Oh, just another 3800 turbo 240z

[benton]

First of all, I'd like to introduce myself as I am still relatively new to the forums. I've been a car guy my whole life, but until now all of my past projects have been domestic nostalgia. A few examples include a '23 custom Model T, '40 Diamond T pickup (modified for drag racing), '39 Ford custom flatbed, 1967 Chrysler 300 (the 440 mopar was a kick in the pants), '83 Chevrolet Camaro (SB 350 transplant as the car originally had a 4 cyl), and my current daily driver is an '87 Pontiac Fiero.

 

 

The Fiero is largely unmodified and desperately needs a restoration. The picture below was taken in 2004 just after I’d taken it out of storage while I was in Brazil for a couple of years. It is looking incredibly depressing today.

 

 

In spite of my long history with American muscle, one of the guys that helped out in the shop drove the most gorgeous 240z I'd ever seen. I'd always known that one day I'd own one. Last summer, after selling a 1958 Cadillac Ambulance (really though, we’ve owned and worked on nearly EVERYTHING), I finally had the money together to start looking for my Z. Within about a month, I found a post on Craigslist offering a restoration project. I had wanted to buy a fixer-upper for several reasons, not the least of which was price. A car in pieces nearly always costs less that a car that runs. The biggest reason that I wanted a project car is because starting from the ground up means I can skip the step of tearing it down. I have many plans for the car, and not much of the original mechanical systems will remain when I've finished.

 

 

My original plans included a SBC 327. My father has a block that recently returned from the machine shop with a set of double hump heads from a Corvette engine. In order to meet my power requirements, however, the 327 rebuild was going to get expensive fast. Fortunately, however, as a member of the Fiero Forums , I've seen many amazing engine swaps. One of the most popular is the GM 3800. The current iterations are an evolution from the V6 found in the Buick Grand National. Naturally aspirated, they make a firm 200 HP. The supercharged versions make 240-260 HP. A few guys on the Fiero Forums have been running turbo systems making well over 500 HP. My goals are a little more reasonable. My 240z will be my daily driver with the option and ability to autocross/drag on the weekends. All this in mind, my goal is a 350-400 HP street machine.

A few weeks ago I picked up a Series II engine out of a 2000 Chevrolet Camaro. It was another Craigslist find, and the price was completely unbeatable. It included everything, including the wiring harness and ECU. By my understanding, it has only 30k miles on it, so it should make a great base. It originally came with a 700R4 automatic, but I like the idea of a real stout T5 (there is just something satisfying about the dance of the clutch and the shifter moving through the gate), so out with the 700R4 slushbox! (It is worth noting that I sold the 700R4 on Craigslist and recovered half of my engine investment!)

 

I am the kind of guy that like to see financial data on builds so I can set my expectations accordingly if I am thinking about attempting something similar. As the build progresses, I’ll update the thread with what I have invested in the project. I’ve got a spreadsheet on my computer that I am using to track everything.

The current plans are to continue stripping and prepping the interior for sealant/paint. Then move to the exterior, and finally, the drive train. I’ll keep y’all posted as I move through several phases of the build, and hopefully, y’all can help keep me on track and motivated. It’s going to be a long journey, though, as I’m currently trying to finish graduate school (MS in Mechanical Engineering), working full time, and balancing it all with my girls (wife and daughters). Comments and opinions welcome. Now let’s get to building!

 

EDIT: Formatting

Edited February 17, 2014 by benton

[cockerstar]

I saw the pic of you with your fiero and thought, "Wow! Those really look like the ABC homes in Richland..." Then I looked at your location

 

Welcome to the boards from someone else in the tri-cities!

 

I don't know much about the 3800, but I do know about Z's and welding/fabrication/powder coating, so let me know if I can be of any help.

 

Looking forward to seeing the progress!

[logr]

Hey, maybe we can all get together for an autox with SSSCC. I haven't been there for a while but am due to come reunite with old racing buddies. I will buy the first cool beverages after the race.

[benton]

Funny you should mention that, Cockerstar. The Fiero picture was taken in Idaho Falls, ID and my Z pictures were taken here in Richland (at my ABC duplex). You'd be surprised how similar Idaho Falls and Richland are both in geography and demographic. In any case, I am definitely in need of a welder. After scraping a good portion of the undercoating off, I found the first spot of rust on the passenger frame rail. The plan is to patch it asap so that I can install new passenger seat mounts (they were removed before I acquired the car) and seal the interior.

logrIl, I'll most certainly take you up on that. I've only been a handful of times, but I'm really hoping to get into it once I get my car done.

Today, I should be receiving my new intake throttle body. The original TB is TBW (throttle-by-wire). Apparently, 1999 and up Camaros had an electronic throttle body governed by a sensor on the accelerator. After discussing this with a buddy on the Fiero forum, I was told that it would be a nightmare if I wanted to retain the TBW with a turbo setup. I was told that it would be MUCH easier to get the cable driven throttle body and run a non TBW ECU. So that is the state of things. I'll have the throttle body on this evening and then I'll start the eBay/Craigslist search for a new ECU.

Edit: spelling...

Edit 2: Format

Edited February 17, 2014 by benton

[Six_Shooter]

Small world, I bought my Z from Richland Washington.

[benton]

It has been a long time since an update as I've had a ton of stuff going on with both work and graduate school. In any case, I'm in the process of figuring out how to make the new throttle body work. There is an air passage on the '98 version that does not exist on the 2000 and later TB's so I'm trying to figure out if it can just be plugged/ignored, or if I am going to need to do some machining on the intake plenum. I've been tossing around the idea of using all of the original equipment (throttle by wire) instead, as I still have all of the original parts. I will be able to use this set up and get the car running. Then, when I break down the engine for the turbo rebuild, I can figure out how to integrate the mechanical throttle body. Of the time that I've spent recently on the Z, the most that I've done is finish stripping out the interior. Now I'm at the point where I just need to patch the frame rail under the passenger's seat and then fabricate some seat mounts. Speaking of frame rails, does anyone reading this have any suggestions on the best/most efficient way to strip the crap off of the undercarriage?!

[benton]

Well, some bad news this time. I've had to put the Z into long term storage. I have taken a new job in Wisconsin and I did not have the means to bring the car with me at the present. As we are currently living in an apartment complex, there will be no room to work on my baby. The long term plan is to buy a house (in about a year or two) and then resume Z production. Until then, keep your ear to the grindstone!