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V1 Pisco's extended city goblin #220 (2009 SS/TC donor) Registered

Desert Sasqwatch
Do you still have the 'stock' parts to temporarily return the engine to its unmodified configuration? May be worth the effort to try to get things working before jumping in with all the HP modifications. I'm just thinking out loud and this is only my opinion. Want to see you be successful.
 
Robinjo
I think you have two strong options here:

1. As DS mentioned; put the stock items back in, get the thing running and then do the upgrades. I know this would be a pain but think it's the better of the two options
2. Flash the new ZZP base tune into the car. It's going to run like poo with the mods on the original tune before adding the mods.

Did the Cobalt run well before disassembly?
 
Rauq
I made those changes, it started and idled ok

I didn't flash a tune yet, I read the tune to send to matt at zzp who sent me back a starting tune based on mods (cams, valve springs, Opel fuel rail, aluminum flywheel, e85) but I have not downloaded it to the car yet. I will have to do that and need to get it on the road to do data logging to make adjustments

I still think some clarification is needed on the sequence of events.

Did you ever run the engine on stock parts and stock tune?
Then you installed the cams, valve springs, Opel fuel rail, aluminum flywheel, e85?
You started the engine after these parts were installed and it started and idled ok?
Then you disconnected the battery and BCM, and when you hooked everything back up, it idled poorly or barely at all?
Has it been/is it still on the stock tune this whole time, or when did you flash ZZP's base tune accounting for the mods?
 
pisco
I still think some clarification is needed on the sequence of events.

Did you ever run the engine on stock parts and stock tune?
Then you installed the cams, valve springs, Opel fuel rail, aluminum flywheel, e85?
You started the engine after these parts were installed and it started and idled ok?
Then you disconnected the battery and BCM, and when you hooked everything back up, it idled poorly or barely at all?
Has it been/is it still on the stock tune this whole time, or when did you flash ZZP's base tune accounting for the mods?


Did you ever run the engine on stock parts and stock tune? NO

Then you installed the cams, valve springs, Opel fuel rail, aluminum flywheel, e85? before stage 2 parts showed up from DF

You started the engine after these parts were installed and it started and idled ok? YES!

Then you disconnected the battery and BCM, and when you hooked everything back up, it idled poorly or barely at all? YES, then made a loud bang foollowed by grinding metal on metal noises that gave me chills

Has it been/is it still on the stock tune this whole time, or when did you flash ZZP's base tune accounting for the mods? ALWAYS BEEN ON BASE TUNE, (I don't know if it is "stock" donor had zzp stickers and at least upgraded map sensors.

it idled fine, zzp told me it would and just not to rev it up at all.
 
G
"YES, then made a loud bang foollowed by grinding metal on metal noises" is quite a bit more than "making noises I didn't like". This isn't likely something a tune will fix or cause at idle.
 
pisco
Oops , "Hey everybody I appreciate the support here and don't want to seem harsh or ungrateful" Typed Immediately after my last reply to @Gtstorey as I had to close the screen and go tend to family matter. Didn't even open my laptop Friday or Saturday, and have had significant time available to make progress on the car.
Everybody - Seriously thank you guys for sticking with me, I know I overshare sometimes but that's just my style. My build has been full of delays and problems starting in 2020 and just recently got past stage 1, at one point almost sold my unfinished kit, Thought I had a bad engine after buying the donor at the auto auction, and now it has ran and I'm nervous again that something is seriously wrong! I went from the peak of my career and having a 4th child to health problems, time off for surgery, a demotion then a slap in the face asked to be a 2nd in command to the guy who replaced me so I can teach him how to do it but the kicker was being laid off over the phone on my way home from the hospital for a cardiac procedure! that was when I listed the kit for sale and I decided I wasn't working for anyone like that again and started a new career. Here is what I was in the process of putting out here.
Hey everybody I appreciate the support here and don't want to seem harsh or ungrateful I do appreciate the input for sure, I think I need to be more clear sometimes. Right now I am not interested in working on the engine at all, I am leaving it as is, flashing the base tune from Zzp and data logging for adjustments. The plan is to have an E85 tune set to local summer ethanol content, e40 to have a mid level ethanol as a steppingstone to, 91 octane, and last a power reduced tune with a lower rev limiter for "guest drivers" (this list will be very small) and street driving. I'm just gonna send it, If something is broken I will have to replace it anyway.
I'm only nervous about having to spend more $$$ at this point.

This weekend I was able to get the brake proportion valve mounted and plumbed, I fabricated a 2 gauge mount by the steering wheel, addressed the brake fluid leak at the reservoir and replaced the nylon tubes with Tractor Supply EPDM hoses, Buttoned up a lot of the wiring but not finished, cleaned up more of the floor pan mess from the brake fluid and still need to drop the floor and clean it right then recoat everything, seat brackets might not work out as well as I had hoped ( angles on the harness belts are way off) so I'm not sure what to do there, adjusted the shifter and can grab all 5 gears now, That leaves - Bleed brakes and clutch, flash tune, mount wheels, align, drive....
 
pisco
This weekends progress.

