Ecotec, Fastback, T-Top Build. (Page 2/21)
Lunatic JUL 04, 05:02 PM

quote
Originally posted by RCR:

Cool build.

Bob



Thanks Bob. Enjoy the show. I'll try and make weekly progress on it.



quote
Originally posted by Tony Kania:

Good luck with you build!

You Canadians make me smile. Not sure why, but there seem to be a lot of great ones.

Now, on with the show...



Thanks Tony. Pennock's is full of great builds from all over the world. Mine is no where near as elaborate as some but I'm having a lot of fun working on it.



quote
Originally posted by Bloozberry:

Look at all that room between the rails! No friggin' fair!



Dave, I might just have a little more room under the hood than you do! LOL. Mine is going to be real easy to work on.



quote
Originally posted by rourke_87_T-Top:


Hello Shayne, that's my username on the G.T. Fiero forum. 8 throttle positions on locomotive.



Hey Rob. I didn't realize that you had a different name on this forum. Now I know and I changed it as seen above.



quote
Originally posted by cam-a-lot:

Looks great Shayne!! Maybe I will pay some shady mob enforcers to kidnap you, lock you in a garage my my shitty swap, and threaten to cut off a finger each week until the engine and tranny mounts are replaced with something like this... Looks awesome bud!! You are an artist



Thanks Pete. I like to do nice work as often as possible. No one like poor quality workmanship. I'll look at your swap one of these fine days and give you my opinion. This will buy me some time before the mob shows up.



quote
Originally posted by wftb:

Nice build , good to see all the progress .If you want to get really fancy with your PS pump block off plate you can get an OEM one .The 06-07 2.2 eco's came with one from the factory .Any car of those years with 2.2 and electric power steering I think .Newer versions of the 2.2 have the PS pump mount removed completely from the cylinder head .



Thanks Steve. Progress is steady. It's sometimes difficult to balance riding the motorcycle, life, work, etc. I'm doing the best I can with the time that I have. The power steering pump was something I whipped up at work. It's a little more personal then just buying and installing a factory block-off plate.



quote
Originally posted by foxgapfiero:

Keeping an eye on your build, I would really like to do the same swap into my 84 Convertible. I think I can do the mechanicals, but wireing is not something I think I can get past. Nice thing about my car It is a manual trans, no AC, no cruise type of car. A lot less stuff to hook up. I have been driving my friends 09 Cobalt around for a few days while he is on vacation and like the feel of the 5 speed, 2.2 combination, but maybe a turbo would be nice?




Wiring is easy. If you follow this thread, I'll post the wiring in time. And yes, some nice detailed schematics as well. Enjoy the Cobalt. Before long, you'll have to give it back! I too would like a turbo but for now, I'll just try and get it together first. Then the power adder can come in play.

[This message has been edited by Lunatic (edited 07-27-2014).]

Lunatic JUL 07, 06:49 PM
This next part of my build thread is for anyone interested in swapping the 88 front suspension into the 84-87 chassis. This is not quite a bolt-in affair but it's pretty easy to do. Some frame notching, welding, elongation of a few holes and a little patience is all it takes. As you can see, at this point of the build, I have the cradle bolted into place using all eight bolt hole locations. (Six were stock while the two rear mounting locations were fabricated). I left the locating stud intact and measured side to side and fore & aft.
Note: Before you begin, you'll need to find a complete 88 front cross member assembly. The control arms, steering rack (and intermediate shaft), sway bar, spindles, calipers, etc are 88 specific and are different than the 84-87 parts.

Start by removing all the old parts. Steering rack, sway bar, brake lines, etc. No pics, you get the idea.

Here's the notch of the frame rail that has to be cut in order to clear the 88 front cross member.
Note: Leave additional clearance for the coolant tubes! I had to go in later on and notch for this additional clearance!


Here are the elongated holes that I had made to the crossmember. Notice the locating pin?




Here you can see the 88 cross member in place after notching.


Now, the gap is a little large. This is due because the offending area on the 84-87 frame. Remember, the back portion of the lower control arm mounts to the bracketry associated in that area. I wanted to fill in the gap and make it look nicer, almost factory. So, I created "caps" for both sides using 14 gauge metal.






Here's the passenger side cap installed. Notice the smaller gap(s) and the control arm clearance.




There are a few more area's that must be addressed. After removing the factory bracketry, you can clearly see the back two mounting locations are floating in the air.


I simply took some 10 gauge steel and formed up a "U" channel, then welded it in. It's around 3" long, and 2" tall. Now, you can also see the step the 88 cross member has. I just added a small plate, of the appropriate thickness, to take up the extra gap. I then drilled a 1/2" hole through the "U" channel and secured the assembly with a 1/2"-13 x 1 1/2" bolt, nut and washers.






