Scumbag's new toy / build - LTZ hatch 6 speed manual

[Scumbagsleeper]

Hey guys!
I’m brand new to this forum but been around the Nissan/Infiniti/Ford forums building stuff for quite a few years. My brother and I have built quite a few things from pushrod turbo cars to SR20/VQ35HR's and also high HP automatic builds. Just haven't been into Chevy until now.

I have been wanting to get into building and tuning Ecotec stuff since the tuning software is so advanced now. I am starting a couple projects to dive in. 1st is this build being a 2012 Sonic LTZ hatch 6 speed manual that I bought from auction in Michigan. Looks like it was a repo car and has ZZP stickers, ZZP CAI, BC suspension Coilovers, BNR wastegate, Forge BOV, ZZP intercooler, ZZP Dual gauge pods, and STR 18x8 wheels. So really there isn’t a lot to do except clean her up quite a bit so I can get plates and then start tuning.

Things to do:
• Fix front bumper and wheel liners
• Weld in glass pack muffler (has deleted muffler won’t pass here)
• Change plugs (NGK 91039 stock .27 gap)
• Fix coil pack springs (one corroded and all were not touching plugs)
• Replace 2 tires
• Install AEM X Wideband
• Install Aeroforce gauge
• Install EFIlive – On order
• Find a couple rear head rests (Who steals headrests??!!)
• Tune car (runs like crap under boost)


Down the road I’ll probably upgrade to E85 and a GTX 2860 and weld up a tubular T2 manifold and make a 3” stainless exhaust.

The 2nd project I’ll probably start mid summer. I have a 1986 Chevy sprint plus and am wanting to put a LE2 6 speed manual setup in it. Wanting to keep it around 1800lb or less. I already bought a 2018 cruze that was a flood car for all the parts.

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[macdiesel]

Wow, nice find. How’s the motor? Compression good? Miles?
Looks like the dusk interior. That’s should be a fun ride when you clean it up.

 

[Scumbagsleeper]

Has 174k on it. As good as it runs I haven't thought about running a compression test. I may down the road as I get a few things together.

This weekend I replaced the wheel liners, had the rear tires replaced, changed the plugs, shoveled out the interior and cleaned it pretty good, fixed up the front bumper that either the tow company or auction forklift ripped off. It looks ok enough to get it on the road.

I'm going to have my brother weld the muffler on tomorrow and I'll also change the wastegate actuator bact to a stock unit until I can start tuning.

I got my EFIlive V3 and started playing with it and found that I can not tune the car. I will have to enable a GM package that currently does not exist..... So that's a real downer that I spent $600 for a scan tool... As I said I'm brand new to GM tuning and read a bunch about EFIlive. I didn't realize only the V2 that is discontinued can tune. Hopefully in 30 days or so the GM package will become available so I don't have a $600 brick laying around.

 

[Scumbagsleeper]

Ordered a stock actuator to work out the problems. Also have to wait on EFI live to get GM tuning available for the V3 unit that came in.

The car cuts spark to all cylinders when boost hits on either actuator (BNR or Stock) the BNR actually hits higher boost and faster of course but same issue. The stock actuator hits about 13-14psi then cuts ignition.

I removed the boost solenoid vac line to actuator.
Then hooked up a vac line from intake manifold to actuator.
Only gets 4psi max

Left actuator with open vac line (on most turbo cars this close to doubles the boost) - Hits 13-14psi and acts exactly like it does hooked up factory.

I'm going to guess that my solenoid isn't working correctly so I need to test the flow on it. I'm also going to do a boost leak check. make sure all the silicone hose and intercooler have been installed right. Also make sure the intake manifold holds pressure.

If I'm missing anything please chime in, like I said I'm pretty new to GM stuff so I'm learning.

 

[Scumbagsleeper]

Tested some stuff this weekend.

Tested boost solenoid - used a hose and a 9 volt and sucked air while energizing it. Worked correctly.

Tested compression - 150PSI on all 4 cylinders

Pressure tested for boost leaks - No leaks

So I decided to wait for the ZZP coil pack to come in on Monday. Put it on and also the BNR wastegate actuator (1.5 turns preload) to do some more testing. So far it is only getting 2-4 misses every once in awhile so the old coil pack was bad / really weak spark. I'm guessing the car may have a tune on it since it is running well on the BNR actuator @ 20psi now.

It's not perfect yet so here is the next plan:

Install OEM Bosch MAF - Date code on mine is 2011 so it's original 174k mile (may have weird spots across it)
Install OEM Bosch Upstream O2 - going to guess the O2 is original from the looks of it. (probably very sluggish)
After install of those 2 parts I may tighten the .27-.28 gap if there are still misses logging.
Also get my wideband installed on the dash

I always replace the O2 / MAF on every turbo project since they are a wear and tear component that should have been replaced at 80-100k. I won't even consider tuning until they are verified working correctly.