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From cardboard cutout concept to 3d modeling (6 versions) I built v4





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To a working product, It isn't real pretty but it sure holds gauges and they are in!
considering I cut this with a battery porta band, smoothed it with an 80 grit flap disc in an angle grinder, and it was my 1st time welding aluminum in 15 years I'm not ashamed but also not done this is prototype #1






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I made a brake proportion valve mount from 22ga stainless because I ran out of aluminum, and used 1/4" thick washers under the front mounting hole to angle the valve away from the bracket
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The double flare, Bubble flare with a couple odd sized tube nuts was interesting. I ended up robbing tube nuts off of a cobalt in the scrapyard, nobody local had any and I'm done waiting on shipping, the kids ask daily why I'm not done yet summer is going to be over soon.


maybe next week we will be talking alignments and splitters vs front wings.....
 
pisco
I flashed the pcm with the Zzp tune and it purrs. Idle smooth no noise no problems, I still suspect the noise I heard was something else but we will see in time. I was also able to get the brake leak fixed and wheels on and fill the trans with fluid, hopefully the syncros like the fluid I was able to get my hands on.
It is absolutely shocking how low it sits after being on jack stands as high as possible to work on for so long.
After work tonight I will be cleaning garage and moving the gob to the "big side" to do a makeshift alignment and test drive today or tomorrow depending on how long it takes.
Pics to come later...
 
pisco
I've been crickets here for a while.
successful test drive #1 last Saturday, a quick alignment adjustment then #2!
took it to a buddy's house to show him (other side of the neighborhood) and a storm front rolled in. In my haste to get to the garage I pulled on to the "main" road which is not heavily traveled and got on it harder than I should have. Kicked the back end out and almost instantly felt a searing sensation on the back of the neck and right tricep area followed by billowing steam. I blew the top coolant hose off the cylinder head and sprayed hot coolant everywhere! What a mess!!!
Limped her home the mile or so in 2nd gently and hopped out to find no hose clamp maybe I forgot that one, I double and triple checked every bolt but not the hose clamps.....

Now I'm slightly worried I have a blown head or gasket. I'm probably just worrying too much and it was the lack of a clamp.
Holy moly that thing rips. I made a couple new friends in the neighborhood on test drive #1, one of them has a v10 R8 he is twin turbo ing... the other drives an rs3 then the c8 corvette guy pulls up on his golf cart and says "This thing looks like all sorts of trouble... I'M IN!!!
You all weren't kidding on the amount of attention the Goblin grabs

I'll add pics soon, still need to fix the hood wrap ( I did a horrible job) drop the floor pan and re coat then reinstall and add the front wang and diy diffuser
I just got off the phone with Kelsey at Rally and she is quoting me
Adam sent MCO and I hope to have Montana plates (or temp tag) by July 4 for an event here
 
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G
I've never seen a blown head gasket cause a coolant line to turn loose. I would think if it was blowing past the head gasket enough to do that, it would run like crap.
 
pisco
had it happen on an old boat, that was a mercruiser 3.0 4cyl no coolant in oil no oil in coolant but the cylinder pressure was blowing out into the coolant passage

anyway now a new issue popped up which may be with my laptop I guess vcm editor won't connect to the vehicle with a tune loaded
I can read the current tune but can't flash a new one sent by zzp.... I'm not sure what to do next looks like I may have to open a support ticket.
 
Traé
had it happen on an old boat, that was a mercruiser 3.0 4cyl no coolant in oil no oil in coolant but the cylinder pressure was blowing out into the coolant passage

anyway now a new issue popped up which may be with my laptop I guess vcm editor won't connect to the vehicle with a tune loaded
I can read the current tune but can't flash a new one sent by zzp.... I'm not sure what to do next looks like I may have to open a support ticket.
Try re-syncing the interface and make sure you’re not connected to the car in VCM Scanner.
 
pisco
Try re-syncing the interface and make sure you’re not connected to the car in VCM Scanner.


I closed the tune file, read the current tune in the car then laded the new tune file and it worked fine. weird glitch I suppose
I got a data log and sent it off now hopefully adjustments can be made and I'll feel more comfortable getting on it, I'm excited to feel more than half throttle and some higher rpms.
 
pisco
going through alignment procedures I noticed the front hub mounting stud nuts were all loose, completely as in not even finger tight....
crazy after I know I double checked them. I will now triple check everything again!
alldata has the torque spec as 85 ft lbs I was being lazy instead of looking for the build video segment with front suspension. twisted a stud in half, parts stores don't stock them autozone told me $36 and a 3 day wait I can buy a whole bearing assembly on amazon for that that comes with 4 studs. U pull-it is my other option as of now I can't find any online anybody care to chime in on that?
 
pisco
I have the drilled hubs from DF so I will just be stealing the studs out of whatever I get
Maybe I make a trip to the junkyard and steal one from a car there
 
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