Don't mind the corroded and ugly looking coolant lines! They'll be addressed.


The front mounting locations line up almost perfectly with the rear factory lower rad saddle bolt holes! A little slotting with the die grinder, and voila.






That's it, that's all. Reinstall all the 88 specific parts and you're good to go.
Note: The 88 coolant tubes are a little different than the 84-87 units. I will use the 88 tubes as that's what I have. (After I repair the kink from the previous owner first).

[This message has been edited by Lunatic (edited 07-13-2014).]

Dennis LaGrua JUL 07, 08:10 PM

quote
Originally posted by foxgapfiero:

Keeping an eye on your build, I would really like to do the same swap into my 84 Convertible. I think I can do the mechanicals, but wireing is not something I think I can get past. Nice thing about my car It is a manual trans, no AC, no cruise type of car. A lot less stuff to hook up. I have been driving my friends 09 Cobalt around for a few days while he is on vacation and like the feel of the 5 speed, 2.2 combination, but maybe a turbo would be nice?




Stand alone "plug n play" harnesses with PCM's are available for the Ecotec. My friends son has the supercharged version of the engine in his Cobalt and he claims that it really moves. This build thread is really incredible and complex. That's why I stick to the easier swaps for now.

------------------
" THE BLACK PARALYZER" -87GT 3800SC Series III engine, custom ZZP /Frozen Boost Intercooler setup, 3.4" Pulley, Powerlog manifold, Northstar TB, LS1 MAF, 3" Flotech Afterburner Exhaust, Autolite 104's, MSD wires, Custom CAI, 4T65eHD w. custom axles, HP Tuners VCM Suite.
"THE COLUSSUS"
87GT - ALL OUT 3.4L Turbocharged engine, Garrett Hybrid Turbo, MSD ign., modified TH125H
" ON THE LOOSE WITHOUT THE JUICE "

RCR JUL 08, 06:45 AM
Although your endcaps look good, I think you made a mistake.



The area between the cross member and the frame rail needs to be open for the coolant tube to clear (unless you were planning on doing something different or the angle of the picture is misleading).

Bob
Lunatic JUL 13, 06:48 AM

quote
Originally posted by Dennis LaGrua:


Stand alone "plug n play" harnesses with PCM's are available for the Ecotec. My friends son has the supercharged version of the engine in his Cobalt and he claims that it really moves. This build thread is really incredible and complex. That's why I stick to the easier swaps for now.



In this case, I'll be using the stock GM PCM part number 12576162. HP Tuner's supports it and there are a few options within the parameter's that allow for fuel enrichment (boost applications) and such. Besides, GM spent a lot of time making this work and if it's good enough for them, it's good enough for me! LOL. So far, this has been an easy swap. I'm just doing a few other things along the way.
Lunatic JUL 13, 07:00 AM

quote
Originally posted by RCR:

Although your endcaps look good, I think you made a mistake.



The area between the cross member and the frame rail needs to be open for the coolant tube to clear (unless you were planning on doing something different or the angle of the picture is misleading).

Bob



Indeed RCR you are correct. Since I never removed the coolant tubes from the 88 parts car, they were already off, I didn't know how "exactly" they were installed. The 84-87 cars had them snake through the control arm and therefore were mounted differently. So I just figured that I could mount them as high as possible. Well, I just worked on the car this weekend and I didn't really like the way the coolant tubes "hung down". Mind you, it was only like an inch but still. Onto the modifications. Thanks Bob for causing me more work. LOL.
Lunatic JUL 13, 07:14 AM
Okay, lets try to protect the coolant tubes and raise them higher within the frame.
Here's the offending area.


Now, if you look at this view, you can see there is a semi-circle relief in the factory crossmember. Let us use this as a reference point and make a notch to match this.


Without showing you all the cutting, grinding and welding, I ended up with this.








Add a little primer.




After some paint and undercoat, we have this.


Here's the additional clearance with the crossmember installed.








I can still push the coolant tubes and have them almost touch the inner wheel well. They are slightly pulled out for the photos.


[This message has been edited by Lunatic (edited 07-13-2014).]

Lunatic JUL 13, 07:22 AM
Here are some parts that went off for sandblasting and powder coating.


And the end result.


Now, I'll have to order some greasable poly bushings and new ball joints, etc.
RCR JUL 13, 09:23 AM

quote
Indeed RCR you are correct. ... Thanks Bob for causing me more work. LOL.



I did something similar on mine, so I know it's better to find out earlier.

Nice job on the repair.



Bob
BabyEating Dingo JUL 13, 04:38 PM
Loving this build. I'm a huge fan of the 2.2 Ecotec. Super reliable, easy to work on, and puts out lots of power for how small and light it is. I don't have the skills to pull this swap off, but one day...