Patientzero 2002 Roush LS3 build

[Patientzero]

I miss forums, can't stand Facebook most of the time. Just thought I'd share my car with anyone that cares.

The car is a 2002 Roush Stage 2, 4.6/5-speed. I bought it from a friend who had owned the car for around 8 years.

It had a few mods already when I bought it. Brakes had been upgraded to the Stage 3 14" Alcons, Steeda sway bars, AJE K-member & control arms, Steeda springs, Longtube headers, catless H-pipe, CAI, SCT tuner, and a few other things. That dash is terrible...
This is what it looked like when I brought it home.

 

[Patientzero]

I drove the car as is for awhile until I had to start changing things.

First thing to go was the terrible Konig wheels and the monstrosity on the dash.




Also installed a Sparco Evo II seat and 4 point harnesses so I could take it to the track. This is from a track day at Grandsport Speedway in Texas on Pirelli Pzero Runflats, hahaha (they were on closeout from Tire Rack)



Needed more camber, lol

After that I upgraded tires in the never-ending search for more grip. Federal 595RS-RR in 275/35-18. I had run the previous version of these tires in the past on a different car at Mugello Circuit in Italy with pretty good results.

 

[Patientzero]

I removed A/C in an effort to shed weight.


Brake pad upgrade, stock Roush pads were toast after the track day.




New steering wheel
Homemade rear seat delete

 

[Patientzero]

Ford Racing 4.10 gear install





Ran a couple SCCA events in CAM-C

New license plates

 

[Patientzero]

Then things started to get serious.

Koni/Maximum Motorsport coilovers with Eibach 425lb front and 325lb rear springs


New powerplant, LS3 out of 2010 Camaro with about 8000 miles on it.



Of course I couldn't leave it stock. Heads came off to be ported.


I weighed the car with the stock 4.6/5speed with AJE K-member and front LCAs. The trunk had been gutted at this point and the A/C removed, also had the Sparco driver seat.


Engine coming out. I can't find the dyno sheet but I dyno'd the car a couple weeks before pulling it apart. Made 260hp/320tq to the wheels on a dynojet. Motor had longtubes, coyote injectors, CAI, and dyno tuned with SCT.

 

[Patientzero]

New headers for the LS from Speed Engineering. Designed to work with the AJE K-member. I welding on V-bands to these and then had them ceramic coated. They fit PERFECT.


Accumulating parts for the swap.


Had valve covers and accessory bracket powder coated by Accucoat in Houston, TX



New 90mm cable throttle body from Warr performance(veteran owned company, recommend) I could have used the stock drive by wire but I would have need to use a Holley Dominator, the HP won't control DBW.




Holley HP to control this whole thing

 

[Patientzero]

Heads back from CNC porting. Then I sent them to my friend Mike at Axiom Race Engines for a valve job and hand blending. I highly recommend Mike for a modular, LS, or nissan build, ANY power level.
https://www.facebook.com/raceaxiom/
Fresh off CNC, these pictures are before the valve job/blending




Putting the short block together. Upgraded the cam to a 3 bolt design from Texas Speed. 232/240 @ .050 with .615 lift. Also got rid of the chain tensioner and upgraded oil pumps at the same time.







I used a KaTech manual belt tensioner and ATI 25% underdrive damper

 

[98snakehorse]

I like where this is going. Welcome to the forum

 

[Patientzero]

Started stripping down the interior to cut weight. Pulled/gutted the dash, removed all the sound deadening, speakers, amps, HVAC, seatbelts, etc.




Started out with the McCloud Hydraulic clutch conversion

 

[Patientzero]

Mounted the Holley in the kick panel in the stock location.


HVAC removed


1st transmission(more on that later) Tremec TR-6060 from 2010 Camaro SS


Started stripping and cutting out all the unused wiring from the engine bay. Mostly ABS wiring.


Loomed and cleaned up the remaining wiring and repurposed the factory fusebox

 

[Patientzero]

Picked up a couple trans coolers, one for oil, one for transmission (the TR6060 has an internal pump). And a couple Spal fans



Upgraded Fuel pumps to a Walbro 255lph and converted the fuel system to a return style using a factory Corvette fuel filter. Using all Russel -6 line for the fuel system.

 

[Patientzero]

Relocated the battery to the trunk with a billet mount

Got the clutch installed. ACT lightweight flywheel and HD unsprung 6-puck




Ended up dropping the engine in without the heads (because I didn't have the heads back yet.)



Started out with an AJE universal trans mount that I had to modify


I used the widest LS swap radiator from Speedway that would fit.

 

[Patientzero]

Stock LS3 oil pan would not clear the K-member, went with a Holley 302-2 oil pan (sorry no picture)


Started mocking up the Racepak IQ3s


I used the template and made a new surround out of textured ABS plastic.

Subframe connectors and torque arm came in


Subframe connectors after welding and painting to prevent rust.

 

[Patientzero]

Needed a way to mount the oil and trans cooler to get some air flow





FINALLY got the bumper painted


First generation trans mount. The AJE mount had rubber bushings so I wasn't concerned about mounting it solid here.



I had to clearance the shifter hole for the MGW mid-mount shifter. It was surprisingly close to the stock shifter location.


Next on the agenda was to get the Maximum Motorsports panhard bar installed along with the Koni's.

 

[Patientzero]

Got the heads back from Axiom Race Engines







I reassembled the heads and got the top end put together. Lapping the valves wasn't really necessary but it makes me feel better.

 

[Patientzero]

The transmission problems began, had to pull the trans to readdress the air gap on the RAM throwout bearing. The clutch wouldn't disengage.


Upgraded from the Steeda caster/camber plates to Maximum Motorsports and got the front coilovers installed.







Started building the exhaust, 3" stainless steel with x-pipe and Borla ProXS mufflers. Eventually I'd like to extend it all the way out the back but this worked at the time.

 

[Patientzero]

Lokar throttle cable hooked up, radiator mounted, and coolant hoses installed.





Custom 4" intake made out of stainless because I like how it looks.





Me pretending to make a startup tune.


Startup video. Ok, not FIRST start but close enough
https://photos.google.com/photo/AF1QipNpuVqM3z2EYK1X1d6aQMeE9zaDsI_-A0Gp2Cu1

 

[Patientzero]

Roll bar construction out of 1.75" .120 DOM







Getting all the new suspension goodies aligned


Dyno day. Made 482whp/443tq on 93 pump gas. I believe with E85 and a different cam it would make 500whp. My cam was originally spec'd for a 4.8 build before I got the LS3, I used it because I already had it.
Video >>> https://photos.google.com/photo/AF1QipMwm5XbYCM4lOEm3RRxQ17hZYkcoccHcfwsIVoA

 

[Patientzero]

The McCloud master cylinder kit failed a few hours after the dyno. I still don't know exactly why but it was leaking internally and left me stranded with no clutch. I ended up getting the car started in gear and blew through several lights and stop signs on the way home.

Phase 2

 

[Patientzero]

First race with the LS3

Some pictures of it cleaned up.

A hobby of mine is photography. I'm a Nikon guy.