Thread: Dirt cheap mods: my never ending struggle

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  1. #1 Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Alright, so as not to pollute the "What did you do to your boat today" thread, I've decided to take after many great people on this site and start my own thread documenting my experiences.

    As an introduction, I am currently an Electrical/Computer Engineering Student Born in North Carolina, now married and studying at UMKC in Missouri (yes, I miss North Carolina, no it wasn't my decision to move). I picked up working on cars after one fateful day at the mechanic where I said "enough is enough" and started binge-watching youtube. It's been a couple of years, and I'm still learning although I've picked up a few tricks here and there.

    While I'd love to have infinite money and throw stacks of change at ZZP for expensive modifications, being a broke college student, I have to settle for the junkyard, craigslist, and forums for my parts.

    I've become a local inhabitant of my Pick-n-pulls here in Kansas City, and currently do odd jobs and sell things on the side (when I'm not buying stuff for myself!). So, if you ever need parts, just let me know!

    The beginning:

    I was looking for a project car on craigslist and after passing up dozens of other cars, I came across this grand prix posted for $500. The driver's side door was smashed in, fender was dented as well, and the engine didn't run. It was a 2002 pontiac grand prix gt stock model with only 117,000 miles. One owner vehicle who had every service record and receipt (literally ever) for the car. A little old lady had bought it from the dealer right off their lot after test driving the exact same vehicle (it was the test car) for almost the msrp price! The interior was in good shape, and with the exception of a minor fender bender and the door smashed in, everything was in good shape. Although the owner didn't know it, there was no frame damage from the side impact, and was for the most part, cosmetic.

    The battery was almost brand new as were the tires, and I checked all the electronics for function. The speakers all worked but were obviously shot, the radio worked but the back-light bulb was burnt out, and the abs was throwing a speed sensor code and almost every engine code in the book. Apparently the car had an oil leak (typical) and they weren't sure if it ran dry. The engine apparently died on the highway and they couldn't get it to re-start. The engine turned over by hand but was hard to turn, and it did crank, but wouldn't start. compression test showed low for four cylinders and none for 1 and 2. I knew the engine was probably toast. But I hoped for the best and ended up haggling the price down to $200!

    Got it home and started tearing into the removal process. Everything went fairly smoothly and I got the engine mounted to a brand new engine stand using my brand new engine hoist!

    Turned the engine over and heard....rattling....I cursed loudly, took a deep breath, and opened the pan....



    The 1 and 2 connecting rods had shattered and fell through the pan gasket sending shards of metal everywhere!

    I was naive and hoped that the block could be saved.... bad choice. Turned out the engine had gotten so hot, it had warped the cam and crank! I spent good money to have them checked along with the heads and block just to find out that the block and heads were cracked in several places....

    Not wanting to give up, I went to the junkyard and found a 142,000 engine out of a chevy monte carlo that was wrecked with airbags deployed. I took that as a sign that the engine was good.

    Turns out it was! bench compression tests came back good, but I still had qualms of putting a junkyard engine in my new car!

    So I did the stupid thing and decided to rebuild it from the block up....

    $1500 later and many many hours of labor and waiting for parts to come back from the machine shop, I finally got it back together. To save money, I actually pieced together my own engine kit down to every last gasket and part to save money. I had the heads cleaned, surfaced, magnafluxed, new seats cut, guides checked, valves re-ground, and cleaned again. For the block, I went with 20thou overbore and honed, checked cam and crank and polished, all bearings replaced, also cleaned and magnafluxed, oil passages cleaned, new pipe plugs and coolant plugs, every dimmension checked and rechecked, and replaced every gasket. I did all of the clearance checks, assembly, and dissassembly personally.

    This is what the result was:



    I spent $40 at pick-n-pull for a new door and fender (unfortunately black in color), and threw them on and tossed the engine in.

    After many many days of long labor and cursing that I didn't label all of my bolts better, I finally got everything back together. At 4:00 in the morning after pulling an all-nighter, I filled her up with coolant (green not dexcrap), oil, checked and re-checked everything, primed the fuel and checked the pressure, charged the battery, primed the oil and checked pressure, and finally turned the key for the first time!

    I have never been more terrified of anything else in my entire life. It roared to life, coughing and spewing! I performed the break in proceedure all while cursing and sweating. It sounded like a freaking motorcycle (I'd never rebuilt an engine so I had no idea what to expect)! It was spewing smoke and smelled of burning oil. I was certain I had rebuilt something wrong and just wasted all that money, but I kept on. After a few minutes, everything started calming down and falling into line (found out later this was the piston rings starting to seat). Finally the initial start up was over and I passed out.

    Later that day, I finally woke and took her out for the first drive! I will never forget that experience. She was chugging along and still smelled like burning oil, but I had done this myself from a collection of youtube and haynes manual with no prior experience!

