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Discussion Starter #1
I'm currently adding further modifications to my GXP. I've replaced the silicone turbo pipes with mandrel bent aluminum, put in a Performance Werks intercooler, Solo Mach Exhaust, GMPP tune and upgrades with both front and back cross-member stabilizers and .25" tunnel brace. I also put on a set of 18x8.5 wheels from Stern (before they went out of business) and had them powder-coated to match the silver of the front wind screen and M bar. It's shod with 18x255/35 rubber. I'm putting in Comp Cams stage II cams, Opel injectors, improved high pressure direct injection fuel pump and BC Racing Coilovers. Then it is off to Performance Werks up near Chicago to add a methanol injection system, large impeller turbo and blow-off valve and then have it tuned.

I've had the car since it was new as my wife had bought it for me as a birthday/Christmas present in 2007. I was born on Dec 23, 1946. My health had be keeping from working on my 1969 Opel GT project car and she bought it so I would have something to drive to shows and do solo and rally racing as well as attend car shows. It is Mean Yellow and has just over 46,000 miles.

Next year I plan on putting on some aero packages and removing all emblems. It will be painted Cadillac Black Diamond with all black intakes and splinters painted to match the silver around the front wind screen and M bar.

Have fun and wish me luck!
 

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Good luck with the upgrades! Are you running a manual tranny? If not then are you planning on beefing up the transmission to handle all those horse's you'll be pushing out?
 

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Good luck with the upgrades! Are you running a manual tranny? If not then are you planning on beefing up the transmission to handle all those horse's you'll be pushing out?
That turbo won't be any problem for the stock manual transmission provided it is shifted sensibly - I have the same set up.

I wasn't aware that Comp Cams was doing anything for the LNF - maybe you could post the specs - I'd be curious to see what they suggest.

FWIW, it is generally accepted practice to also upgrade the valve springs when you swap cams - not that you WILL use higher rpm - there is so much mid range there really isn't much need to buzz the engine, but one can inadvertently take it a bit high and the stiffer springs are a sensible protective measure.
 

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Waiting on these “comp LNF cams”

Betting he meant ZZP cams
 

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For what it's worth a few years ago I was looking for a cam for my car .Comp Cams with whom I've dealt with in the past recommended getting the specs and have one custom ground . GM has one listed in their Performance parts book part #889 58648 but I've never found anyone who can get one . A few other vendors I talked to said basically what Comp told me that I would need to get one custom ground .ZZP is the only vendor who has a listing for Ecotec cams and components .they have 5 different ones listed .
 

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Discussion Starter #8
Here are the specs for the cams, I'm sorry it took so long to get back online.

ZZPerformance Stage 2 Cams
224° int duration, 438" int lift
218° exh duration, 420" exh lift

Got the head off and it seems that the dealership never performed the recommended retightening of the turbo/manifold interface during regular service, so the unit was leaking and losing boost. I thought it was coking of the intakes. When we got the manifold off we found that the unit was cracked on the s divider which is common but the crack continued down towards the outer wall and climbed up to the flange surface and finally to the outer surface. The unit is toast and I was only able to locate 2 new on the shelf units in the states both in Texas. Hopefully it will be here on Monday. I will be sending it out to be port matched to the head, sent to be annealed and then have a ceramic coating applied. The turbo housing had the same issues so I called Performance AutoWerks. They can ship me a big wheel this coming week but if I want any of the other Turbos it will be a 6-8 week delay. Man that will cut into my driving for the summer. So I'm settling for the Big Wheel. I looked at getting a unit from ZZPerformance but it would require additional modifications as their units are made for the HHR and Sonic so are not a direct fit for the Kappa. Really don't want to mess with my Solo Exhaust setup and 3" CAT or the linkage for the wastegate.

Since everything is going to delay completion I've ordered an Oil Overflow unit from DDM to install.

