C2's Alero Updates

[leroBob]

What's the end game with the site?

[[ion] C2]

I might buy it and update it

[leroBob]

They should just gift it to you.
. Those three haven't even logged in since when? The value is less than a 2 liter of Pepsi.(Red dog job reference)

[[ion] C2]

Centerforce, as expected, is not very receptive to the idea of making a custom flywheel to work with this swap.

I reached out to RPS Carbon to see if they'll help. They are known for comfortable to operate clutches that hold power.

[Oldsnut]

Originally Posted by leroBob

They should just gift it to you.
. Those three haven't even logged in since when? The value is less than a 2 liter of Pepsi.(Red dog job reference)

Bite Me!! I am on here 2-3 times a day to delete spammers registering and see whats up. Everybody thinks they know everything.

[leroBob]

Originally Posted by Oldsnut

Bite Me!! I am on here 2-3 times a day to delete spammers registering and see whats up. Everybody thinks they know everything.

I stand corrected! I like the passion.

[[ion] C2]

Using advice from Tony @ UMS Tuning on how to reach out to a clutch company, I was able to get a reply from RPS, the company that makes super easy to drive, high torque capable carbon clutches. They supposedly are just as smooth to operate as a stock vehicle.

Originally Posted by RPS

I love working with Tony and would be interested in helping you with your goals. A one-off custom RPS Super Lite 8" BC3 triple disc carbon clutch capable of 1,000 lbs-ft of torque to the tire is $8,000 and takes 3-4 months to make.

[Oldsnut]

Originally Posted by [ion] C2

Using advice from Tony @ UMS Tuning on how to reach out to a clutch company, I was able to get a reply from RPS, the company that makes super easy to drive, high torque capable carbon clutches. They supposedly are just as smooth to operate as a stock vehicle.

Your patience with this project is amazing!

[tw0123]

I love the passion and desire you put into the car Chris!!! Although I couldn't imagine dropping 8k just for a clutch!!! Can't wait to see the progress

[That01Olds]

Originally Posted by Oldsnut

Bite Me!! I am on here 2-3 times a day to delete spammers registering and see whats up. Everybody thinks they know everything.

I am deceased lol. I hope you're doing well Andy! LeroBob someone has to be logging in to keep the site running and going. Can't wait to see the finished result Chris!! I'm seeing less and less Alero's on the road these days, but I still think of the site when I do see them. A few low mileage and clean ones have come up as of late too! So they're still out there, which is always nice to see! Cheers!

[[ion] C2]

Finally got the car back from the transmission shop after 2 months.

Clutch Masters was taking too long and being unresponsive and difficult to communicate with, so I took a new OEM style bearing and removed the plastic portion and had a -3 AN fitting welded to it, making my own plastic-less bearing setup. After bringing the part to them last Monday and expressing that I will pay more to expedite this as it's been sitting at their shop for 1.5 months, I returned on Tuesday to find out they haven't touched it and no one wants to work on it, so maybe another week and a half and they'll call me.

However, they did the remove and reinstall today and now I have it back. Unfortunately they touched a bunch of stuff doing it. Gotta get another alignment because the steering wheel is turned terribly to go straight. A clamp on the turbo to charge pipe coupler was completely off so massive boost leak. They left their custom engine hoist hook attached using one of my cam tower bolts. And other minor things. Hate to have it in various shops so damn often.

I just want to drive it.

[[ion] C2]

Had some family in town and took one person for a ride to the restaurant we were going to about 20 miles away, and noticed the car kept essentially acting like it wanted to kill us lol. Would push you left and right at random like a strong wind, apart from torque steer.

Control arm was loose. Easy fix and now she's nice and tight.

I've been pondering the AWD conversion. It would be very easy to have RPS make a carbon clutch for the existing transmission and just run it like that... do some custom suspension, interior, paint on the new chassis and call it good.

AWD is going to be a major money pit, and now that I'm starting to send money over for the $8,000 clutch and looking at the $20k in known parts, plus all the other stuff, I'm hesitating...

$20k of stuff:
- AKDBuilt RT4WD Billet Viscous Coupler
- gearDriven Honda AWD K-Series PPG SYNCHRO GEARBOX Manual Transmission with Quaife LSD
- Drag Cartel AWD K-Series transfer case & gear set
- Oldschool Capital OEM rebuilt Civic Wagon rear differential
- K-Tuned TSX shifter KTD-TSX-AC2 and cables

$8k:
- RPS triple disc carbon clutch with flywheel pilot bearing accommodation

unknown cost:
- engine/transmission adapter flange (need to design and have machined)
- custom transmission mounts
- custom center driveshafts
- custom rear subframe
- custom front CV axles
- custom rear CV axles
- custom rear control arms or trailing/lateral link setup
- rear hubs (undecided from which vehicle, GM Epsilon?)
- custom adjustable coilovers
- fuel tank/fuel cell as OEM tank will be in the way
- revised exhaust routing


It will probably cost $40-50k in the end, at the low end, and I'll have a very custom setup that may be tricky to maintain.

