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Discussion Starter #1 (Edited)
This thread has been too long time in the making.
My name is Rod and I own a 2005 Cobalt SS that i hope has the chance to enjoy some friendly competition with some Corvette owners in my area.

.... I think the Cobalt is pretty sweet and a decent platform to play with, one question though what do you think the time frame on that little motor will be with 750 hp beating it? You really need to start a thread in our other cars section with pics and progress of your project. One of the cool things about this forum is we can appericate the bad ass no matter what form it comes in.
Good luck with your project.
I originally posted a couple of things about my Cobalt 10 months ago and I have been waiting patiently for some substantial pictures to show of my project.
When I first posted I mentioned my project, the plans were to build my car to 750whp. The project has been a very slow process and it has changed direction several times.
To achieve the 750hp mark, we are building the complete engine, with many new custom parts made specifically for the project.
I am staying with the original 4cyl, LSJ. We removed the S/C in favor of two turbos. These turbos will be run in a sequential setup. The smaller turbo, GT28-76, will be to maintain low end boost for street drivability, as my car will be my daily after work driver. The larger turbo, GT4508, is for my top end power.
The engine sits only waiting for the custom crankshaft to arrive early next week. We have over designed the engine and it will comfortably handle 1200bhp @9500rpm.
In the early part of this year the transmission became a costly venture and for a fwd car, it was more than I was wanting to spend. That was when the decision was made to go all out and convert my Cobalt to RWD. We are pairing up my engine to a T-56 with upgraded internals, including a Viper mainshaft.
I have waited months for that conversion to happen and after firing the first shop, the second shop is finally moving forward.
The shop, Distinct Images Custom Cars, is doing a complete race chassis, 4link suspension and NHRA roll cage good to 7:50. We will use different rear ends for the street (Posi) and track (spool). I have emphasiesd to all involved with the project that handling on the track as well as in the corners is a paramount concern to me. To this end I understand that I give up something and that is why I will spend time swapping parts and adjusting the suspension, depending on what surface I will be driving on.
The exterior of the car will remain as stock as possible. We will need to do a couple of alterations to accommodate engine bay cooling and turbo intake.
The interior will obviously have many changes but again, we are working to maintain the Cobalt's original look, apart from the major changes needed to accomodate the conversion. We will upgrade the interior look by wrapping all plastic with leather. We have an award winning shop handling the "show" component of the project.
As I mentioned before, I am hoping to be able to race some local Corvette owners at the BC and Alberta race tracks.
The expectations are that we should have this car on the road in March, '08.
While the following pics are showing the car far from finished, the last 3 weeks has been bringing steady progress and the next few months will see plenty of big changes.
The first picture is just to give an idea of the size of tires we are using for d/r's. The other pictures are of the frame/suspension being test fitted.


 

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never thought id say this but thats pretty damn cool for a cobalt
 

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Discussion Starter #3
never thought id say this but thats pretty damn cool for a cobalt
Thanks. That's cool to hear that from a Corvette owner.
 
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Discussion Starter #5
Anyone who puts that kinda dedication and vision into their car gets mucho respect here:thumbsup:
Thanks, that much appreciated and totally different from the many Cobalt naysayers, who just tell me "you should have just bought a Corvette"
I mean I read about some of the modifications you guys are doing to your cars and it seems nothing escapes the "mod bug". There is only a different starting point.;)
 

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Discussion Starter #7
:surprised

Talk about an endeavor.

Great to see the progress pics, keep us posted on any neat things you run into along the way. Nice to see someone doing a 4-banger up right!
I have ran into a lot of things already, one being the PITA fwd was.
The other thing I learnt the hard way was that when ordering 1-off custom parts, 4-5 weeks means 4-5 months. There has been a whole lot of hurry and wait. Only the past 2 weeks has there been some serious headway been made. The shop doing the complete conversion expects the car to be ready for the next shop in 4 weeks. Before too long they will drop the car onto some wheels to show me how the ride height will look.
After the test fitting is done the parts all go for powder coating and then the fun really starts.
I was really happy to see the car cut for the conversion. I will be really happy to finally see the floor/tubs in the car.;)
 

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Were you wanting the car to be RWD in the begining? I can't believe it's more cost effective to conver the car to RWD than it is to build a FWD trans. Was it a case of "for this much more it can be RWD".

Either way BAD ASS. I can't wait to see the final product. I love the looks of the Cobalt I just dislike the Fwd aspect of the car. Good luck and keep us posted.:thumbsup:
 

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Discussion Starter #9
Were you wanting the car to be RWD in the begining? I can't believe it's more cost effective to conver the car to RWD than it is to build a FWD trans. Was it a case of "for this much more it can be RWD".

