My Corvette Life: 1990 Callaway Twin Turbo Project

Discussion of Corvette based Callaway Cars including: 1987-1991 RPO B2K Callaway Twin Turbo Corvettes (C4); Callaway SuperNatural Corvettes (CL-1/CR-1); Callaway C12; Supercharged Corvettes; Callaway C16; 6th Generation Callaway Corvettes (SC560, SC580, SC606, SC616, SC620, SC652); 7th Generation Callaway Corvettes (SC627/SC757); NEW Callaway C8 Corvettes - and more!
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Chris, look at SEM Brand paints. They are nice, and spray evenly with good matches to o.e. colors for trim, etc.

Speaking of things like this, check out this thread: http://callawayownersgroup.com/viewtopic.php?t=1272

Window Weld and SEM Chip Guard are two which come to mind :thumbs

Window Weld was used to hold AeroBody lenses in place and the Chip Guard is used on the black rub strip and rear plate fill areas of AeroBody.

Hopefully you find this info to be useful in your endeavors.
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by Never_Lift »

1988Callaway#16 wrote: Sat Oct 02, 2021 1:53 pm Welcome Chris! Nice find. I’ll be subscribing and watching. I have an 88 Callaway convertible #16 that needs some work also. Kevin


I’ll watch, but don’t subscribe (tin foil hat on), as this is interesting to armchair observe. I got nuthin to really add which hasn’t been said other than I fixed up a few TPI cars in my time and everything said so far is right

How’s 88/016 coming along, and where’s those videos

I’d watch that also if you did some to go with your work
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by My Corvette Life »

*89x2* wrote: Mon Oct 18, 2021 7:40 pm Chris, look at SEM Brand paints. They are nice, and spray evenly with good matches to o.e. colors for trim, etc.

Speaking of things like this, check out this thread: http://callawayownersgroup.com/viewtopic.php?t=1272

Window Weld and SEM Chip Guard are two which come to mind :thumbs

Window Weld was used to hold AeroBody lenses in place and the Chip Guard is used on the black rub strip and rear plate fill areas of AeroBody.

Hopefully you find this info to be useful in your endeavors.
Thanks for these tips. I've noted them down for future use. :thumb1
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Glad to continue help. Perhaps you will consider adding a plug for www.callawayownersgroup.com to your videos :hi

In the meantime, a few things to note on your latest clip...

The triangular plate is from the NOS kit. It was installed to move the geometry of the throttle linkage forward with the NOS plate sandwiched in the throttle body/plenum area. It's not some fabbed up bracket as you explained. Whoever installed the NOS kit, butchered the lower bolt. Extract it, then helicoil the threads to install the factory bracket back into place. :cool

Next, take a look at your emblem on the plenum - the bowtie should be RED. You can touch that up easily, but don't miss it. :thumbs

For covering ports, I like to use Frog Brand painters tape. It's super sticky, but easy to remove. I would not stuff paper rags in ports or think it would keep debris from those turbo tubes. Use extreme care, please. :stop

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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Additionally, I was in my shop and want to share with you some additional parts which WILL come in handy during your restoration. Injector Clips and O-Rings.

BWD # 274773 = O Ring Kit for the TPI Rails

Sorensen #800-9417 = Fuel Injector Retention Clips (they may stretch or snap while removing them during injector swap)
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Thanks for the mention of the Callaway Owners Group in your clip :hi

In the one post I made above, you can get the o-ring kit from AutoZone to take care of all the ones needed on the fuel rail :thumbs

The stock injectors were 22 lbs and for 1989-1991, were Rochester Products with the numbers: 1209 5235435 on the top of the body of each

Ford SVO Branded injectors were a popular mod, but that's not what you have.

Your injectors are, as you say, from a Daewoo, which was a car manufacturer owned by GM. Anyways, Rochester Products was another GM subsidiary, and that's why the fuel system was full of their parts in the 80s/90s.

