http://www.solsticeforum.com/forum Sub forum specifically for add-on forced induction (turbo or supercharger) major modification to the 2.4 l Ecotec en Sat, 21 Nov 2009 00:03:01 GMT vBulletin 60 http://www.solsticeforum.com/forum/images/solstice2/misc/rss.jpg http://www.solsticeforum.com/forum http://www.solsticeforum.com/forum/f93/hahn-stage-iv-sale-60638/ Fri, 20 Nov 2009 19:09:24 GMT check out classifieds thanks check out classifieds

thanks ]]> Forced Induction 2.4 l Ecotec gbm http://www.solsticeforum.com/forum/f93/hahn-stage-iv-sale-60638/ http://www.solsticeforum.com/forum/f93/my-defunct-turbo-project-60565/ Tue, 17 Nov 2009 00:45:24 GMT I'll start this thread by telling the story of why I bought my car and what the plans were, then I'll get on to the pictures.

Having recently graduated from college (2005), working in the auto industry, and living in the Detroit area I wanted to buy a sports car and I was adamant on buying an American product. When I saw the Sky at the auto show I was very impressed with the style and called a local dealership to put down a deposit. I took delivery in May of 2006 and immediately started planning/mocking up my turbo kit. My intention was to produce this in volume as a high end kit. I took on a "business partner" who was very knowledgeable but not very organized. After over a year we ceased communication and I was left with an exhaust manifold prototype that did not fit properly and an array of random parts I had purchased. I stared the project over, on my own, in the fall of 2007.

I worked with a great company on the new manifold. I made the necessary changes to make it fit properly and everything was moving steadily. I had the fuel system, pipe routing, intercooler mounting/placement, and tuning all worked out. The car was going to be completed in late 2008/early 2009. Then the market fell out. In one week my wife lost her job, my daily driver died, and my job was threatened. Sadly, I had to get rid of the Sky.

The project was left unfinished. Maybe someday I'll buy another Kappa used and finish the kit. At least that will give me some closure.

On with the pics!

Here are pictures of the first prototype. I was using a V-band flange on the manifold with a TiAL V-band stainless steel exhaust housing (GT2860). NO GASKETS! This required an external wastegate, which fit snugly between the turbo and head. This design was abandoned because I did not feel the tight placement of the wastegate could not be guaranteed with production variance.





I made the decision to switch to an internal wastegate in order to simplify the packaging and manifold design. This required me to change the merge collector in order to fit the new flange. The turbo placement changed slightly too, since I could pull the turbo closer to the head (and away from the power steering reservoir). Here's the completed manifold when it was tacked together. I'll have to get some pics of it now that it's done.



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