Scott's 1993 Boosted SL2 (Updated: Apr. 26, 2010)

[tk23]

I have not listed everything here because I am still unsure about certain items. I've probably forgotten some stuff too lol.

Background:
Well, I purchased this car in late June of last year (2007) but the idea of a turbo Saturn has been floating around in my head ever since I got my first one (about two years ago). It was listed at 76k miles, but I'm not totally sure on the actual mileage. A few documents that I found in the glove box say 176k. This car only cost me $1000. It has brand new tires, and A/C.

Pics from CraigsList Ad:


My Pic:



Goals:
My hopes are to finish this by late May 2008 in time to make the GM EFI Race at Raceway Park (Englishtown). I want this car to be able to be driven on the street and strip. It will have a mild setup on the street (probably no more than 10 psi of boost). At the track I will run in excess of 25 psi. I am going to use all "stock" Saturn parts (i.e. a Saturn intake manifold, throttle body, etc...).

I want to run a 12.5 e/t at the track at most. Anything more is a gift. )
Fan Switch


Progress and Various Pics:

 - T04E Turbo


 - SCAT Rod



 - MS Wiring 1


 - MS Wiring 2


 - MegaSquirt


 - MS Launch Control Momentary Switch



 - Gauge Pod with Boost and Wideband Gauges Installed



 - Tie-Plate (Girdle)



 - Manifold Progress



 - Engine Removal


 - Stock Internals


 - Valves



 - Head


 - Head Porting 1


 - Head Porting 2


 - Head Porting 3


 - Head Porting 4


 - Head Porting 5


 - Head Porting 6



 - Walbro Install 1


 - Walbro Install 2


 - Walbro Install 3


 - Walbro Install 4



 - ACT Clutch 1


 - ACT Clutch 2


 - ACT Clutch 3



 - DIY Volt Booster that I got flammed for on PR



 - Wiseco Piston Specs


 - Wiseco Pistons 1


 - Wiseco Pistons 2


 - Wiseco Pistons 3


 - Wiseco Pistons 4

[tk23]

More Progress:

Well I took the transmission apart today (MP3) with the help of my cousin...and I was kind of dreading how you have to take everything apart to get at the differential. But, after doing it, I realized that it was a real simple process. The tranny seems to be in very good condition. The pin, spider gears, and roll pin all look nice. I'm starting to think that even if this car had 176k miles on it, that the previous owner took very good care of it. Next comes the PG and welding of the diff pin.



Transmission Disassembly 1


Transmission Disassembly 2


Transmission Disassembly 3


Transmission Disassembly 4


Transmission Disassembly 5


Transmission Disassembly 6

[tk23]

Well, today I brought everything for the turbo project to the machine shop. The guy is a long time friend of my dad and I know that he does quality work. I hope that it doesn't take too long lol. I really want to get this project done.

List of things that he's doing:
Balancing
Bearings
Re-surfacing Flywheel
Honing Block for more clearance for forged pistons
Machining Rods so they fit into pistons (sides, tops, and boring out bushing a couple thousanths)
Polishing Crank

[JRSTANGE]

awesome!

[The Shaolin]

You're going to have a hell of a time getting that trans back together.  

Good progress though.

[tk23]

awesome!

Thanks

You're going to have a hell of a time getting that trans back together.

Good progress though.

Thanks. It shouldn't be to hard...I have my FSMs if I forget anything lol.

[tk23]

Got some more goodies today from the boneyard. Intake cam from a 95 wagon, fan/shroud from a Volvo 940 (not sure if this will work yet), and two steel rims for my slicks (with some decent tires mounted on them already). Also ordered an oil pump and .030 shims from SDA .


Boneyard Run


Intake Cam 1


Intake Cam 2

[mars_volta]

2 intake cams and a stock intake? 25 psi?  good luck.

[tk23]

2 intake cams and a stock intake? 25 psi?  good luck.

Lol yeahhh buddy! . We shall see how everything holds up lol.

[tk23]

A little more progress tonight: Got the Phantom Grip installed, and checked my wastegate. It seems to hold up to around 25-30 PSI so I'm excited ! My dad will be welding the diff on Saturday.

Pics of Progress and Turbo:

Phantom Grip 1


Phantom Grip 2


T04E 1


T04E 2


T04E 3

[tristanlee85]

it the angle of the picture, or do the rods not fit into the piston?

Otherwise, the progress looks good.

[tk23]

it the angle of the picture, or do the rods not fit into the piston?

Otherwise, the progress looks good.