    Got it inspected, and surprise surprise, my "outer tie rod end was loose" and would "cost around $300" to fix. So I told them to hold on for a few minutes. I took my other car, drove to the local advanced auto, picked up a tie rod for $15 (discount code of course) and drove back with some tools. Much to the shock of the manager, I proceeded to change my own outer tie rod right there in NTB's parking lot! The manager came out and stated that he would "call the cops" if I didn't stop. To his surprise, I replied "I'm already half way through, go ahead, call the cops, but I'll be out of here before they ever get here, and you'll loose a customer for life!" As expected he stomped back inside to do nothing. The whole job took less than 20 minutes, and I walked in, threw my keys to the same manager and said "you gonna fail me for anything else?" and he just stammered as every customer and employee stifled back laughs (and some just cracked up!). Needless to say, I passed, and finally got to drive my baby worry free (for now)....

    Just as I'm starting to feel good about what I've done, BAM! Code P1811 and it stops shifting into 4th....

    to be continued!!! (I'm tired of typing, this has all happened in the past and is dealt with finally)
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  2. #2 Re: Dirt cheap mods: my never ending struggle 
    GrandPrix Junkie ItHurtz's Avatar
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    grab a cummins turbo and weld on a flange to the crossover
    2000 GTPT Sold-brandonhall10 built trans
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  3. #3 Re: Dirt cheap mods: my never ending struggle 
    GrandPrix Junkie SgtMarshal's Avatar
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    great story, love the "I'll call the cops if you don't stop." what a complete loser.
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  4. #4 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Quote Originally Posted by SgtMarshal View Post
    great story, love the "I'll call the cops if you don't stop." what a complete loser.
    haha thanks SgtMarshal! That's one of my favorite moments at any mechanic. Almost as stupid as the one with my wife's car where I took it in for an alignment and they messed up so bad the car was shaking and the steering wheel was off!

    I drove it right back to the shop and the guy at the counter insisted "wheels misaligned cannot make your car shake". Needless to say, after he skeptically agreed to perform the tests, I was immediately transferred to the head mechanic because they had not only misaligned the car badly, but they had also messed up the tire balancing!

    I hate crappy mechanics!
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  5. #5 Re: Dirt cheap mods: my never ending struggle 
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    Keep up the good work buddy!
    You'll get it all sorted out.
    Question...Is that your stuffed tiger in the top right corner of the finished engine picture?!
    Lol!!!
    https://m.youtube.com/watch?v=M2bVi9h19yA
    2007 Antique Bronze Metalic Grand Prix GT...bone stock.
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  6. #6 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Quote Originally Posted by LEVELX View Post
    Keep up the good work buddy!
    You'll get it all sorted out.
    Question...Is that your stuffed tiger in the top right corner of the finished engine picture?!
    Lol!!!
    https://m.youtube.com/watch?v=M2bVi9h19yA
    Haha that's hilarious! I never noticed that before or new it was up there!

    I'd love to take credit for that, but this is actually my mother in law's garage I was borrowing for this project that was before I got my own garage. I'm honestly kind of afraid to ask her why it's there.....
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  7. #7 Re: Dirt cheap mods: my never ending struggle 
    SE Level Member green97's Avatar
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    Nice job its brings a lot of satisfaction from doing things like this yourself. I have been pretty upset with the experiences I have had lately on quality of work doing alignments and tire balances myself.

    Did you use new torque to yield bolts or just reuse the old ones? Everybody seems to say these motors are so finicky to rebuild and that they don't last long after doing so. Curious to see how it turns out over the long run.

    By the way I have been out of college for 8 years now and still go to craigslist ebay and junkyards for parts for projects its a good way to save money if you know what you are doing.
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  8. #8 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    thanks green! The secret is your shop needs to have a torque plate when they bore the cylinders. This is because the cylinders actually distort slightly when the heads are on. That and literally replace EVERY tty bolt (flywheel, torque converter, crank, cam, cam retainer, rocker, head, main side and top, etc.) And make sure to pack the oil pump with Vaseline and pressurise the oil properly.

    Hopefully it'll last a while!
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  9. #9 Re: Dirt cheap mods: my never ending struggle 
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    It's all in the machine shop that needed to do the line bore on the mains.

    Most of these engines are 500~ mile wonders before they let go again if they aren't properly put together.

    If that isn't done and the motor doesn't let go then consider yourself a lucky guy.
    1999 Chevrolet Silverado K1500 Classic Z71 - Intake/Gibson Exhaust/20% Tint
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  10. #10 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Yup. I'm at 2,500 miles already so I'm hoping I'm in the clear
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  11. #11 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Ok, so I'll be continuing the story soon, but I'm excited about my latest mod/junkyard find:



    Yep, those are two custom borla mufflers just chilling on a grand prix I found. Retail, $350. Junkyard, $18. Actually found the whole $900 exhaust system, but it was dented badly and I wanted to delete the resonator anyhow. Had a friend weld in a pipe to delete resonator, and I cut off old mufflers and these bolted right in place!

    I was a bit scared to delete the resonator and upgrade the mufflers, as I've heard that it can effect exhaust scavenging effect and make it raspy.

    I'd be curious to throw this thing on the dyno to prove my feelings, but the throttle feels more responsive, and I've actually been getting a few mpg better fuel economy since the upgrade!

