Turbo I, Mike's build thread

[Llia]

Not a Sonic, but I picked up a '92 Isuzu pickup last week:

Super cheap, 300,000 miles, the thing runs like a top I can't believe it. A/C blows cold and heater core works. This will be my parts hauler and work truck.

4ZD1 gas Isuzu 2.3L motor, 2 barrel carb, MSG-5 speed mechanical clutch, 4.10 7.5" GM corporate rear.

I've been searching for an ultra-rare Borg Warner NWC T5 that came bolted up to an Isuzu 1.9L gas motor in '82-'84 S10/S15 trucks. I plan to swap it in the Isuzu truck (or use the Isuzu bellhousing/input shaft) to get rid of the Isuzu MSG trans for good, but parts are hard to come by.

I had a silver one. It was a hand-me-down from my brother. Not sure if all manual clutches are hard but I remember it not being easy to push.

I used to call it the Isuzu Brahma, until I realized that Brahma was just the name of the bed cover.

 

[mja]

I had a silver one. It was a hand-me-down from my brother. Not sure if all manual clutches are hard but I remember it not being easy to push.

Isuzu love Yes, this is pressing the manual clutch with manual steering:

 

[mja]

A few days ago ran against EPYON96R at the track, who whooped me at 14.8 to 17.2. My trans got hot and wouldn't shift and boost wasn't building, so I hit the brakes and trapped 61mph instead of breaking something.

I thought a retune that BNR sent was the issue, but went to work on mechanical maintenance before. Since Rudy's car breaks less cuz he's not an idiot and his auto is consistent, he was the test base, running E85, bolt ons, & maybe 200lbs heavier with passenger + rear seats. Our 1st test run was on the old tune, cars were really close. These are the videos after uploading the 2nd tune, we thought Id be slower so this was kind of a surprise (no video from 1st run)





Lesson - E85 is awesome & BNR tuning shouldn't be second guessed.

 

[mja]

The V3 Triton turn lamps don't fit the rear in a bad way, had to hack it good, still didn't fit perfectly so now there's some dents in the panels behind the tail lamps opcorn:

Flashers on:
V3 Triton on left, VLED "HIGH VISIBILITY AMBER 21 LED 3156 3157" on right

Both V3 Tritons

Parking lights:
V3 Triton on left, VLED "HIGH VISIBILITY AMBER 21 LED 3156 3157" on right

V3 vs LED, flashers:

Both V3's, parking lights:

...& both V3 flashers/blinkers:

 

[2014 Blue RS]

those V3s look bright

Sent from my SM-G950U using Tapatalk

 

[mja]

 

[carsNskis]

Lights look great! Night shots of the headlights? I'm curious to see the cutoff line

 

[mja]

Lights look great! Night shots of the headlights? I'm curious to see the cutoff line

Thank you sir! I'll get some next week, the intake manifold is currently off the car for a secret dyno project

 

[mja]

So folks, the secret dyno project will stay a secret. But it has something to do with a different car and Trifecta and parts.

Stock casting imperfections:

Taking down the port openings:

About 8% done with one runner lol, it's how I like to spend my afternoons.

 

[mja]

It's been a while since an update, have been working on finishing up my degree.

Here is a dyno of the stock vs ported manifold on a relatively stock 1.4t sonic with a tune (this is a different Sonic with only a Trifecta tune):

I'd say the ported *intake* manifold does exactly what we'd think it does. Loses a lot of mid range torque and gains a little above 5600 rpm. Probably not worth it for an everyday driver.


We axed the ported *exhaust* manifold project, things got too busy. Next up for Turbo is a BNR E85 kit to run a 50/50 mix E85 & pump gas.

 

[mja]

Spring cleaning for Turbo..

Oil change/filter - Royal purple 5w30, check/reset spark plug gap, clean AEM dryflow filter, inspect common failpoints, 2 new Pirelli's under mileage warranty, alignment, transmission gear oil change - Royal purple 75w90 synthetic, 2.2 quarts.

