*Edited 2/21/06. See new pics lower in the thread!

Hi everyone. I'm starting this thread a little early to get a head start on it. I'll keep it up to date as best I can. As many of you know, I'm building a turbo charged automatic Cobalt. Here she is...



My goal with the car is have a %100 street and emissions legal car producing the most power possible within that limitation with an automatic trans.

Well, it looks like I'm back on track after many set backs, first engine getting destroyed being one of them.



I spoke with Ferrea today (supplier of my valve train) and they should have my package shipped to me by Friday (2/17). Car will be back together probably the next day. I wanted to give all of you a complete list of what I have done so far, and what is to shortly come.

As you can see, I have the RK Sport body kit which was done professionally for about $600 painted and installed. I had the rear 3 windows tinted %20. Then I sent it in for the major engine work which is where I am now.



I had my Transmission done by IPT transmission. This was probably the most important part. IPT rebuilt the trans to handle just about anything you can throw at it. IPT gave me a 3000 RPM stall converter as part of the package for the turbo. Then I had a LSD installed which i got from Engineered Performance. IPT is making a custom controller for me that will allow me to dial in firmer shifting for performance driving and smooth shifting for daily commuting. In cabin, on the fly adjustability.

The engine has had the rotating assembly rebuilt using the stock crank, Eagle rods, and Wiseco reduced compression pistons. That was the easy part actually.




The head was the reason my first engine was destroyed. We used the Bates Engineering valve springs that are described in the Ecotec build book. They were supposed to allow us to spin the engine 1000 RPM faster. Well, one failed right away and caused a valve to drop.



In my quest to replace the head, I learned about the difference in cylinder head castings between the 2004 and 2005 model year of the Ecotec engine. See my thread on that one here. Thanks to Maven for the lesson there.

So I had to buy a brand new head (expensive, ouchy) and this time I went with a Ferrea valve train. I don't have it yet, but I already feel better about it. This time I have replaced the entire valve train, not just the springs. And the springs are dual coil, so if one breaks, the other will prevent a valve drop. This set up will allow a new red line of 8000 RPM.

I intend to break the engine in normally aspirated for a short time. Then it goes to Hahn Racecraft for the installation of the turbo. I haven't been releasing this email for a while because I couldn't be sure it was going to happen until now. So here's Bill Hahns note:

Geoff,

The package as described here is capable of 475 HP on 110 octane fuel, but will be usable on the street at an approximate power level of 325 HP on 93 octane. Splitting the difference with, for instance, 100 octane unleaded is also an option. We would set up the different boost/power levels to accomodate your preferred fuel option(s).

An item not addressed below is the catalytic converter. This can be upgraded (the stock piece will not be appropriate) to suit your particular needs insofar as emissions preference and testing requirements for your region.

Our accomodation to you would be the complete installation, and resultant tuning work, at no charge. This is an approximate savings of several thousand dollars overall. We would expect to recoup our investment via the developmental information gathered during the process, as well as in the attention this car will then achieve as it demonstrates itself to the public via enthusiast internet boards, race/show events, and magazine coverage. I'd like to also see what your plan is in this regard as far as getting the car exposed.

====================

Intercooled Cobalt Turbosystem with following upgrades:
Super 20G Turbo
Turbonetics Raptor blow-off valve
StreetRace Sheetmetal intake manifold
PortFueler fuel enrichment system
Profec B electronic boost control system with steering-wheel mounted remote control
3" stainless steel cat-back exhaust system


Please let me know what you think,
Bill Hahn Jr.


Anyway, I have additional plans as well for suspension work in the coming year. Electronics after that. Still putting together what I want to do there. Right now I'm trying to figure out what I'm going to use as a Front Wheel Drive Drag Radial tire to use at the strip when off-street.

Here are most of my notes to date with my current price list for the above work:
Engine parts (ecotec 2.2L L61 engine)
Rods Eagle CRS5765C3D ARP 2000 bolts (650 HP) $330
Piston, pin, and ring sets Wiseco K583M86 $460
8.9-1 comp ratio and standard bore
Rod bearings GM Goodwrench $22
Head gasket and bolt Kit (GM Goodwrench) $110
Girdle Bolts $95
Springs and valves Ferrea
Sport Compact Competition Plus Valves
F1961P Exhaust Valve 21.18 *8 $169.44
F1963P Intake Valve 21.18 *8 $169.44
Sport Compact Valve Springs
S10057 16.53 *16 $264.48
Titanium Retainer
E11033 12.82 *16 $205.12
Adjustable Cam Gear set
Goodwrench Performance # 88958613 $362.68