    Plus, the sound is absolutely sick! Purrs at idle, growls when you give it some gas, and roars at open throttle! It is not overpowering in the cab, and it's not raspy at all! I'll have to post a sound clip eventually. My car is so dirty right now that I'm too embarrassed to post a video of it!
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  12. #12 Re: Dirt cheap mods: my never ending struggle 
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    Don't delete the resonatttttoorrrrrrr put it backkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk.

    It is raspy.

    Your ears are lying to you.
    1999 Chevrolet Silverado K1500 Classic Z71 - Intake/Gibson Exhaust/20% Tint
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  13. #13 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Haha I'll post a video later. I promise it's not!
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  14. #14 Re: Dirt cheap mods: my never ending struggle 
    Donating Users Bronco Boy's Avatar
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    Quote Originally Posted by blueguy91 View Post
    Don't delete the resonatttttoorrrrrrr put it backkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk.

    It is raspy.

    Your ears are lying to you.
    ^ This. I drove for 2 weeks without the resonator and Borla's and I have never hated a vehicle so much.

    I am blown away to read that he likes it. His hearing aid batteries must be dead?
    Chris B
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  15. #15 Re: Dirt cheap mods: my never ending struggle 
    Donating Users Bronco Boy's Avatar
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    You have driven the car with this exhaust, right? Driving is the only way to experience how bad it is.
    Chris B
    2009 CX-9
    ** SOLD ** 2002 GT
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  16. #16 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Lol guys, you have to remember I am on a mostly stock L36 NOT a L67 like most of the folks here. While with more modifications/horsepower, it might get raspy and sound bad like all of you are describing, as of right now,

    1. to me it doesn't sound raspy at all
    2. my MPG has increased up to around 22mpg city stop and go driving
    3. I love the sound now
    4. No, I don't have hearing aids, I'm probably the youngest poster here
    5. The throttle response has improved slightly

    Here's a video as promised to how it sounds. I'll have to take another when it's warmed up because I know people are going to confuse the short ram air intake noise from cold start up as the exhaust sound. For now, trust me, that higher pitched noise is the air intake. Oh, and the squeaking is the belt tensioner pulley, I think... anyways, unrelated.

    https://youtu.be/q_13wYAqK1k
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  17. #17 Re: Dirt cheap mods: my never ending struggle 
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    "4. No, I don't have hearing aids, I'm probably the youngest poster here"

    You don't have them yet, is what you meant to say!
    But when you do need them, go old school.
    Get a Tin Ear funnel!!!
    They're "retro"!
    2007 Antique Bronze Metalic Grand Prix GT...bone stock.
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  18. #18 Re: Dirt cheap mods: my never ending struggle 
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    "4. No, I don't have hearing aids, I'm probably the youngest poster here"

    You don't have them yet, is what you meant to say!
    But when you do need them, go old school.
    Get a Tin Ear funnel!!!
    They're "retro"!
    2007 Antique Bronze Metalic Grand Prix GT...bone stock.
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  19. #19 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Quote Originally Posted by LEVELX View Post
    "4. No, I don't have hearing aids, I'm probably the youngest poster here"

    You don't have them yet, is what you meant to say!
    But when you do need them, go old school.
    Get a Tin Ear funnel!!!
    They're "retro"!
    haha I'll keep that in mind Levelx. Then I wouldn't have to worry about charging them either!

    Hopefully I won't need them for quite some time though.
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  20. #20 Re: Dirt cheap mods: my never ending struggle 
    GTX Level Member wstefan20's Avatar
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    Anyways, if we're really talking about annoying, then while it doesn't have to do with my grand prix, I made the mistake of offering to replace my neighbor's transmission for cheap. He insisted on getting a junkyard low-mileage (which I'm not a fan of, but hey, if you're broke, you do what you gotta do!).

    I had no idea what I was signing up for.... it's a 1998 gmc yukon (aka chevy tahoe) with four wheel drive.... bad idea.

    To start out with, I could immediately tell the transmission had been serviced before due to all the zip ties, mismatched bolts, etc.

    The worst part of this removal is that unlike the silverados and other trucks with 4L60Es, the tortion bar frame bracket is literally 2 inches away from the rear of the transfer case, so the only real option I had other than to remove it with the engine was to:

    1. Remove the rear transmission mount and crossmember
    2. Remove both front and rear driveshafts
    3. unplug and move all wire harnesses
    4. remove the entire front exhaust up to both headers back to cat
    5. unbolt the transfer case and strap it to tortion bar to get it out of the way and keep it from falling
    6. remove starter, torque converter bolts the usual
    7. pivot the entire engine/trans assembly down to access the bellhousing bolts
    8. swear, curse, and almost drop the sob to the ground
    9. remove the transfer case separate

    There's plenty of steps I'm probably forgetting. This was by far one of the worst transmission removals I've ever had to do. Probably wouldn't have been as bad if I had a lift, but I don't so...

    At the end of the day, I'm tired, and really really glad for many reasons that I don't own a tahoe and drive a front wheel drive car.
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