The Shaolin's Boosted RWD stupid Saturn Project

[The Shaolin]

Hey dudes,

Figured I'd get the thread rolling on here as well. I was originally planning on going FWD:

http://www.brewcitymuscle.com/forum/showthread.php?49960-The-Shaolin-s-Stupid-Swap-Project

But, after getting the engine and trans into the engine bay and seeing how very far off everything was....I figured if I was going to have to do a TON of cutting and welding I might has well make it worth my while right? This way I don't have to fuck with things like custom axles, knuckles, front suspension geometry (too much, anyways) I figured it was more work, but less headache, if that makes sense.

So, on to the parts:

L61 2.2L Ecotec from a 2003 Cavalier
AR5 Transmission from Sky/Solstice
240SX rear end and rear subframe


What I need to decide yet:

This was planned as a supercharged FWD setup originally...and I didn't realize until today that there's not much hope of fitting the supercharger, as it's going to be positively buried in the firewall. (Although it would be neat to have a cone filter in the middle of the dashboard....hahahaha). So, I'm contemplating either going with a different blower, or turbo.

My vision of the car has been revolving around a supercharger for awhile...and I like that I won't have to worry about the intake, exhaust manifolds, intercooler, downpipe, oil lines, etc...as I already have parts that will bolt on for all of this. Still, it looks like it might be easiest in the long run to sell all that and buy all the LNF stuff that will bolt on.

I'd really like to run a 2.4L LE5 bottom end (forged from factory), or the 2.0L LSJ bottom end (already set up for boost) rather than build this engine. We'll see.

I'm also planning on running a megasquirt for full standalone control.

[Crawlin]

Don't worry about how far under the cowl it is.... if this local guy can get it to work, so can you!

http://www.youtube.com/watch?v=X8_x_DLfgLY

hahaha

[The Shaolin]

Yep, I've definitely researched Jake's car and talked to him a bit. I wanna get down there and check it out sometime when it's not buried at the back of the shop ;)

My transmission showed up today!
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/228717_620751628449_184800787_33741449_2811689_n.j pg

http://i19.photobucket.com/albums/b174/schlawin/DSC_04861280x768.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/225659_620772945729_184800787_33741808_3833528_n.j pg

Mock up trans!

What my basement looks like. This all came off the car!

http://i19.photobucket.com/albums/b174/schlawin/DSC_04811280x768.jpg
Before:
http://i19.photobucket.com/albums/b174/schlawin/car/DSC_0022a.jpg
http://i19.photobucket.com/albums/b174/schlawin/car/DSC_00771024x768.jpg

Where the car sits:

http://i19.photobucket.com/albums/b174/schlawin/DSC_04831280x768.jpg

Starting to cut:

http://i19.photobucket.com/albums/b174/schlawin/DSC_04841280x768.jpg

http://i19.photobucket.com/albums/b174/schlawin/DSC_04851280x768.jpg

Subframe
http://i19.photobucket.com/albums/b174/schlawin/DSC_04891280x768.jpg

[KidCougar]

out of all things, why a saturn?

[Crawlin]

says the man with a Cougar :) hahaha

all in jest :)

[xxtremeteam]

should be very cool

[Bobby "Big Daddy" Flay]

says the man with a Cougar :) hahaha

all in jest :)

werd

[sloLs1]

finally got on here to check it out! i love the way that car looks!

on a side note... in the next 2-3 weeks ill be getting back to my ls1 project!

[The Shaolin]

out of all things, why a saturn?

Because it's in my garage, taking up space, and I'm bored and I have an angle grinder? Because nobody's done this before quite the way I'm doing it?

Most of all, why the fuck not?

Seriously though, I've had the car for almost 10 years. I wanted to do something special with it. It wasn't worth selling it and I didn't want to put another shitty engine in it. I've already got a fast car, a bike and a daily...


finally got on here to check it out! i love the way that car looks!

on a side note... in the next 2-3 weeks ill be getting back to my ls1 project!

Thanks!

Glad to hear it, make sure to take some pics!

[Beagle]

finally got on here to check it out! i love the way that car looks!

on a side note... in the next 2-3 weeks ill be getting back to my ls1 project!


Thats what I like to here!!!

[sloLs1]

Could there be 2 rwd red sattys rolling around this summer?!

[The Shaolin]

Could there be 2 rwd red sattys rolling around this summer?!

Hahaha. I still have zero idea how you got yours going so fast. I really don't see myself getting done any time this year, we'll see though. If you ever wanna swing up and check it out, I've got some homebrew on tap for ya ;)

I will say that this is definitely the forum with the most RWD Saturn projects....lol.

[Flicktitty]

Sounds like a cool project, best of luck, do you have a 240sx rear subframe yet? if not and your lookin for one check out www.wi240sx.com ;) someone on there should have one.

[The Shaolin]

I do have the subframe and rear diff, but I'm still looking for knuckles and some stock suspension parts to play with...thanks for the link :)

[WhatsADSM]

240sx rear is a good choice. If you are looking for an LSD I would definitely recommend the s15 HLSD. Good luck with the build

[spooln30]

That trans is made by Aisin. Pretty close to the R154 in my Supra. Cool build.

[1siksrt]

cool build, i still plan on shutting down the neon after i hit nines, part out some stuff.... then get to heavy fabrication to make it rwd as well :)

[The Shaolin]

Thanks guys!