Engine work
Machine labor for engine build $1007
labor for R&R $1684.38

Transmission
IPT custom transmission $2976.30
Engineered performance LSD $575
IPT Electro-Manual controller $569

Instrumentation - Autometer
Carbon Fiber Mounting Cup 2121 $38
C2 line
7175 air/fuel ratio $72
O2 probe accessory 2244 $92
7159 boost/vac $200
7144 pyrometer EGT $160
Nexus line
6400 CPU $200
6891 Software $ ?
6459 Boost/Vac $250
6445 EGT $230
Probably gonna need some plumbing / Bungs

From Chevy
sport pedals (PN# 12499875) $81.13

Clifford Matrix 2-way remote starter with turbo timer $600
w/GPS $900
K40 Undetectable Dual w/ Laser jammer $800
window tint 3 rear windows $180

Body shop
Body kit (RK Sport) $580
paint and install $620
Ram air hood (RK Sport) $850
Hood P&I $

Suspension
Shock, strut ?
Pro-Kit springs from Eibach 3899.140 $208.91
Anti-roll bars 3899.320 $346
Control arm bushings
Engine mounts

Wheels (4x100)
18x7.5"
Pirelli PZero Nero M&S P225/40 ZR18TL 88WM+S

Front drag radials ?

Front and rear disk brake kits
SSBC $2100


I'll continue to post updates in the coming weeks as work progresses. Hope you all like the info.

 

Kick ass bro, 'Twill be stupidfast.... And crazy expensive...Damn.

 

god dman boy!!!!!!!!!!!! I like the concept bro! good thing you upped the tranny cus 300 hp WOT one time prob would kill it! i would say you sould hit 12's easy (autos easier to launch) youll def need a drag tire cuz you are never going to grab the ground

 

ditto

 

keep up the good work, whyd you pick the 2.2 to upgrade? just curious, why no other car/model?

 

Why not? It'll be kick ass when finished! I'm glad everything is coming along!

 

Wow, I see all the things you did/spent on the 2.2L.

I'm starting to get rough figures for my NA all motor 2.2, keep up the good work.


----And Bring Some Pride For Us Auto Guys ----

 

Not always... FWD+300whp+Automatic = wheel spin!


Halfcent, I have admired this project ever since I heard of it a couple months ago. I can't wait to see it finished. Good luck in this time consuming project!

 

Here are some pics of the engine just before we reinstalled the head. Car will be on the road tomorrow.

Here is the timing end of the short block all put back together and ready.



Here is the top of the block. You can see the brand new replacement Wiseco piston there. The other 3 were fine and were reused. Notice the nice concave "dish" shape for forced induction use.



Lastly, and most expensively, the brand new head with the Ferrea valve train. No EGR casting. Dual coil valve springs (hard to see I realize), titanium retainers, triple groove valve stems and locks, stock cams.

 

while it's apart why not upgrade the cams? stock going to do fine for you?

 

wow, this is awesome and a hell of alot of work and money, good luck i bet you cant wait to drive it around, i wont be doing this work for a few years most likely unless i win the lottery ill be stuck at stage 1 for a while

 

yeah i thought turbotech sold forced induction cams for the 2.2, maybe since we dont have a tuning computer that could be a factor

 

i'd love to hear the final outcome and #'s you're putting down... can't wait to see it totally finished!

 

WOW! Good luck with everything. Can't wait to ya' get that beast to the dyno or track so we can get some numbers off of ya'.....and for roughly $17507.88 you better be hitting the 12's!!!!!

 

Three reasons. First, I am using the GMPP adjustable cam gear set. So I will be able to manipulate the timing during Dyno Tuning just fine. Second, Cam replacement can be done on our engines without removing the head. You just take off the valve cover and you have access to everything you need. So I wouldn't have to rip it all apart again. And lastly, nobody I have talked with and nothing I have read so far tells me that a different cam will do any better then the stock unit with the goals I have for the car. So I haven't changed it.

 

ok. reasonable.

 

This is really starting to shape up! Well done! Cant wait to see the end result!

 

wow! $$$$$

 

Pretty cool..... I would of just bought a faster car stock.... purchased a used ss camaro for 23k and dumped 3k into it....

 

You could use that arguement for any car that you mod though.

 

this car is gonna be fast as hell though

 

It really isn't about how much money you spend but what the final product is. Halfcent could have spent even more but all that matters is that there is no other cobalt like his.

 

How many PSI of boost and WHP will this setup give ?

 

325 in street form

 

Not yet. Wait till my warranty's up .