Cavy project 09

[607Motorsports]

It's been ages since I've updated this section or given you guys any updates on the Cavy so I figured I'd take a minute to do so Quite a bit is going on this winter on the car yet again. Last season I was very satisfied with where I got the car but it still had some bugs and those are being taken care of this winter.

For one I maxed out my 750cc injectors last season when I pushed the car to 28psi so I've decided to upgrade those this season. I also had a couple oil leaks coming from my upper cam towers... nothing big but just annoying and I found that I really needed to address my upper crankcase ventalation a bit more so a custom PCV system has been put together for this season.

I also decided to ditch my log turbo manifold and had an equal length tubular turbo header designed and made for me. Below is the list of upgrades for this season and some pics Comments and questions are always welcome.

-Bosch 1000cc saturated injectors
-custom PCV system
-Custom tubular turbo manifold
-new water pump
-devilsown meth injection kit
-Synapse BOV
-Greddy Profec electronic boost controller
-LS1 80mm tb conversion (currently a 62mm)
-Custom made adjustable traction bars
-K-member brace





I also decided to port my compressor housing a bit while I had the turbo out. Sorry for the bad pic but you get the point.

[607Motorsports]

No responses? LOL

[mikecentola]

Looks good man! I must have missed the thread earlier haha

[crazybrew609]

ooops sry i thought i responded to this yesterday


looks awesome buddy.. hey i might be getting at you later on in summer and some plans i have and i might need your help with some tuning

[bpipe95]

Saw this over on NYspeed. Interesting build.

[607Motorsports]

I'm just busting balls Thanks guys, it's coming along. I'm really hoping to have it wrapped up by April so I can start the tuning.

Brew no problem at all man just let me know, I'm probably getting rid of my Cobalt sometime in April and moving on to another project

[GranMassaX]

i'll comment when I see some dyno and track numbers

[607Motorsports]

Dyno time will be in late April/early May

[Captain Moai]

awesome. A quality built car and a cavalier owner that isn't a douche. I commend you sir, on both counts.

[607Motorsports]

Thanks man much appreciated! I really just wanted to build something a little different and out of the norm.

I have been working on the car quite a bit and I found I had to entirely redo most of the damn turbo setup for this manifold. I have the new downpipe done and it's a 3" v-band of course I also completed the turbo side charge piping mock up and it should be welded up and pipes flared this weekend. The only thing left is to finish up the fabrication of the new dump tube and weld it up and then everything should be ready to put back together.

Last season I ran into an issue with my upper crankcase having far too much pressure in it and it caused my cam towers to seap in a few spots. I'm hoping to new PCV setup I have put together for this year will take care of that issue.

I should be able to post more updated pics over the weekend

[crazybrew609]

us LSJ guys need to drill a hole in the oil cap and stick a breather filter in it just to fix that issue

[607Motorsports]

Originally Posted by crazybrew609

us LSJ guys need to drill a hole in the oil cap and stick a breather filter in it just to fix that issue

Interesting... I've never seen that one but on my Cobalt I had 2 8AN fittings welded into the valve/cam cover and run to a catch can much like the Honda guys do.

The problem on the Cavy is that the upper cam towers aren't able to be vented because there is no baffling in them and the also have very close tolerances to the cams. The head is supposed to have a port between the intake runners but it is just not large enough to vent out all the crankcase pressure when adding boost to the mix.

[607Motorsports]

Updates w/ some numbers...

Well I was finally able to get the car to New Era Performance for some tuning and numbers. Unfortunately the tuning did not go smoothly at all... the tuner there (Mike) did the best that he could with the car but Cavy's are definately not his specialty (they are no ones ) so he was very handcuffed.

Regardless he did manage to tune the car in for 1 bar of boost before running out of fuel in the fuel tables. Since the tune however I noticed he did not touch my pulsewidth multiplier tables at all which will net me a large amount more fuel so I will be doing my own further tuning from here on out and will likely head back to New Era later this summer for more numbers on higher boost. I found out that I am probably the best person to tune this car since it's such a pain and I have had a few years of experience with it.

In no way am I knocking Mike or New Era, he did a great job with the car, it runs 100% better than it did when I took it to him and I appreciate the 6-7 hours he spent tuning the car with me.

Anyways at 14psi the car put down 371whp 379wtq... I have yet to have the opportunity to put more fuel into the car or turn up the boost due to being so busy and bad weather around here but this weekend I plan to try working it up to 20ish psi... this should easily net me around 450whp... not too bad for just a little Cavy

[mikecentola]

nice! Got any update pics?

[NYCDSM]

Not bad i like this build even tho im a ultra hater of the GM quad four motor. everything looks very nice!

[607Motorsports]

No new pics yet but I'll grab some here shortly once I actually drive the car I'm far from done pulling power out of the car but this gives a me a nice base tune to work off now. The car runs decent but does need some tweaking here and there. I have no doubt at 25psi the car will put down 500whp and that would more than satisfy my for this build.

No worries about the GM quad man, there are many funky things about the design of the engine that have made me slap my head many times asking WTF was GM thinking It does have it's benefits though... mines been bored and stroked out to a 2.6L with a TON of internal work done to the oiling system.

[mikecentola]

500whp eh? that's not bad

too bad its wrong wheel drive

[hurleyint1386]

nice. looks like it'll be pretty fun to drive! haha

[607Motorsports]

Wong wheel drive is correct sir The next project will be RWD for sure...

I'm currently trying to sell my Cobalt SS/SC and once it sells the new project will begin