I got my 2006 ss/sc a little over a year ago and parted out my cavalier. After messing around with the supercharger set up it got a little boring. My brother and I built a cavalier and threw a GT35r on it and right now its at 474 whp. Once you ride around in a sub 500 cavalier it doenst take much to get bored. Due to this lack of boredem I decided to start building a turbo kit. The goal for the car is 300 hp DD. Here is what I have so far!

ZZP log manifold
Garrett T3/TO4E 57 trim
LK9 Intake manifold
Tial 38mm wastegate
Open dump
Stattima BOV (ZZP Tial knock off) Hopefully it works...
80lb Injectors
2.2 Tensioner pulley
2.2 Belt
Welded lsj alternator
3" cold side charge piping
2.5" hot side charge piping
Hahn intercooler
3" exhaust (going to modify my old cti cav exhaust)
dynomax ultraflow bullet muffler (for resonator)
dynomax ultraflow muffler (for the track and summer)
Removeable section for the stock muffler (For DD use and when the wife is riding with me lol)
Custom dash dual gauge pod (made it myself, didnt turn out too bad)
LM1 wide band
Innovate G3 AFR gauge
Innovate G3 Oil Pressure gauge (on the turbo feed line)
Greddy profec boost controller

Sold the supercharger set up late January and have been working on it when I get a chance. Right now all I need to do is finish the exhaust and get the plastic wheel wells trimmed so I can mount the bumper.

Here are some pics!

Hahn Intercooler



Saab Intake Manifold



Throttle body spacer







Cold side piping











MAF flange





1 peice cold side!!



Hot side charge pipe







BOV Placement







Intake manifold shaved and painted





Intake



Once It gets street worthy the it will get a nice bath!!

 

Downpipe started



Progress





Top view



View from the bottom





Finished downpipe!





Now on to the exhaust!!

 

Weksos.







Looking good so far.

 

Looks like a solid build. Keep it up.

 

Here Is what the finished engine bay will look like



I am glad I was able to keep all the charge pipes under the motor.

I am also looking into getting an intake manifold made with ross machining parts here soon. We picked up almost 40 hp on the cavalier when we switched.

 

this is the kind of cobalt i want to see more on this forums.

 

You have a bad ass setup/ I am running a very similar setup and Im making 461whp at 23psi. I made 290 at 10psi so Im sure you will be very happy with your build it looks great. I am running the saab intake for now and a s256et turbo. I want to upgrade to the ZZP LNF intercooler and charge tubes and a bigger turbo to get into the 500 range around 20psi.
Lookin good

 

You'll be a little more than 300.. LOL !

 

Nice, Looking real good.

 

We have manifolds ready to go:

Turbo Tech Racing Ecotec Intake Manifold - ON SALE! - Turbo Tech Racing, LLC

 

Got the bumper on and the exhaust is to the twist beam!! I am hoping to get everything done tomorrow. I really want to start driving this thing!!

 

Really nice work here! Wish I has a welder at home I would love to have 3 piece intercooler piping. Sick looking downpipe too that will flow really nice. You should make upwards of 350 at 20 psi and a conservative tune. Pretty nice DD if you ask me

 

do work son!

 

you forgot to add a clutch to your parts list... just sayin

 

That would be why the goal is 300 hp right now

Down the road I may throw a gt35 on and a twin disc clutch, after the motor is built.

 

Nice fabrication.

 

Very nice work man, cant want to see pics/vids when its all done.

 

I found some pics of the gauge pod I made.

 

How much would you charge to fab me up one of those? haha

Your gonna need a clutch very soon. Even on 15 pounds the stock unit won't last long.

Is a 35r an actual option for us? What a/r turbine housing would you run with that? I have the same manifold as you and i'm on a 3076r but it has an .82 turbine housing and it doesn't hit 17 psi till almost 5g

 

When driven properly, the stock clutch can last a long time. Mine lasted well into the 350's.

And yeah... a 35R is an option. Its a really large turbo. Unnecessarily large, to be honest. But it can be made to work well if you buy and research SMARTLY and don't order it with a giant A/R turbine housing.

You still interested in that Billet 5557? I might just sell it now.

 

I can make a gauge pod, Its not a show piece by any means. It takes some time. I would consider doing it for $150 shipped to you.

I would run a gt35 with a .63 ar housing. Electronic boost controllers work wonders with turbos. On my cavalier I can fully spool 21lbs by 3800 with a gt35r. Although thats on a 2.4l motor. I will post a vid of the cavalier on the dyno. You can hear how hard the boost comes on. Makes the car very streetable.

The key to keeping a clutch last, is to not drive like a retard on the streets. I will be going with a bulley stage 4 when I do a clutch. The one on the cav is an animal. Holds nearly 500hp with out an issue. I have a guy that gets a great deal on them as well. Peddle feel is amazing compared to a spec clutch.

 

Alright i'll keep that in mind.

What does the electronic boost controller do for spool time? Thats so crazy 3800... what cams are in it? And thats a sick manifold too. I would probably spool my 30r right at 4 grand if i had the .63 turbine housing. I need to get on that. That was a ball bearing 35r i'm assuming?

I like my clutchmasters stage 4 but i might try something else when I swap trannys. What clutch are you getting... Bully?

 

With the greddy profec you can keep the wastegate fully closed untill you want it to open. Just using a spring, it will slightly open once you get on it. We have our wastegate opening at 17 psi. It took off almost 800 rpm off the spool time. You also need to play around with the timing in the tune. Both of those items will make your turbo spool. It makes a hell of a difference.

The cavalier has a quad 4 motor, not an eco. It has .410 lift cams and revs to 7k. It made 474 whp at 6500rpm. It was a Ball bearing 35r.

I will be getting a bully stage 4, sprung hub and I will resurface the stock flywheel.

 

I noticed that actually. My old ebay wastegate used to stay closed a lot longer than the tial does, and it hurt my spool time when I put a mbc on as well. Starts to bleed off at like ten psi I can see it in the gauge. Never knew the electronic boost controller would do that. So the greddy profec is what I should look for? And yes, timing is big.

That's a hell of a nasty cavalier man. The head im getting has hks 272's in it they're pretty popular in the dsm world so i'm hpoing it should help a little.

 

A lot of people either hate or love the profec. I have had pretty great results with it on the cavalier. Although, be prepared to spend a few hours dialing it in. Once you get it set up it is really nice. It also have a Hi and Low setting for boost as well, with separate settings for both.