Or I could spend $5-8k on a smooth clutch and deal with having no traction at high throttle at low speeds... there are a lot of fast FWD cars out there... I do love the idea of being able to go from 0-60 with traction, and reduced torque steer, and overall safer stability, but man, it's a cost. I have so many projects. I'm $70k in on my truck (including $12k purchase price). I have a $30k UTV. I'm building an addition on the house. I just got into RC car racing (which is cheap comparatively). It never "made sense" to modify this car, but I like upgrading things and seeing the fruits of my labor. I've been at the point where I want to "finish" it, have it be clean and complete, and easy to drive.

The main thing is my fabricator has been very uncommunicative, and he's expensive. It's supposed to be cheap, fast, good, pick 3, but with him I think it's just going to be good, expensive, and slow. It's been 3 months since I dropped the other chassis off for fabricating the half cage and fender bars, but I haven't heard a peep. Texted him the other day, no response. I would need to rely on him for all the custom fabrication, and I hate to think how long that will take, and how pricey it will be.

Just trying to be realistic. Financially I keep falling into the rut of credit cards to get what I want, then paying things off when I get a nice chunk of change from the business, and having a little extra in cash leftover. To do AWD and quickly, it will require going into credit debt again, and I still have a huge mortgage and some student loans. I just need to confirm what I want.

Why do I want to make it AWD?

1. It would be able to accelerate fast at lower speeds without losing traction.
2. It would be safer in handling (arguable, FWD is pretty forgiving overall, and if you're heading into a turn, you aren't on the power anyway)
3. It's unique and cool.

Are those reasons enough to spend $50k?

I'm starting to think not...

If I had $500k sitting around with my house paid off? Yeah, why not. But when I'm in an industry with a risky product and an uncertain future, I think it's smarter to keep things simpler. I was even thinking of selling the Can-Am and just adding fancy suspension to my truck so it's more capable/comfortable off road. Seems smarter than having so many vehicles.

Sorry for the long post, rambling about my thoughts.

[dbral]

Able to understand what you are thinking and would probably hold off on the AWD too. That swap would make it a very fun and unique car.....but it already is the way you have it now.

It would be very easy to have RPS make a carbon clutch for the existing transmission and just run it like that... do some custom suspension, interior, paint on the new chassis and call it good.

Amen....and enjoy the he!! out of it.

[[ion] C2]

It's funny, on the Facebook group, everyone voted 50/50 on going AWD. Easy to tell someone to spend money because it's a cool result, but I don't think they actually considered cost/benefit.

I sold the AWD trans today, and spoke with RPS who is happy that they can much more easily make a carbon triple disc clutch. This will also benefit anyone with the Getrag F23 because it will exist, although, expensive.

When I have my custom suspension made, it will also be available to anyone who wants it, and should be more reasonable. Properly designed adjustable coilovers for the Alero, finally!

I'm going to make the car the best it can be in FWD configuration and enjoy it. I've modified this car since 2006, always adding to my list of upgrades. It's time to be smart and focus my efforts on what will bring the maximum enjoyment.

[dbral]

Looking forward to the suspension/clutch details and results. Awesome that what you are developing will be available for others as well.

Hoping for some track day stories/vids. in the future. An Alero that can compete with modern cars would be fun to watch.

Yeah man, button it up and and just enjoy it. Wow, you have been at it for almost 20 years now!

[[ion] C2]

Texted the fabricator over a week ago asking how the fender bars and cage are going. No response.

Flew my drone over to see if anything's been done to the car. Looks like the interior is taken apart and the fenders are off, but no fabrication yet.

3 months it's been there.

[dbral]

GRRRRRRRRRRRRRRRRRR>>>> That sounds awfully familiar..... The only advice i have is to keep your cool, but if you don't, i completely understand and would not blame you. Keeping my fingers crossed bud

[[ion] C2]

I nudged him again and he replied with little tidbits about how space is limited to bend the cage up but it will be happening soon, and he's getting the plates for mounting to the chassis today.

Meanwhile I decided to drive my car around for my errands 35 miles away since I hadn't driven it in a few weeks, runs great, but then the MAP sensor died while I was coasting on an offramp. Stranded in the right lane of the exit ramp right at the intersection with my hazards on, yet people keep flying up nearly hitting me. One guy smoked his tires after I laid on the horn when I noticed he didn't seem to be stopping AT ALL as he came zipping up to my ass. Don't know how he missed. I've been in a few crashes and I thought for sure he was gonna contact.

Luckily someone was able to help push me out of the killzone to this spot, where it got towed safely to the shop and fixed almost immediately.

[dbral]

Happy you are safe. Was involved in an accident a few weeks ago with similar results as far as the after-accident traffic was concerned. People are in a hurry these day it seems.

Good that shop fixed it quickly this time. Hoping for better news with the rest of the project.

[[ion] C2]

Drives great aside from me stalling it taking off lol: https://youtu.be/aHdRGi9K5Ls