Randy
 

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Discussion Starter #9
I looked up the performance cams from GM for the Ecotec. Here are the specs. GM 88958648

Ecotec Performance Camshaft Set

For increased power in naturally aspirated and turbocharged engines
Duration @ 0.050" lift is 247° on the intake and 249° on the exhaust
Maximum lift is 0.499" for the intake and 0.499" on the exhaust
Lobe centerline is 116°

About 710.00

https://www.gmpartsdirect.com/oem-parts/gm-ecotec-performance-camshaft-set-88958648

Randy
 

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Ecotec Performance Camshaft Set

For increased power in naturally aspirated and turbocharged engines
Duration @ 0.050" lift is 247° on the intake and 249° on the exhaust
Maximum lift is 0.499" for the intake and 0.499" on the exhaust
Lobe centerline is 116°
From what I can see, the stock cams have In 203 deg, and EX 193 deg, but it should be noted that this is at 1 mm of clearance, which is around 0.010" less than the 0.50" your specs use.

Lift is 0.400" (give or take a couple of thou).

Looks like the performance set is a significant bump up - which explains why some head work is desirable to allow then to function properly.

Frankly, I'm not sure having more power, mostly above 6,000 rpm is worth it.
 

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Discussion Starter #12
Both the Engine and Transmission control units have been sent off to PerformanceAutoWerks for a base tune on top of the GMPP. I'll schedule a dyno session once everything is running and give the base line and the final run results at that time.

Randy
 

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Discussion Starter #15
That turbo won't be any problem for the stock manual transmission provided it is shifted sensibly - I have the same set up.

I wasn't aware that Comp Cams was doing anything for the LNF - maybe you could post the specs - I'd be curious to see what they suggest.

FWIW, it is generally accepted practice to also upgrade the valve springs when you swap cams - not that you WILL use higher rpm - there is so much mid range there really isn't much need to buzz the engine, but one can inadvertently take it a bit high and the stiffer springs are a sensible protective measure.
Yep on spring replacement. Use to assemble motors for a ProStock 1/4 miler back in the day. Also looking at timing chain, guides, tensioners and all the little bits this motor uses.

No I have an Auto but it has been gone through and upgraded with BMW racing parts. They used the same Auto.

Randy
 

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Discussion Starter #16
Well, the exhaust manifold finally arrived. The original dealer who said he had 2 and wanted prepayment actually didn't have one. Finally found one in Wisconsin. I've had to file a claim with my credit card company to get my money from the Texas dealer. The old turbo is being shipped in the morning to Performance Autowerks and the head, intake, cams (and fiddly bits) along with the exhaust is at the machinists. When I get the manifold back I will have to take an hour drive up to Warsaw, IN to have them anneal the exhaust, then I will be sending it to Indy to have them ceramic coat it. Looks like at least 3 weeks before I'll be back on the road. Then it will be up to Performance Autowerks to finish the tune. Wonder if I'll be able to make the Power Tour?
 

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Discussion Starter #17
Baseline tunes for the control units have been done and are being shipped back today with the 5th injector kit from Performance Autowerks. Should be here Monday. I still haven't heard back from the machine shop on the head and port matching of the intake and exhaust.

The turbo is currently being machined for the larger compressor wheel and the cast iron housing is being ceramic coated chrome with the turbine housing getting a chrome powder coat.

Wondering if I will get her back together before the 4th of July.

Randy
 

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Discussion Starter #18
Here is what is done by BMW racing for the automatic:



Valve body is custom calibrated to provide the ultimate in clutch application power and clamping force. Clutch apply time is greatly reduced and inadequate, sluggish line pressure rise is totally eliminated (The valve body modifications performed by us are of a proprietary design and are unavailable elsewhere).
Hi Energy friction plates and IPT laser cut, surface treated 1008 steel plates are installed in all shifting clutches.
New one way clutches (sprags) are installed in all locations
Planetary splines are heat treated to prevent stripping.
Cryogenic treatment is applied to input shaft and planetaries to eliminate stress related failure
Sun shell is heat treated to prevent stripping
Lube system is redesigned to provide increased flow and cooler operation
Lock up system is revised to improve converter clutch application, clamping force and torque holding capacity.
IPT’s proprietary package of modifications represents the most robust and capable 5L40E automatic gearbox configuration available anywhere.
They want about 5000US for this and another 1400-2000US for the torque converter rework.

Randy
 

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No I have an Auto but it has been gone through and upgraded with BMW racing parts. They used the same Auto.

Randy
I didn't realize that the Kappa used a ZF/GM sourced trans. (My BMW was never available with anything but a manual so I never needed to look into it).

Can you install the slightly later 6 speed version in the Kappa? Wonder if the BMW paddle shifters would also work....
 
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