 

[Scumbagsleeper]

Pretty sure I'm going to start building a twin scroll manifold. Going with a Honeywell / Garrett twin scroll that should be good for 300ish whp. Not shooting for that HP but will have a little extra for later. Hopefully the turbo will come in next week so I can start cutting the manifold plate and twin scroll plate. Got to order some tools for the mill also.

 

[Scumbagsleeper]

Got the new Bosch 02 and MAF. I had to cross the old Bosch OEM MAF number to the new part number. They don't make the old version anymore. It works great, so far I am getting 7-8 mpg better estimate. I'll know after running a tank through it. Had them swapped out in my work parking lot in 10 minutes, that was easy!!

 

[sonic24740]

if it hasnt had a timing chain with that mileage may want to have one done soon. i got a 2013 rs that had a lot of aftermarket stuff and a tune around 124,000 had it two weeks and threw a rod threw the pan. the exhaust cam jumped a couple teeth and that was the end.. nice build up so far.

 

[Scumbagsleeper]

That's weird. As I said I'm totally new to the GM platform so I'll look into that for sure. The SR20 cars that we used to build never needed a new timing chain. Done rebuild after rebuild on old $200 engines with over 200k miles pushing 300+ HP and still on original chains, tensioners, pistons & rods. I have to wonder if the tensioner fails to allow slack or something... Maybe when I get a spare engine in the shop to rebuild I'll measure the stock chain and see if there is stretch compared to spec. Guess I'll research research research.

 

[Scumbagsleeper]

Had my brother weld a bung on the old cat pipe. Thought about making a stainless 3" unit but I'm going to swap the turbo out for a larger billet wheel Garrett twin scroll as soon as EFI live decides to make the V3 GM tuning package. Kinda wishing I went with HP tuners now....

 

[Scumbagsleeper]

Picked up a bad LUV engine to start the twin scroll manifold. Got the Garrett billet wheel turbo in and am cleaning it up and modifying it to work with the LUV engine. Tested the stock injector to see real flow numbers. They are 304cc @ 3 bar and 344cc @ 4 bar. I am currently at 100% on them and need to run bigger units. Also thinking about going to a return fuel system like every other car I have built. Wouldn't cost much and I have almost everything laying around to do it.

Good news. EFI Live V3 has GM support so I can now start learning to tune the GM stuff!!!

Bad news. messaged BNR and they said the VIN came back as tuned by them but they want full price and to buy their cable to do tuning since I'm not the original owner. I was going to buy injectors and a retune from them until I go big turbo but I guess I'll figure it out myself along the way.

 

[Scumbagsleeper]

It's been awhile. I have just been daily driving the car because I have been building a turbo 5.3l 4x4 Sierra for pulling trailers. Need it for work so it took priority. I'm past 190k miles now and the only thing I have done is change the right control arm with a OEM GM unit and change the front brakes because one of my pads broke in half and was making noise. I upgraded to bigger Encore brakes in front. Ran to the junkyard and picked up what I could and ordered ceramic pads and drilled/slotted rotors.

I have 50lb injectors on the way, flex fuel sensor and also all the stuff to convert the rear to encore rear disc brakes. As soon as I am done tuning the truck I'll start on the sonic.

 

[Scumbagsleeper]

Got the 50LB injectors installed and tuned. Also installed a E85 sensor and enabled the flexing tables. Had 59% ethanol in it and it started right up in 25 degree weather.

 

[Simplyjesse]

So where's the sonic at now bro? You were under appreciated and a day late to this forum like me. **** Looks more like a build diary haha. Still a dope build page though and I'm glad to see a serious build, most people quit at bolt ons. I finally spun my clutch. Thanks to finally taming the knock, advancing the timing in the 2.7 pressure rato area, and the wot box. Got her pushing 27#'s on 9, meth and CX T3 next. Would love to see the whip, got instagram? Cheers from Vegas

 

[Scumbagsleeper]

I bet it pulls good with advanced timing and 27lbs! I don't use instagram or most social media platforms. Still driving it as a daily and it will have 200k miles in a couple more weeks. The only other thing I have done is change out to shelby GT500 injectors to max out the ecu before having to rescale everything.

 

[RichSPK]

It's been awhile. I have just been daily driving the car because I have been building a turbo 5.3l 4x4 Sierra for pulling trailers. Need it for work so it took priority. I'm past 190k miles now and the only thing I have done is change the right control arm with a OEM GM unit and change the front brakes because one of my pads broke in half and was making noise. I upgraded to bigger Encore brakes in front. Ran to the junkyard and picked up what I could and ordered ceramic pads and drilled/slotted rotors.

I have 50lb injectors on the way, flex fuel sensor and also all the stuff to convert the rear to encore rear disc brakes. As soon as I am done tuning the truck I'll start on the sonic.

View attachment 15710

Oh! From a Buick Encore! I just kept thinking of the old Renault Encore/Alliance.

 

[Scumbagsleeper]

Oh! From a Buick Encore! I just kept thinking of the old Renault Encore/Alliance.

Yep, Buick Encore brakes and rotors, Cheap upgrade. The rear caliper plates and brake cables are sonic RS parts.