My DIC, which is 4 mpg high, wasn't seeing over 46 mpg on freeway stretches for a while. It's been months since getting a 40mpg tank. Now the car is at 54-56 mpg freeway and I'll easily hit 40 mpg this tank. Seems basic maintenance makes a big difference on our cars.

Alignment at Goodyear, my caster on the right side is off a little... Goodyear tech says a hole can be reamed out to correct for this adjustment but it's minimal so they recommend not to fix it. I'm not sure its a good idea to be widening stock suspension holes, but suspension is a weak point for me If there are any suspension experts around, I'd appreciate some advice in ways to get the alignment within spec.

My idea is to throw parts at it:

j/k I'm at 85k miles, past GM's service interval for new shocks. So sport suspension kit

Also ordered

One of my VLED SMZ fog lights decided to stop working, driver side. Probably from the water/condensation collecting around the vent area under that portion of the bumper cover/wheel well. They had a 1 year warranty and of course were purchased 13 months ago :blankface: The SMZ's are also discontinued. Their micro LED headlights replace the outgoing SMZ's, and there is a 2 year warranty on them:

 

[mja]

Finally tracked down a broken front power window issue.

There are two fuses for the LT and up earlier models front windows, one for the passenger and one for the driver side. It's listed in the manual as 'front power windows' = passenger and 'driver power window express up/down' = driver. I kept blowing a fuse for the whole front window circuit but the driver side was fine, no problems.

Swapped out passenger side with a good window switch and good window motor, new fuse, nothing. Just a blown fuse a few days later each time. After checking resistance the harness was fine. Turns out a loose connection/pin at the fuse box was taking out fuses. Been working fine since.

 

[mja]

I asked BNR if I'd need 52 lb injectors for GTX and E45 and ...

 

[mja]

Racer X fab thought this through. So many taps LOVE THIS :banana:

 

[Tormach]

O.. that is perty.

I will be watching your build for your review of it. Def plan on getting one soon.

 

[Papasonic]

Beautiful piece, looks like $$$

 

[mja]

It really is art, Im fine with it on the kitchen table for now

 

[mja]

GM 'Sonic Performance Suspension Kit'

Rear springs (old/new)

Front springs (old/new)

Front bump stop size difference

Rears were a breeze, glad I got these out of the way first

It's possible to take the top nut off the strut without GM's tool. But buy the tool :blankface: This fiasco lasted 45 minutes for each of those nuts.

Used a real nut on reassembly

One of my strut mounts fell apart or was busted from some time ago. A little axle grease should keep it going another 80k miles

Should probably change that cabin filter

And the final job. It looks same as stock opcorn:

Why doesn't every Sonic come with this suspension??? My verdict shows that GM believes Sonic drivers want a quiet ride that can go over railroad tracks with ease. Cuz that's it, that's all that's better.

OEM vs GM Performance -

Body roll: GM performance
Handling: GM performance
Looks: GM performance
Noise: OEM
Railroad tracks: OEM
I suppose for pulling a trailer, OEM would win too. Sonitruck.
Ride quality: same for both

The look is PERFECT. The front hasn't settled but I see about 0.5" now. The rear is noticeably lower, about 1". This kit makes the Sonic look like a normal car. Still have some rubber squeaky but hopefully that'll go away after a week or two of driving.

Thank God the body roll is gone. OEM suspension does not like power upgrades.

A big thank you to Crate engine depot for offering the lowest price on this kit!

 

[carsNskis]

I run this for RallyCross because it classifies as stock class. Never had issue with railroad tracks, or berms, ruts, etc

[emoji593][emoji809][emoji472]

 

[mja]

The front end most def hits bump stops over the tracks near me above 15 mph, not pleasant. As far as railroad crossings go, these are pretty rough though.


I think you told me a while back carsnskis that we couldnt tell a difference between the two suspensions in everyday driving. Cruising in a straight line I really can't tell, ride quality is on par with stock stock springs, love it.