Well, I finally am underway with my project for break; cheap/cool engine mods for my car.

The cheap:
Ported/Ceramic Painted Exhaust Manifold
Chamfered Heads
Smoothed intake runners

The Cool:
ZiLLA Motorsports Ported and Polished M90 housing
New 180* Thermostat (bah dum chhh)

So far I have the engine down to the LIM being taken off, the S/C apart, the PEM finished and paint drying as I type this, and a few other odds and ends taken care of.

Pics so far:
Engine torn down, waiting its turn:


PEM (close to finished):



Side Note: Welding cast iron is a ROYAL PITA. My welds looked like crap (hence not in the pics) but held up to grinding and weren't porous, so that's the good. This should flow much better than stock...

Spare crossover with heatshield removed and coated (will fab TB heat shield):


I need to get a fuel rail disconnect tool, as the one I got didn't work, and get the rail off and painted (silver) tomorrow, then get the nosedrive and rotor plate wrinkle coated and baked while my parents are out of the house tomorrow/Sunday, as well as get the heads chamfered and clean up the LIM.

More pics will come as it progresses!

_________________
Bye Bye:

RIP sandrock

Nice progress Ed!
PEM may not look so hot, but it'll get the job done!
Can't wait to see some more video updates after these mods. Your youtube account needs to be updated.

_________________
-Car Guy Carl
"Penelope" - 2003 SLE - 247k Miles
"Sydney" - 2000 Honda S2000 - 98k miles

Nobody ever welds cast iron pretty. Don't sweat it. Did I send enough rod for you?

_________________

Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers

Looking good Ed. You will like the extra kick in the pants from those few upgrades. Have fun!

The biggest problem with welding cast, is if you get it too hot it WILL crack as it cools. If you made it through the cooling without it cracking, you did a good job. Progress looks good Ed, I can't wait to do my EM (a little jealous).

_________________


1999 Bonneville SE with the heart of a 07 Grand Prix

Bill, there are 2.5 rods left. Perfect amount.

No cracking that i could see. I was careful to move between runners, and had the flange bolted/clamped to a jug i made of 1.5" steel tubing, which kept the flange from warping. I also stopped a couple times and let it sit for a while.

_________________
Bye Bye:

RIP sandrock

Looks good Ed! I agree video must follow installation!

_________________
Will
88 Cutlass Ciera Brougham International | 120k mi | White w/ Dk Claret Int. | Roller to be S2 L67/4T65E-HD | 1 of ~5100 3.8 FE3 Int'l series
91 Riviera | S2 L67 Swap/4T60E | 127K mi | Antelope Met. w/ Tan Int. | Saved From Death By Crusher
92 Bonneville SSE | L67/4T60E | 77K mi | Med Slate Grey w/ Two-Tone Grey Int. | Low Miles Time Capsule
92 Lumina Z34 | LQ1/4T60E | 177k mi | Torch Red w/Grey Int. | Rusty In Odd Spots
99 Tahoe LT | L31/4L65E | 276k mi | Spiral Grey Metallic w/Grey Int. | Truck for Truck Things and Portable Concert Hall
03 Park Avenue Ultra | 212K mi | White Diamond Met. w/ Shale Int. | Southern Time Capsule
05 Acura RL | 155K mi | Carbon Grey Pearl w/Ebony Int. | The Super-Hooptie Daily

Progress looks good Ed! Will be anxious to see it put all back together and see how much the mods improve performance! x2 on video!

_________________
Eric

2005 SLE, Greystone Metallic, 152K.

A few mods..

You need headers

_________________

_________________
LUCAS Member # 534.
96 olds cutlass supreme SL 4 door 3100 4t60 *3.33 gears* *Fe1* 115K bone stock DD

Just got done wrinkle coating the Nosedrive and rotor plate. I think it went well, all I could find was VHT wrinkle, so I hope it and my job match up with what Bill did.

Pics:






There are a few minor flaws, but not enough to justify trying to touch up. Never see them anyways, hopefully.

Later I'm going to work on chamfering the head ports, and cleaning up the LIM. Not working too quick, don't want to mess it up, and it doesn't feel so over-bearing if you do it a little at a time.

_________________
Bye Bye:

RIP sandrock

Looks pretty good so far, Ed!

_________________
-Car Guy Carl
"Penelope" - 2003 SLE - 247k Miles
"Sydney" - 2000 Honda S2000 - 98k miles

Well, didn't get the heads or LIM worked on, aside from cleaning up the mating surfaces on the LIM gaskets, but I did get the S/C assembled (I know Wren's Techinfo said 24 hrs, I waited 6 and was careful, didn't damage the wrinkle). There is a difference between what I wrinkled with the VHT and what Bill did with the Krylon, but I'm not sure as to whether it was the paint or the application processes used. I'm leaning more towards the latter.

