★★★★ 665.79 HP / 611.19 TQ ★ E-FORCE BUILD ★ GRAND SPORT ATTACK PACKAGE @ CoW ★★★★
01-23-2012, 11:53 AM
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St. Jude Donor '07-'08-'09-'10-'12-'13-'14
★★★★ 665.79 HP / 611.19 TQ ★ E-FORCE BUILD ★ GRAND SPORT ATTACK PACKAGE @ CoW ★★★★
Congratulations "BIG AL" on you GRAND SPORT E-FORCE BUILD!
665.79 HP / 611.19 TQ
on 93 Octane, WITH CATS, NO METH
Some time last year, Al brought me his new 2010 Manual GS.
At first we installed the normal VARARAM, STAT, AMERICAN RACING HEADERS, and CoW TUNE
with our 4.10 REAR END CONVERSION. The car was a TOTAL BLAST to drive!
In short order, somehow Al managed to blow up our rear end. Not sure what
the hell he did, but he busted it none the less. We made the decision to
re-install his original GS (ZO6 type) rear end and back it up with a new ZR1 CLUTCH.
Next, Al decided to go with the EDELBROCK E-FORCE SUPERCHARGER.
NOW, the car was really fun to drive....This was an EARLY system from BEFORE
there was actually a DRY-SUMP kit available. We made a DUAL-CATCH-CAN
system for him and kinda made our own DRY-SUMP system. This car was FAST.
In "CLASSIC AL STYLE" the car showed up shortly there after on a flatbed
as somehow he managed to EXPLODE the new ZR1 CLUTCH we installed for him.
Al mentioned a problem shifting into 3rd under power and we quickly figured
out why the clutch exploded. The 2008+ 6060 TRANSMISSION has synchronizers
that just simply SUCK. They get notchy or grind when cold and don't really
like to be shifted quickly. Over time, and pretty quickly, the synchros wear
out and the trans does not shift under power or at higher RPMs. When AL
attempted to find third at WOT (under boost) at 6,000+ RPMs... 3Rd WAS
NOT THERE.
With the clutch not engaged at RPM making good power under boost, the new ZR1 CLUTCH simply EXPLODED due to centrifugal forces
at that RPM. We have seen a few cases of this happening and we have
developed a solution.
While the TRANSMISSION was being converted tothe CoW/ROCKLAND MAGNUM BUILD with ZR1 SYNCHROS, we had some time to develop
a MUCH BETTER CLUTCH for cars like this wanting HOLDING POWER with all the
smoothness and comfort of a STOCK CLUTCH. During that time we also noticed that
Al's drive shaft in the torque tube was bent so we replaced it with a nice 3.5 inch
aluminum shaft with upgraded guibos from THE DRIVESHAFT SHOP.
During the build we kept noticing rear end fluid leaking from the back of the car, but we never
could find a leak... After going over AL's rear end with our new USB MICROSCOPE
we were able to see a huge crack that only opened up under power and closed up when
the car was on the lift making it impossible to spot. This actually happened to us twice
and to make this problem go away for good, I decided to TIG-WELD the PASSENGER
DIFFERENTIAL COVER. Now, AL can beat on this thing to his heart's content
without having to worry about the the rear end breaking.
While we were fooling with the car...AL decided that he NEEDED MORE POWER.
The next mod was to install the famous CoW CAM. This time we made a change and
modified the LOBE SEPARATION a bit to make CoW CAM work better with the BLOWER.
We call this new design "CoW CAM 2" and it worked very well. Now that we
had installed a rather aggressive cam, we expected to lose some boost, so.....
We set out on a mission to develop the first EDELBROCK E-FORCE 8 RIB PULLEY SET.
The set consists of all new aluminum pulleys with a 10% overdrive on the crank and a 3.25
underdrive on the blower. We ran two tests...The first one you see on the dyno was the
3.5 pulley that made 7 psi and 632.53 HP and the 3.25 pulley that made 665.79 HP
@ 10 psi of boost. VERY NICE! With all that boost, we decided we needed to cool off the
intake charge and then began the next challenge. We installed a large 4 row aluminum
radiator and moved the GS engine oil cooler to a better location and installed a
SECOND INTERCOOLER and a large computer controlled intercooler pump
capable of flowing about 14 GPM which is 4 times the flow of the pump that comes
with the Edelbrock kit. All of the hoses were replaced with larger ones and when finished
the coolant capacity of the liquid to air intercooler system was doubled.
After finishing that system, we then made some small modifications to the car
and created a really nice COLD AIR INDUCTION SYSTEM to help feed outside
air to the large E-FORCE air filter. When finished, this helped us lower out IATs SIGNIFICANTLY
and also permitted us to make multiple BACK TO BACK RUNS WITHOUT waiting for the
BLOWER or the INTERCOOLER SYSTEM to cool down. This was a HUGE BONUS!
While making all of these changes to AL's MONSTER GS, we decided it was time for a new
fuel system. We decided to use the AEROMOTIVE A1000 IN TANK PUMP with their
REGULATOR and FUEL PUMP CONTROLLER along with plenty of #8 RUSSELL
HOSE and FITTINGS. Despite how crazy this car was turning out to be, It was important
to us to have the best idle possible so we knew we needed to get some top shelf
85 LB/HR LS3 FUEL INJECTORS FROM JON @ FUEL INJECTOR CONNECTION
in Cumming Georgia. Jon pioneered most of the injector mods people are selling today
including a really special new INJECTOR TIP that he custom machines in house. When we've
got a big build that requires FLOW and PRECISION, we always use Jon's injectors.
Topping off this crazy build was a Mild 2 WILD kit for AL's NPP mufflers and a
YELLOW TOP OPTIMA BATTERY.
Have a look at some of the following pics as they definitely help tell the story of this build.
And last but not least... NO BUILD SHOULD BE WITHOUT OUR NEW CoW BOOSTER!
Thanks everyone for watching and THANK YOU to BIG AL for participating
in such a nice build. This build boasts some really nice numbers and allowed us
to use his vehicle to help develop some really cool new products for the C6 CORVETTE!
Thank you BIG AL!
Chuck CoW
Last edited by Chuck CoW; 01-23-2012 at 03:46 PM.
02-28-2012, 07:35 AM
#8
Naples FL
Welcome back! Great right up! Just curious how this build compares to Eric's? Amazing stuff...
03-26-2012, 03:41 PM
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St. Jude Donor '07-'08-'09-'10-'12-'13-'14
This really was a great build!
This really was a great build!
We just got a deposit to build another one just like it....
This really is a FANTASTIC COMBO!
Chuck CoW
We just got a deposit to build another one just like it....
This really is a FANTASTIC COMBO!
Chuck CoW
03-26-2012, 06:52 PM
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Incredible! Having had work done on my car I have first hand knowledge that Chucks expertise and dedication are second to none!
Now if I only could scrape together some pocket change, say 15-20 grand like I'm sure Big Al did, I'd be booking my appointment with Chuck today! Lol. Great Build! Good Luck and Enjoy it!
Now if I only could scrape together some pocket change, say 15-20 grand like I'm sure Big Al did, I'd be booking my appointment with Chuck today! Lol. Great Build! Good Luck and Enjoy it!