240sx rear is a good choice. If you are looking for an LSD I would definitely recommend the s15 HLSD. Good luck with the build

I was eyein up that S15 diff, but figured I should get it running before I start making upgrades! The subframe looks like a pretty close fit, two of the lower bolts are a fraction of an inch away from lining up with where the stock lower control arms bolted in.


That trans is made by Aisin. Pretty close to the R154 in my Supra. Cool build.

Yes it is! When I was looking for information on this trans, the one thread that kept popping up was comparing it to the R154 from a supra forum!



cool build, i still plan on shutting down the neon after i hit nines, part out some stuff.... then get to heavy fabrication to make it rwd as well :)

THAT would be something to see :)








Anyways, update today, I went to Gibson's in Neenah...dropped the rear end out of another S13...I need the knuckles and lower control arms, figured I'd take the whole subframe because it was easier to pull. Spent an hour getting it out, they sent a truck to come pick it up for me...they left it in the truck, I go inside to pay at the counter...told them I had a rear end assembly....he's like "Well, that's $150".

"I brought $100 cash. That's all I got"

"You're not getting that for $100".

"Alright, fine. I'll leave the differential, I just want the subframe."

"WOAH WOAH, HANG ON, you didn't tell me you had a subframe too! $100 for the subframe, $175 for the diff. $25 a piece for the axles and struts. $375 plus tax"



Freaking ridiculous. I wish there was a picknpull on this side of the state line...had awesome luck and fair prices at the Chicagoland ones...

So, I might go back on Monday and try to get the axles and subframe, but $150 is still rape. Might just say "fuck it" and go to a picknpull next weekend...the hour plus drive might be worth it.

[wrath]

"WOAH WOAH, HANG ON, you didn't tell me you had a subframe too! $100 for the subframe, $175 for the diff. $25 a piece for the axles and struts. $375 plus tax"



Freaking ridiculous. I wish there was a picknpull on this side of the state line...had awesome luck and fair prices at the Chicagoland ones...

So, I might go back on Monday and try to get the axles and subframe, but $150 is still rape. Might just say "fuck it" and go to a picknpull next weekend...the hour plus drive might be worth it.

I would have said, "For $375 I want the whole car". I would have left it all there... It's not like they pulled it out for you and shipped it to you.

[The Shaolin]

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/267741_628286428649_184800787_33846670_7680142_n.j pg

I see now why SloLS1 dropped the engine and tranny in seperate....hah!

[BR3W CITY]

engine load leveler/tilter for the win!

When I did my engine, I put the truck up on stands so the trans could clear the floor even at an extreme angle on the leveler. Might make it a bit easier on you.

[The Shaolin]

The car is on stands. I'm probably going to have to jack it up higher and slide the engine/trans assembly in from underneath.

I can't lift the engine any higher, the top of the hoist is in the rafters. Even with the leveler cranked all the way to one side, the angle isn't great enough, the engine hits the firewall and radiator support at the same time.

[waldotaz2003]

nice project on the way ....:headbang

[The Shaolin]

Well, just about due for an update here:

I ditched the ecotec idea. It was too tall, the exhaust comes out on the wrong side, no RWD mounting bosses on engine...I sold the engine and transmission I picked up.

I think I'm going to through a boosted rotary in it. ~250whp should make this a perfect little roadster, and the rotary would be awesome and hilarious.


Anyways, I moved since those last pictures and have finally been actually working on the car.

A lot of the unibody in the back had to be cut away to get the rear subframe to fit...I'm working on boxing all that in and adding mounting points for the subframe.


Here's the suspension just about in place:

http://i19.photobucket.com/albums/b174/schlawin/car/DSC_03231024x768.jpg

You can see the notching that had to be taken out of the frame here:

http://i19.photobucket.com/albums/b174/schlawin/car/DSC_03251024x768.jpg


How the rear part of the subframe will attach to the car: 2x4 tubing will be made into a new crossmember.
http://i19.photobucket.com/albums/b174/schlawin/car/DSC_03241024x768.jpg







The front subframe is out of a 1991 Mustang GT. Here's what it looks like, roughly jacked into position. A little more rectangular tubing should tie it all in nicely.


http://i19.photobucket.com/albums/b174/schlawin/car/DSC_03271024x768.jpg

[The Shaolin]

Here's how the front of the rear subframe will be installed:

http://i19.photobucket.com/albums/b174/schlawin/Saturn%20Swap/DSC_0344.jpg

Look ma, no jack! Subframe hangs from vehicle from nothing but the mounting bolts for the first time:
http://i19.photobucket.com/albums/b174/schlawin/Saturn%20Swap/DSC_0345.jpg

[Wagonbacker9]

Coming along...

[Flicktitty]

this is gonna be pretty cool, looking forward to it.

[sloLs1]

this is pretty sweet... its my dreams coming to life haha

[blackmage]

haha this is awesome. keep the updates comin

[The Shaolin]

Finished tacking the crossmember into place tonight:

http://i19.photobucket.com/albums/b174/schlawin/photobucket-42039-1351556879901.jpg

Still have some minor alignment issues, but one of the control arms is bent, and the wheels move slightly backwards as they travel upwards, so it's real hard to do this at full droop. It's within 1/4", I can dial the rest in later.