LE5 turbo setup
 

I am building a turbo setup for a 2006 Cobalt SS 2.4 LE5. I have called and emailed Alphafab, Hahn, and ZZP, they all suck at customer service. So it appears that I will be putting my own system together. I have a pretty good handle on what turbo I want. It will be a Garrett GT3071R, 56 trim, .5 A/R. (350 hp at 7000 rpm, no plans to ever go much higher, need it to spool quick for as much low-end as possible.) My main questions now are:

1. Where to buy the actual turbo?
2. Where should I look for an exhaust manifold?
3. What injectors use the same connectors as my stock injectors? (I know how to calculate size.)
4. I plan to fabricate my own intake manifold. Is there a bigger DBW TB that uses the same voltage sweeps as the stock TB?

It is not going in a car so don't worry about fitment under the hood, etc. I'm heavily involved in fabrication and the automotive world but not at all involved in sport compacts so I am a little out of my element when it comes to where to actually buy all this stuff.

why not just get the whole kit from zzp and then that way you know you have everything lol? ZZP has everything you will need for your set up man. their email service does take a little to get back so maybe try calling or like i said just order a kit from them.

ZZP flat-out, in plain English, told me that they do not have time for me and will not speak to me on the phone. Alpha will not put someone on the phone who knows WTF they are talking about and it takes them weeks to reply to emails. Hahn expressed some interest but also will not put any knowledgeable person on the phone. Also takes weeks between emails from them. Between the 3 companies they have held my project up for about 3 months and I'm done waiting for incompetent asshats to take my money. If its this hard to buy something from them I can only imagine how difficult it will be to get service once they already have my money. I honestly do not see how any of these companies survive. I own 3 companies, the oldest of which is 10 years old now. If I had customer service twice as good as Hahn, Alpha, or ZZP I wouldn't have made it past my first year.

ive never heard of zzp treating anybody like that at all. i would guess that if you contact them again wanting to buy their kit they will be much more helpful then saying you want to do a custom set up lol. zzp is the best for performance stuff when it comes to a cobalt and basically the only place to go to lol. ive never heard of Alpha for a cobalt platform and Hahn in my eyes is a waste of time lol

ZZP does not offer phone contact:

Contact Us

Anyway, at this point I wouldn't do business with them.

I would say then, at this point your best bet is to take the car to a performance shop so they can build a turbo manifold for you. As for the turbo itself, you should be able to find it online or ordering through a performance shop (expensive).
injectors, I think, someone correct me if im wrong. 42lbs needs an adapter and 60lbs should plug in... I think im running the old 39lbs from zzp without adapters.

4. I don't know.... lol

I would just make my own manifold but I thought there was a plethora of aftermarket already? Is there not?

not really....
remember the cobalt wasn't a popular car
and is gone lol

Ottp makes a stainless manifold but zzps is a little nicer. Worth the cash imo.

If you only want 350 hp you could run a 2871 and heave a ton of low end. Bnr sells a 2871 that bolts onto the stock lnf manifold which is cheap to buy on this site from someone.

Again, this isn't going in a Cobalt, a car, or even anything with a body. Space is not a constraint. Surely SOMEONE makes an exhaust manifold for an Ecotec engine that bolts to a turbo???? It doesn't have to be for a Cobalt, just Ecotec.

NOW we're getting somewhere!

Who is OTTP? Link?

Who is BNR? Link to that also please?

Like I said, I can fab just about anything, work on just about anything, build absolutely anything, but when it comes to sport compact aftermarket I have ZERO submersion. If you asked me where to buy just about anything for an LS2 I could tell you a number of places. But if you asked me where to buy a valve cover for an Ecotec I would draw a blank. Even if you don't think it helps me, list of some Ecotec performance companies. I'll go check them out and see if they have anything constructive.

Ottperformance.com

Bnrsupercars.com

Thanks, I found the OTTP manifold. Looks pretty much like crap welding-wise, but I guess its cheap enough and would work.

I'm not seeing that turbine housing at BNR though? Is there a link directly to that product?

You might have to find their number and call them. Their website seems to be down

Too much turbo, someone is selling a like new gt2871r on here for cheap

Also, someone is selling a bolt on bnr2871 in the classifieds that will bolt on to the lnf manifold and give you exactly the spool and power you're looking for.

As far as I can tell the bnr sold. I don't see the other...

Just to vouch for Ottp, it may take a little longer to get stuff but josh does his best to cater to your needs and make sure your satisfied. He's a one many operation but his customer service is A+

Why do you say too much? Both the 2871 and 3071 were recommended by the Garrett Adviser but my air flow and PR's fall smack dab in the efficiency island on the 3071 and are all the way out at the edges on the 2871. I'l post pics in the morning if you like. I would be interested to see your interpretation of the maps in either case ...

The 28's aren't as far out as I recall them. I must have been inputting something wrong initially. But the 30's don't look bad either. Interested to hear others' takes.

Inputs:
Parameter Value
Ambient Air Temp (°F) 90.0
Barometric Pressure (psi) 14.61
Displacement 2.4 L
Crank Horsepower Target 350
Number of valves 5
Volumetric Efficiency 95.0%
Fuel Type Pump gas
Air/Fuel Ratio 11.5
BSFC (lb/HP-hr) 0.55
Intercooler null
Effectiveness 0.7
Pressure drop (psi) 1.0
Mid Range RPM 5300
Peak Power RPM 7000
No of Turbos 1

Results:
Parameter RPM 1 RPM 2
Pressure Ratio 2.06 2.06
Intake Manifold Temp(°F) 142.07 142.07
Crank Horsepower Actual(hp) 264.38 349.18
Airflow corrected (lbs/min) 28.69 37.9
Boost Gauge Pressure (psi) 14.5 14.5
Crank Torque (lb-ft) 261.98 261.98


http://www.patooyee.com/miscpics/tur...T2871R (1).png

http://www.patooyee.com/miscpics/tur...T2871R (3).png

http://www.patooyee.com/miscpics/tur...T3071R (1).png

http://www.patooyee.com/miscpics/tur...T3071R (2).png

http://www.patooyee.com/miscpics/turbomaps/GT3076R.png

Another thing ... I'm reading that the LNF exhaust mani doesn't fit the LE5.

I have an lnf exhaust mani on my le5. You just have to swap the coolant pipe on the back of the block with an lnf one.

Great, I read something about the exhaust ports not lining up. So you can confirm that's not true?

Just spoke to BNR. He takes the stock K04 LNF turbine housing and machines it to fit the 2871. If the LNF manifold truly fits the LE5 this seems like the obvious way to go for me. BNR's prices are very reasonable as well.

yes thats what he does and with the lnf cars they make 370-415whp with the bnr 2871

Idk why anyone would say that. There are plenty of people using that manifold. My car runs great. You just have to get the right gasket.

Check out my build thread