boosted 2200 Build
Saturday, August 17, 2013 5:08 PM
Update:
Today was a great day, got alot done on the car, more than I was expecting. Got the entire motor mounted in the car, all bolted up. Got all the accessories bolted up, and have the charge pipes pretty much all done. Oil feed for the turbo is hooked up, I still need the pump for the return. I Need to buy some more parts, fuel line fittings, and a few couplers for the charge pipes. I had to fabricate a new bracket for the coolant tube. Only problem I had today was with the wastegate, as many people said in the beginning. It hits the radiator. I know they make adapters at certain angles, but i have to look and see whats available. I was able to mount the downpipe and everything just looks awesome.

On to the pictures!
Motor all cleared!


TC in:


Motor/turbo in:






Need to find 2 more screws for the MSD coils as the stock ones were too short.




Charge Pipes, tight fit but i think it looks good:


Oil feed:


Modified coolant tube bracket:


Underneath shot:


All accessories in:


More updates to come, Hopefully order the parts i need to connect the fuel lines, and finish the charge pipes this week. Also want to buy the radiator hoses and a belt.



XtremE2200CaV: The Build has Begun
http://www.cardomain.com/ride/3864109/2001-chevrolet-cavalier-sedan-4d
Re: Boosted 2200 Build
Saturday, August 17, 2013 5:49 PM
This makes me wish I would have painted mine before reinstalling it.

It looks good!




"A car just isn't a car without a little blood, sweat, and beers." -- Shadowfire
Re: Boosted 2200 Build
Sunday, August 18, 2013 2:12 AM
Everything is looking good. 1 word of warning, build a heat shield for the alternator. My buddy kept overheating and destroying alternators on his boosted 2200 because the down pipe was so close to it.



Re: Boosted 2200 Build
Monday, August 19, 2013 9:29 AM
Hey man, that's a good looking build. I will be doing a similar build in this coming winter hopefully. I have been contemplating it for many years and now that I'm out of the military I am going to do it. Its a 98 4dr sunfire 2.2L, so I'm glad I'm not the only 4dr that will be like this. Are you using the stock crank and just polishing and cutting it? I was wondering if they would hold up pretty well b4 I went and bought all my parts. Keep up the good work.
Re: Boosted 2200 Build
Monday, August 19, 2013 12:39 PM
I also wanted to ask what exactly are you doing for fueling upgrades? Just tuning or a piggyback?
Re: Boosted 2200 Build
Monday, August 19, 2013 6:50 PM
Crank is stock, but was cut, polished, oil chamfered, and came out awesome, The machine shop did a great job. As far as fuel goes, I upgraded everything. The stock fuel lines were rusted really bad, there are pictures on one of these pages. Upgraded to Russell 6AN lines throughout the car. The racetronix pump in the tank with cobalt stage 3 60lb/hr injectors and the aeromotive 13107 regulator with boost reference. I also threw an MSD booster pump inline to account for the change in diameter of the fuel lines. Increase in area results in a decrease in pressure. I will have a fuel gauge on the regulator for tuning purposes. The car will be tuned with HPT.

Small upgrade, cut down a fitting for the turbo return to have welded. It clears the starter, however im worried that the nut for the 10AN fitting will rub. This is really my only option at the moment. I also got my hands on a 4inch OD piece of aluminum tubing that I plan to modify for the filter connection. See pictures below.





More to follow


XtremE2200CaV: The Build has Begun
http://www.cardomain.com/ride/3864109/2001-chevrolet-cavalier-sedan-4d
Re: Boosted 2200 Build
Monday, August 19, 2013 8:15 PM
Very nice fuel system setup. Most people forget about the increase in area resulting in decrease in pressure. Ya I was wondering about the PITA oil setup you have for the turbo. I am going to start putting together a build of my own once I get home and finish up being in TX at Hennessey Performance attending Tuner School. I also took some EFI University classes as well as having some tuning experience and will be using the Sunfire as a guinea pig to hone my skills before I take on some of my bigger tuning projects, like my daily driver(built 03 Cobra, KB 2.2L, lots of extras). Most of my setup i will probably build or fab myself, just so I can have it exactly how I want it. Definitely will follow this build as I will hopefully get some good ideas from what you have been thru to get it going. Keep up the good work.

Re: Boosted 2200 Build
Tuesday, August 20, 2013 1:15 PM
Meant to say I had a 98 Sunfire 4dr with the 2200, not the 2.2L. I know the difference. Was talking about my s10 motor one the phone to wife while typing the post. Brainfart!!
Re: Boosted 2200 Build
Tuesday, August 20, 2013 2:20 PM
This oil setup is going to be very difficult.
Can you look at possibly getting a different starter?
I'm not sure if a different one will fit, but its worth a shot.
Start with a SBC, or a BBC, the 2200 block has some similarities between those.
Who knows, maybe the starter bolt patter are the same?
Re: Boosted 2200 Build
Tuesday, August 20, 2013 2:25 PM
I just went looking at starters online.
What if you remote mount the relay solenoid?
That is what is really in your way, and I do not believe there is any reason why it cannot be removed and remote mounted.
Extend the wires, and mount it to the lower radiator support.

Might be worth a try?
Re: Boosted 2200 Build
Tuesday, August 20, 2013 2:29 PM
Solution ..... Remote mount it!

Generic Starter Solenoid

But you get the idea!
This is what I would do.
Re: Boosted 2200 Build
Tuesday, August 20, 2013 3:19 PM
TJ: Good luck with your build. I have spent a long time with this build to do it right and make sure it will last. I have gotten some great help from alot of people on here. There are people on here who are very knowledgeable with these motors who can help you out.

