04-01-2016, 12:22 AM
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#1
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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3500 5 speed turbo build
Thought I'd share my build over here
just a quick catch up, I have a 2003 Grand Am GT that I swapped a 3500/5spd into last year with some bolt on's. Put over 15,000kms on that setup
Bit of a budget build so using 2 front LX9(3500) manifolds with a custom crossover and a Borg Warner S300 turbo from a 7L CAT machine, I had bought a turbo crossover fabbed up for a 2nd gen J-body with a flipped UIM for dirt cheap which didn't work at all lol
so grabbed a new turbo flange and pretty much started over trying to hug the engine as close as I could to make way for a 3" downpipe
The red transmission cap should give you a good reference point for how much it moved
Got the turbo mounted and did a quick mock up, happy with how things are going so far but still lots to do before May...
Dropped my turbo off at Re-Speed to get the turbo outlet flange changed to a normal 3" V-band
before
after
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3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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04-01-2016, 12:25 AM
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#2
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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04-01-2016, 03:57 AM
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#3
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Premier V.I.P. Member
Join Date: May 2011
Location: Ferdinand Indiana
Posts: 2,742
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I like where this is going
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3rd alero- 02 GX 2.2 5sp coupe. drove for 3 years 55,000 miles. Sold for a kids first car, and missed
01 Intrigue GX
2016 Chevy SS, Jet Black
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04-01-2016, 07:53 PM
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#4
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OSV coming soon!!!!!
Join Date: Jun 2006
Location: lindsay, ontario
Posts: 2,375
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looking good Mike! Guess that means you won't make the season opener in Whitby on April 10th... I'm thinking of going down for it...
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Misty: 3400, S&S headers, TCE 65mm TB, CAI, 180* TStat, Milzy motor & tranny mount, 18" BOSS 328 & much more... going osv!!
Silver: 2.4L, 5 speed, GAGT seats, front & rear STB's, all red tails, led headlights, Magnaflow muffler, Milzy Motor mount, WAI, Cosmo short shifter; sold n missed
Tequila: 2.4L, GA interior swap, scrapped...
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04-02-2016, 08:14 PM
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#5
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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Thanks guys and what season opener Tim? Obviously I'm no where near driving yet lol but hoping to be burning rubber May long weekend!
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3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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04-02-2016, 10:16 PM
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#6
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OSV coming soon!!!!!
Join Date: Jun 2006
Location: lindsay, ontario
Posts: 2,375
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I'll send you the link through Facebook... Used to be run by the gmco club but he folded it a year or so and another club took over the meets... It's held at the landmark cinema in Whitby at Thickson rd and the 401... Starts at like 5pm or sobering like that haha!
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Misty: 3400, S&S headers, TCE 65mm TB, CAI, 180* TStat, Milzy motor & tranny mount, 18" BOSS 328 & much more... going osv!!
Silver: 2.4L, 5 speed, GAGT seats, front & rear STB's, all red tails, led headlights, Magnaflow muffler, Milzy Motor mount, WAI, Cosmo short shifter; sold n missed
Tequila: 2.4L, GA interior swap, scrapped...
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04-17-2016, 08:42 PM
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#7
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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07-10-2016, 12:10 AM
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#8
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GX Member
Join Date: Nov 2015
Location: Goose Bay, Labrador
Posts: 40
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Did you get this build finished? Because this is awesome.
What was the power like before with the NA 3500 and 5-speed?
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1999 Alero GL Sedan - 3400/4T45E
-HP Tuners custom tune in the works
-Hopefully much more in the works besides maintenance.
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07-10-2016, 11:23 AM
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#9
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OSV coming soon!!!!!
Join Date: Jun 2006
Location: lindsay, ontario
Posts: 2,375
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He's almost done... I'm bugging him to finish it by the end of July to bring it to the mini meet we're having lol
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Misty: 3400, S&S headers, TCE 65mm TB, CAI, 180* TStat, Milzy motor & tranny mount, 18" BOSS 328 & much more... going osv!!
Silver: 2.4L, 5 speed, GAGT seats, front & rear STB's, all red tails, led headlights, Magnaflow muffler, Milzy Motor mount, WAI, Cosmo short shifter; sold n missed
Tequila: 2.4L, GA interior swap, scrapped...
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07-10-2016, 12:29 PM
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#10
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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Ya still working away on it, hopefully soon! The manual V6 was a blast to drive N/A, hit the track twice and got 14.4@103mph I believe(traction issues)
heres some updates I haven't posted yet
So I spent some time finishing off my last charge pipe and came up with this contraption
which put my MAF down here
Not even 24hrs later and I chopped off half of that charge pipe and started from scratch though lol but happier with the placement of things, I'll grab some pics later when it's not so dark in the garage
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3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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07-10-2016, 12:30 PM
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#11
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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__________________
3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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07-10-2016, 12:31 PM
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#12
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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Might as well update this I guess, it at least give me a nice "journal" of my build lol
Got my drive train out a little while ago
Inspected my "stage 3" ebay clutch and rather happy with it after 16,000+kms with no proper break in and beating the shit out of it
drilled my pan for oil drain, thought I could get away with a nut and loctite but not enough thread showing
So dropped it off at a local shop that I use for my TIG welding(Re-Speed) and some beauty cars out front
Last year I lost my steering rack tabs.... NOT this year or anytime soon lol 1/8" plate on both sides
Lifted fuse box 1" and relocated wires from the front out the back
last year I had some TERRIBLE traction issues the 2 times i hit the track... Got a closer look at my poly rear mount and damn?
New one is here so little fire with the old lol
GTP 36# inectors/connections and my PCM flashed for them thanks to Scott!
ohh and got myself a WOT-Box for some 2-step launch control and no lift shift
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3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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10-15-2016, 11:46 AM
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#13
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GX Member
Join Date: May 2005
Location: Phoenix AZ
Posts: 120
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very impressive and well documented build here. I like what youve done.
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10-16-2016, 08:15 PM
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#14
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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Thanks man, guess this needs some updating as the car is driving...
https://www.youtube.com/watch?v=KgG87WFq6VI
3" downpipe, wanted it to be 1 piece but wasn't happening
Girlfriend painting all the exhaust parts with some POR-20 heat paint
Some heat management
Quick clean to make sure no debris was inside
Notch for oil return
Screamer pipe
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3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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10-16-2016, 08:16 PM
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#15
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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Words can't describe how much I ****ing love this thing! Lol
Quick driving video
https://m.youtube.com/watch?v=cWxD0UAkkOw
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3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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10-22-2016, 11:13 PM
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#16
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Premier V.I.P. Member
Join Date: May 2011
Location: Ferdinand Indiana
Posts: 2,742
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awesome. Car looks great, sounds fantastic!
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3rd alero- 02 GX 2.2 5sp coupe. drove for 3 years 55,000 miles. Sold for a kids first car, and missed
01 Intrigue GX
2016 Chevy SS, Jet Black
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11-08-2016, 01:02 PM
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#17
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Swank
Join Date: Jan 2004
Location: Alberta, Canada
Posts: 921
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Sounds like a beast, nice work!
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If you don't stand up for something, you'll fall for anything.
I don't have the Alero anymore, now I drive this
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08-20-2018, 08:46 AM
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#18
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GX Member
Join Date: Sep 2014
Location: London ON
Posts: 39
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Thanks guys
3500 #2 went in last yr.
Wot-tech cam
Yellow LS valve springs
P&P intake manifolds
Nice to see photobucket went back to 3rd party hosting
:applause:
__________________
3500, 5 speed, S&S Headers, 65mm TB, CAI, 2.5" Catless DP/Midpipe
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