No it's not the angle of the pic, you are correct. I had the machine shop take some material off of the top of the rods (because due to the way that the pistons are made: the strength of the piston is where some material would have had to be removed). Ricesucks!!! told me that he had to get some material removed from this same job number (00711-2736, I think) from Wiseco. I'm not sure why these pistons are made this way? But, the machine shop called me this morning and I'm going to grab all the stuff in a little bit. I should have some new pics up shortly.

Thanks for the comment .

[JRSTANGE]

wow, internal wg with a boost reference port for say a ebc. interesting.

[Pimped_SC2]

Since when did ACT make a sprung 6 puck?

[JRSTANGE]

as of the last year or pretty recently.

[tk23]

Since when did ACT make a sprung 6 puck?

Since about a few weeks ago . It's on their site, the part number is ST1-HDG6 I think...

[tk23]

Update (04.25.08):

Well I checked the crank (mains/rods) with Plastigage and it checks out. Bearings will be on the way shortly. I have Windo-Welded the TAM and transmission mount. The transmission is together. But, while putting it together, I almost snapped a bolt lol (check out the pic below). Also, I got everything back from the machine shop last Friday.


Welded Differential


Transmission Assembly


Stretched Bolt


Forged Pistons/Rods 1


Forged Pistons/Rods 2


Forged vs. Stock

[tk23]

There has been a little delay with my project. School is crazy right now due to this being one of the last weeks. I am done by May 14th though. Here's a slight update: I should have the head back together by Sunday (but I am not sure on this). I have already started to clean the valves, use grinding compound on the head, etc... I just received my bearings from eBay and I'm also going to try to get the bottom end put together by this week. The deadline is not May 30th anymore because I will not be attending the GM High-Tech Performance race. However, once I am out of school, I should really have the ball rolling . I hope to be done sometime in June.

[yillo]

sweet

[ricesucks!!!]

damn, 25-30psi?  we better see 450hp!!!

good luck with everything!

[tk23]

damn, 25-30psi?  we better see 450hp!!!

good luck with everything!

LOL I highly doubt 450 . Thanks for the comment though!

I was thinking of putting the bottom end together today, but the weather is shitty and drag racing is coming on soon (and by soon I mean 2.5 hours lol). Too much school work to do too ugh .

[tk23]

I've been working here or there on this project, but since my grandfather just passed away, I haven't had much time. I do have the crank in the motor and I'm going to be working on it again today . I'm glad that I can finally get some stuff done. Pics soon!

[morgansonsc2]

what is this thing going to be boosted at. Will a stock block hold up to 30 psi? I mean, dont get me wrong, it all looks great but i think you may see about 300, but i dont think the engine is going to hold together. Other than this minor detail it looks amazing and well thought out. If you took the time to get some real turbo cams you could easily see 350.

[tk23]

what is this thing going to be boosted at. Will a stock block hold up to 30 psi? I mean, dont get me wrong, it all looks great but i think you may see about 300, but i dont think the engine is going to hold together. Other than this minor detail it looks amazing and well thought out. If you took the time to get some real turbo cams you could easily see 350.

Thanks for the compliment man. I'm not sure how much it can hold but we'll see haha. Motor is probably around 60% back together as of this point and it will probably be back in the car by the end of this week. As for the cams, I have taken some material out from the key-way to retard both of the cams. This puts the centerline of both of the cams at about 108-109. Intake opens at about 6 ATDC and exhaust closes at 9-10 BTDC at .050. I did this because I was comparing some Buick turbo cam spec sheets with my cam specs. Pics will be up soon, as stated before, but probably once the engine's back in the car.

[d3ad1ysp0rk]

what is this thing going to be boosted at. Will a stock block hold up to 30 psi? I mean, dont get me wrong, it all looks great but i think you may see about 300, but i dont think the engine is going to hold together. Other than this minor detail it looks amazing and well thought out. If you took the time to get some real turbo cams you could easily see 350.

Thanks for the compliment man. I'm not sure how much it can hold but we'll see haha. Motor is probably around 60% back together as of this point and it will probably be back in the car by the end of this week. As for the cams, I have taken some material out from the key-way to retard both of the cams. This puts the centerline of both of the cams at about 108-109. Intake opens at about 6 ATDC and exhaust closes at 9-10 BTDC at .050. I did this because I was comparing some Buick turbo cam spec sheets with my cam specs. Pics will be up soon, as stated before, but probably once the engine's back in the car.

Wanna hold off on finishing til I get the AIC working, so I can rock the claim to "New England's fastest Saturn" for a little while at least...?