Bobby: The starter was my first concern, i was thinking about looking into a Powermaster starter to see if i could rotate the solenoid. I did not think that a SBC or BBC starter might be able to work. If thats the case, im sure i have a starter somewhere because we are currently building a BBC and a SBC for the family race cars. I am going to try the fitting to see how it goes. I did order a Turbowerx scavenge pump for the return to make sure the oil leaves the turbo. I do not want oil building up into the turbo at all.


XtremE2200CaV: The Build has Begun
http://www.cardomain.com/ride/3864109/2001-chevrolet-cavalier-sedan-4d
Re: Boosted 2200 Build
Tuesday, August 20, 2013 9:46 PM
Bobby Higgins wrote:Solution ..... Remote mount it!

Generic Starter Solenoid

But you get the idea!
This is what I would do.


I already suggested that two weeks ago haha.



Re: Boosted 2200 Build
Saturday, August 24, 2013 6:04 PM
Update time guys:
Got some more work done on the car today, Was able to bleed the brakes, mount, plumb and wire the MSD Booster pump, finish charge pipes, and clean some things up. I received the turbowerx scavenge pump, as well as a few other parts. The transmission cooler lines and return fitting are done at the welder, and will be picked up this week. I was able to pick a new spot for the wastegate, so I ordered some 1/2" stainless flanges to have welded together. Im trying to figure out how everything needs to be ran, vacuum wise between the BOV, wastegate, Profec B, Boost Gauge, fuel reg, etc. etc. etc. I was also able to mount and wire the MSD coils.

Picture time:
Turbowerx Pump:


MSD Booster Pump:


Time to bleed! Wilwood DOT 5 fluid was used, remember it is a 16 piston system. Pedal feels AMAZING, There is a Wilwood Proportioning valve that will have to be adjusted.


MSD Coils:


New Wastegate Placement: My idea calls for mounting the wastegate down low, straight down section of pipe, and have the wastegate sit at the bottom of the radiator. The picture should give you a better explanation. If this works, I plan to run the dump out to the bumper on the passenger side


Gettng closer, Need to get radiator hoses, some more fuel fittings, and a belt, most likely this week as well.


More to come.




XtremE2200CaV: The Build has Begun
http://www.cardomain.com/ride/3864109/2001-chevrolet-cavalier-sedan-4d
Re: Boosted 2200 Build
Monday, August 26, 2013 5:36 PM
Re: Boosted 2200 Build
Monday, August 26, 2013 6:43 PM
Build is looking absolutely awesome! I have a ?? is RD fabs still doing the mani's? or am I to little to late.
Re: Boosted 2200 Build
Wednesday, August 28, 2013 7:18 PM
Nick, Im going to say they arent, but I could be wrong on that. I contacted Chris and dealt with him when my set-up was designed.

Update Time:
Got the return fitting bolted up to the turbo, fits nice and there is enough room for a fitting but it will be tight overall. I got the scavenge pump mounted and wired as well. Looks pretty good. I purchased new radiator hoses, new belt, and radiator caps for the transmission cooler. More updates to come.











XtremE2200CaV: The Build has Begun
http://www.cardomain.com/ride/3864109/2001-chevrolet-cavalier-sedan-4d

Re: Boosted 2200 Build
Thursday, September 05, 2013 11:57 PM
Looks good Vinny. Enjoy following your updates. Keep up the good work and I hope to hear/watch a video of a first start very soon!!!!
Re: Boosted 2200 Build
Saturday, September 07, 2013 6:41 PM
Thanks TJ, I cant wait to hear this thing lol

Update Time:
The past 2 weeks have been really good. I was able to get alot done. Found a way to mount the wastegate, plumbed the oil for the turbo return, wired the starter, and just so much more. I ran all the vacuum lines for the BOV, Wastegate, fuel reg, etc. Fabricated a 4inch tube for the intake, and bought the coupler for the turbo. I have injector harnesses coming. I still need to route a wastegate dump, and a few little things here and there.

On to the pics:
Turbo Coupler,

Changed the wastegate spring:


Wastegate is mounted:








Some more weld porn:




New GM 2 Bar map sensor, Was plug and play:


Intake Tube:




Oil Lines, 10AN Russell Nylon hose with protective sleeve over to protect against heat:


Tranny Gauge sensor:


Getting Tight:


More updates to come, hopefully starting it soon


XtremE2200CaV: The Build has Begun
http://www.cardomain.com/ride/3864109/2001-chevrolet-cavalier-sedan-4d
Re: Boosted 2200 Build
Saturday, September 07, 2013 6:46 PM
Fantastic work man, she's coming together real nice!



"In Oldskool we trust"
Re: Boosted 2200 Build
Thursday, September 12, 2013 6:32 PM
Update time: Picked up some new plugs, air filter, wire sleeve and injector harnesses. Pictures below.

Injector Harnesses:


NGK Racing Spark Plugs, U groove electrode and cut back tip for better spark. These are also 2 steps colder:




New K&N filter:


02 Sensor adapter, 90 degree, it clears!


MSD Wires, Moroso Ultra 44 Sleeve, 8.5mm:


Ready to go:


Rockers need to be adjusted:






More to come soon!


XtremE2200CaV: The Build has Begun
http://www.cardomain.com/ride/3864109/2001-chevrolet-cavalier-sedan-4d
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