Also got the fuel rail cleaned up and drying overnight from sitting in the parts washer, still not sure whether I'm going to paint it silver or let it be, will decide in the morning.

Pics:



(What you see on the rotor case is the gasket maker that squeezed out and I tried wiping off, will clean it off better later when the paint isn't so soft)

_________________
Bye Bye:

RIP sandrock

Are you going to reinstall the cross over heat shield?

Or were you thinking of just going with the throttle body heat shield?

I would think that making both work together would be best option for keeping the throttle body from getting heat soaked.

Just my 2 cents.

_________________


1999 Bonneville SE with the heart of a 07 Grand Prix

I destroyed the heat-shield, lol. I could use the one that's currently on my car, but I also cut the bolt off that holds it on, so I'm not sure, lol.

Looking at ZZP's site, it appears they leave the shield on and ceramic paint that, I thought the one we installed on Jovan's car didn't have the heat shield. I probably should re-install the heat shield, there is some thick insulation in there that can only help it.

_________________
Bye Bye:

RIP sandrock

Well I'm not trying to be a er. I was just basically curious. I'm sure you'll figure something out if you want to have the heat shield there. I was kind of planning on doing the throttle body shield idea too.

Taking the shield off lets you inspect the pipe for cracks and coat it up to protect it. So it's not like you did it just for looks or for no good reason.

_________________


1999 Bonneville SE with the heart of a 07 Grand Prix

Do the elements in your oven typically glow purple, or did you have neons installed? That's wicked.

_________________

WHITE WHINE - 1992 SSE Supercharged 236.26 ci (.040 Over) 15.090 at 90.2 MPH on old engine w/ slipping trans & melted O2 sensor - Gen 3 M62 and matching TB, Gen 2 Pully, Zillamotorsports Ported LIM, YT 1.72 Roller Rockers, SII FPR & Injectors, Hypertech Thermomaster chip w/ 160 Thermo, TransGo Shift Kit, Infinity/Pioneer Speakers & a 10" Alpine Type R Sub, all the watts, 140 amp Alternator, Ricepipe CAI w/ heatshield, Pilot Angel Eye Foglights, Clear Corners, '02 17" Chrome Bent 5's, Magnaflow F-Body Muffler and Hi-flo Cat, Ceramic Coated Ported Exhaust Manifolds, Fan Override, Monroe Reflex struts, red calipers
2009 G8 GT - Sport Red Metallic, loaded, SOLO Axlebacks, Rotofab Intake, Tuned, autodim mirror, removed intake manifold cover, HSV GTS triple gauge pod, two tone red-hot shifter and HSV SuperSport steering wheel, GXP rear sway bar and diffuser, 3.45 diff and various Camaro suspension bits, LED Taillights

LOL, I saw the same thing!



Looks good Ed! Lookin' forward to see it all put back together again. Did you ever get the fuel rail off yet?

_________________

'93 SSE "Guinevere" RIP 1993 - 2019
'01 SSEi "Chloe" Mods: Intense FWI | GenV | WBS Intercooled | 3.2 MPS | 1.9 YT Rockers | SSAC Headers | N* TB | TEP Trans | 3.29 FDR | Torsen LSD
DTM Tuned | Dual AeroForce | Solid Mounts | 255 Walbro Pump | Fuel Logs | GXP STB & Sway Bars | CSS Lowering Springs | GXP Brakes | Disabled DRL
Magnaflow Mufflers | Magnaflow Cat | GXP Seats & Trim | 35 % Tint | Cleared & Tinted Tails | repinS Retrofited Morimoto Mini H1 | 19" GT500 Wheels
'09 G8 GT "Abigail" Mods: Rotofab | LS3 Heads, Intake & Cam | Kooks LT | Solo Exhaust | Tien Springs w/ GXP Struts | Whiteline Swaybars | BMR Subframe Connectors
Achievements: Guinevere - 264k mi | 16.27 @ 84.10mph | March '11 COTM :: Chloe - 223k mi | 13.85 @ 102mph | January '09 COTM :: Abigail - 192k mi | 12.85 @ 112mph

LOL, that's just the crappy camera on my Bionic, it was glowing red, lol.

Yeah I got the fuel rail off, went to NAPA and got a better disconnect kit and they popped right off. However, I decided I'm not going to paint it ATM, I don't feel like it's gonna turn out good enough to justify it.

Got the heads cleaned up and chamfered, got the LIM cleaned up and the burrs and ridges knocked down, then I got the PEM on, decided I wasn't about to break off the rear bolts and left the stock crossover on, then got the LIM on, tensioner on and set the S/C on and started a couple of the bolts.

I'm heading out in a little bit to go load pigs, and after we load 2 more loads of pigs in the morning, I should be able to get it buttoned up, change the oil, fill it with coolant and hopefully it fires up with no leaks.

_________________
Bye Bye:

RIP sandrock