Either way BAD ASS. I can't wait to see the final product. I love the looks of the Cobalt I just dislike the Fwd aspect of the car. Good luck and keep us posted.:thumbsup:
The plan wasn't originally to go RWD. The problem was the expense of getting 1-off gears made for the fwd manual transmission. No one wanted to do the gears with out a larger commitment of sales.
I didn't want to convert to an auto because I love manual.
When the price of the gears came in, the company added the cost of the tooling (which they planned on keeping) and then there was going to be the shipping/duty/insurance/exchange. By the time it added up we were looking at $14,000. for the tranny. We would then have had to change the uprights/halfshafts/wheels and assorted related parts. By the time it was all said and done it was going to be close to the cost of the RWD conversion.
Then there was still going to be the need to do a sub 10 second, NHRA rollcage.
By going rwd we solved many problems. Say goodbye to the traction issues and fwd, torque steer. Also, I won't be dependant on mainly custom drivetrain parts. Most of what I am using are straight off the shelve. The parts that are custom, like the driveshaft, we are having two made so we always have a spare.
This also goes for our custom engine internals, as we are building a spare engine.
Then the biggest thrill of all is knowing that I will be powered by my rear wheels. I am 48, so I grew up with rwd and I miss it so much. I also agree that GM screwed up when they didn't put the Cobalt on a RWD platform, such as the Soltice/Sky.
As for updates, I will give them as we move forward.:D
 

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Discussion Starter #11
That's very cool :thumbsup: . I heard that the motors in those are very well engineered.
Yes, all of the Ecotec's are very well engineered.
GM has chosen to leave some weak links in each motor but once those are upgraded these engines are very stout.
There are several racing crews who are running the 2.2 Ecotec at 1,400hp and those cars are running in the low 8's - high 7's.
The LSJ itself is being replaced by the LNF, which is a direct port injection, turbo charged engine. The LNF meets emissions standards where the LSJ doesn't.
 

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Discussion Starter #13

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Cool project!

You're insane!

and that's why you fit right in here...
:thumbsup:

Keep us updated and don't forgt the pics.
 

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Discussion Starter #16
Cool project!

You're insane!

and that's why you fit right in here...
:thumbsup:

Keep us updated and don't forgt the pics.
That's what I keep hearing from my wife. She used to ask me what this was costing and I would tell her "you don't want to know" Now she doesn't ask, she just says " I don't want to know, do I?":rolling:




nice tires :agree:
Those are 390's d/r's and they are insane on a Cobalt.
The street tires will be 335's on the back and about a 265 on the front.
Other than the tires, not much will be different on the outside of the car, so only astute drivers will realize something is "different" about my Cobalt.;)
 

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Discussion Starter #17
Here are some more components of my project.

Powering my engine are these two lovely snails. The larger is the GT-45 and the smaller is the GT-28.

I have two different set of custom rods, one from Macias Racing and 2 sets from Pauter Machine. I am actually building two engines so that I have a spare.


The following picture is the initial design for my turbo header. We are waiting for the chassis and engine placement to be finallized before the rest of the header is to be done.

This is one of two Turbo Switching Valves, which will be used in the sequential turbo setup. The white cotton looking material is aerospace grade insulator which withstands temperatures in excess of 1,000*s.

This unit is a totally custom Boost Swithcing Unit that will operate the aerospace transducer and turbo switching valves.

The following pictures are some parts that have come back from being coated.
The pistons received better than a ceramic coating, they received a zircon-ceramic coat, which is similar to diamond dust, and the piston skirts received the anti-scuffing coating. The valves all got the zircon ceramic coat, as did the intake, exhaust runners and the combustion chambers of the cylinder head.
The shiny coating on the valve cover, front cover and the sides of the head is an Aluminum flake coating, which in person is supposed to be even shinier and cooler than the pictures show. The engine block is still being done and we should have that back next week. This aluminum flake coating is supposed to be superior to powder coating as it is impervious to the elements. If oil gets on the engine, I have no idea how that would happen, it is just a matter of dish soap, water and a tooth brush to clean it up. Degreaser is a no-no.
If you look at the picture with the pistons next the head, you can compare the polished piston to the new coating.



Here are some of my parts to help with cooling. The ribbed tubes are the equivalant of Laminova tubes. The Meziere water pump is one of two we will be using. One for the intercooler and the other in place of the stock water pump. In addition to those parts we are using a customized "Supercooler" that will produce 800 watts of cooling power.

Meziere water pump

Supercooler

Bully Clutch has come aboard as a sponsor and will be supplying me with clutches. This clutch will allow for street driving but I will need to adjust my driving style when in traffic.

A.R.E. Dry Sump Kit

SFI Approved McLeod Bell-housing


Here are my custom billet cams. The custom grind was done by Bates Engineering. The specs are
INT 221° @ 0.050" - 275 LL, max. lift 467.0"Vlift @ 1.7:1 - Config Stock Centerline 10° Retard Cam Timing Intake
EXT 221° @ 0.050" - 275 LL, max. lift 467.0"Vlift @ 1.7:1 - Config Stock Centerline 6° Retard Cam Timing Intake

These are the cylinder sleeves we are using , also from Bates Engineering.

Stainless Steel Brake Company were the only ones who were able to supply us with the big brakes needed that would fit behind a 15" wheel for my slicks.

These are the custom seats for the car but I will be changing the suede in favor of leather.

The car will be street driven but will need to be setup for the track which means swapping out the Pro Street carrier and axels to a strictly drag racing set. Once this is done the car will be trailered to the track in my matching trailer.
 

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i would not want to run into you on a cruise night !!!!!:WTF great job i like diffrent stuff and it looks like youre doing a top notch job good work :cheers:eek:h one more thing more pics!!!!
 

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:thumbsup: :thumbsup: F ing WOW:thumbsup: :thumbsup:
 
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