BlackJack's 2003 Olds Alero GL 3400 V6 Turbo Sponsored By: -->

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Started with just a body kit before I knew there was anything performance related available. Once I started in on the performance, I was going to ditch the kit, but found out it works good functionally for the intercooling setup..

Wife was nice enough to grind off the bottom of the front bumper on a parking lot curb, so I took advantage and skirted the bottom with flexible poly material. Helps hold the front end down with less air passing underneath. Plus now I can actually run over speedbumps without angle cutting them. Note the driver's side duct has the intercooler pump behind it, the passenger's side will shortly have the external transmission cooler mounted in it.

Hard to believe with all the power it puts down that I'm only ranked #6 for Alero performance mods!!

sPEcS:
- T70 turbo
- 50mm BOV
- 48mm wastegate
- liquid/air intercooler
- 4t65e-HD trans from an '03 Pontiac GTP
- LSx performance throttlebody (80mm)
- Boost referenced AFPR
- #42 Injectors (soon to be upgraded to #65)
- Walbro 340 (255 LPH) fuel pump
- Custom fuel rail
- Ported and polished Lower intake manifold
- Custom Upper intake fabricated from 3500 engine (not shown)

SPECIAL: Exterior coating applied which prohibits the adhesion of rediculous "ricer" emblems such as "GTR" badges and the like.

Overall Turbo components:
During liquid intercooler install - (now you see why the body kit)
Liquid-air intercooler install used a scirroco radiator with high-volume pump for circulation. Future will see an "ice bucket" setup for extreme intercooling.

Intercooler exchanger rated for up to 700+ HP. I dont have quite that much yet, but leaves a tiny bit of room to grow!

Turbo - T70, .70 AR cold side, .84 AR hot side, doubles as a chipper-shredder in the off-season!! There were a few doubters out there that thought it would never spool, but it kicks in at about 2500, and reaches full boost (15psi until trans gets built) by 3500-3800 RPMs.

50mm BOV and 48mm wastegate
MAF - pulled from a C5 Vette, had to increase the MAF tables to take over where the poor overworked MAP sensor leaves off. One day soon, the MAP sensor will be upgraded once the data mapping issues can be incorporated into the computer. Original on the left, new one on the right. Quite a size difference. Also incorporates a built-in IAT sensor so no more blowing it out the charge pipe.

Head Gaskets - full copper .070 with stainless rings, from Gasket Works. Reportedly, the pistons will blow out through the oil pan before these headgaskets give, and I'm going to do my best not to test that theory ;)

TRANSMISSION SWAP
(Driver's side view)After smoking a couple of stockers, I researched upgrades for the 4t45 transmission. I found that up to date, the fastest times held by a 4t45e N-body platform was somewhere around 12.4 in the 1/4. Not even close to my goals. ZZPerformance was reputed to have a 4t65 build that was holding deep into the 9's, and looks like 8's are right around the corner for them. Time to pump up to a 4t65.....

(Passenger side view)I'm still saving for the heavy build, but for now, the stock 4t65e(HD) from the '03 Gran Prix GTP is reputed to be holding to the high 11's in alot of cases. Bolting this stock unit in will allow me to work out all the kinks before dropping the big money on a built unit. The swap incorporates solid mount for no torque loss (yes it's bumpy), and also required the GTP flex plate and torque converter. For ease of install, stock GTP axles and hubs were used, although custom machined hub spacers were required because the wheel-base is wider on the GTP.

Battery Relocation kit from Summit Racing puts the battery in the trunk since the turbo kicked it out from under the hood. Meets NHRA regulations for being sealed, vented to the outside. Neatly houses the Optima "red-top" battery. Soon to follow, external battery shutoff necessary for aftermarket power adders.

Exhaust - I don't have any current pics yet, but not hard to imagine a full 3" downpipe from the turbo all the way to the rear axle. No cat, no muffler, and definitely no EGR to bog it down.

Turbo Phase 2: Previous set-up had it's limitations, and more flow would be needed. New upper intake manifold was fabricated using the 3500 body, hacking off the old neck, and welding in a 3" pipe with LS1 flange. Mock-up is shown on a non-functional garage engine for fit. Coming soon, pics of the setup actually installed. Most recent pics are on my camera which I left at my parents during my last visit, so I can't retrieve them till December ....DOH!

Thanks for viewing (and reading). I know I ramble alot, but how else do you explain the madness?

For those of you that have been waiting for video, we're less than 60 days out!!

THANKS FOR THE SUPPORT FROM THE FOLLOWING SITES AND THEIR MEMBERS:
AleroMod
N-body Power
MalibuClub.ca
GAGT
GAOClub
N-body.net
GMPT
60DegreeV6
GMV6PCM
ClubGP
AZClubGP