I'd be VERY curious still what each injector ohm reading might be. You can bench test still. :hi


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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by Jeroenvgfn »

Thanks for sharing, love the videos
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Good score on the oil primer, and thank you again for the mention of www.CallawayOwnersGroup.com in your videos :beer







On the "aluminum spray", that's nice, but aluminum is very easily cleaned in a hot tank for most parts. A good machinist or machine shop can help with this, and it's relatively inexpensive. The problem with painting aluminum is that you are just covering dirt/debris, and the "paint" will flake off eventually, regardless of what kind. Spend the time, do it right :thumb1

Speaking of aluminum, you will find several anodized (Blue) parts on your car. Be careful with those, preserving their finish. The AC Compressor manifold is one, you will see a pulley, some turbo-related fittings, and other stuff, as well. :hi

On the scope, looks like the cylinder heads (casting 10088113) are the 1988-1990 Corvette castings. Once you get the valve covers off, check the rocker arms, they look like they are full roller rocker arms :cool
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Keep up the good work! And than you for the continued mention of www.CallawayOwnersGroup.com :hi










If you have not gotten your discount from FIC, here's the current one:
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Keep dropping new clips. Here's the latest two:






The triangular black (rusted) pan is a sump for the oil system. The turbos are also water cooled, but you'll find those lines when you remove the banjo fittings off the turbos.

Original catalytic convertors are gone. Those bullet cats might be loaded inside, or not. Will be interesting to see. The 88L-91 cars had two AC cats with a straight pipe in the center, then to a factory Y pipe with the factory sport mufflers and Callaway embossed oval tip.

The disconnected harness beside the transmission *might* be the CAGS plug for the 1-4 skip shift. It was frequently disconnected to avoid skip shift function, but generally plugged w/ caps. Yours is hammered, and tough to tell exactly what it is. Let us know once you trace out the wires. :hi

Keep pushing on, as you're right, this is a great car to save.
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Good video today.

Callaway is on the Corvette Monroney, as you can see in the lower left, dealer delivered... And you mention on the build sheet, too.

1990 and 1991 cars got CALLAWAY Window stickers, not a 2nd sticker. :thumbs

Also, your car came with the blue transparent top, only. Not RPO C2L, dual roof panels. It would've been $915 as an option. :hi



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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

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Was wondering where you went/what happened, or if we should send a search party. Looks like you have encountered the fun of needing specialist tools, which some you have to fab from box-end wrenches, etc. Good times. :thumbs

Please keep us posted on what it costs to rebuild turbos and if the bearings are truly available. Good call on sending them to Rotomaster, and lucky for you, only TWO miles away :thumbs



Previous Owner wrote:Car Specs: 1990 Callaway Twin Turbo AeroBody #34,100hp NOS, GS brakes and cross drilled rotors, Brey-Krause bar,5 pt harnesses, stage3 clutch, dual exhaust/no mufflers, complete MSD 6+ ignition
Previous Owner wrote:My Callaways are doing great! We have moved to central Texas for the winters and I brought my '90 TT Aerobody, '04 SRT10 ram and 71 chevelle down to the land of 'high air density'.
We got down here last year in October, just in time to catch the 'Texas Mile' http://texasmile.com/resultsoctober2005.asp and I entered the Callaway.
With a tech session which required me to borrow a bungy cord to strap the battery down, I was on the runway blasting full speed at full boost. There were some technical difficulties with the timing lights on the Sunday so my first run on motor/boost only, was not recorded. The car ran clean, smooth and at 54 inhg of boost.
"Speaking of CO2 cooling"
While I waited(for an hour) for my second run with boost and a small shot of nitrous I got In Good with the Subaru club who told me to stop by their booth and get some dry ice for the intercoolers. They showed me how they chipped a 3" thick block of solid CO2 off around the corners and mounted it on top of the intercooler of their Wrxs and Imprezas.
On my second run I launced and once into 2nd gear armed the nitrous. I ran the whole mile pushing 60inhg with an air/fuel ratio just a little lean for my liking for nitrous. It was recorded at 167.079mph. The car felt solid and stable all the way down the track with no brake fade at the end.
I then went to meet up with the Subaru guys who set me up with the dry ice blocks. I used a wrench to chip the edges off to where the hood would close around them and waited for a few minutes for my 3rd run.
Run 3, consisted of me realizing that 12lb of boost, 100hp shot of nitrous and intercoolers chilled to -109 degrees F, that there is no way that my expensive kevlar clutch (which has given me problems from day 1) will not hold. By 3rd gear the motor starts revving, the clutch is slipping, there is nothing to do but ride it easy down the mile and hang my head.
I was 8mph away from getting kicked off the track for my cars maximum speed (175mph) without a roll bar. The timing lights were again malfunctioning so no speed recorded for me(slow anyway).
My 167mph run put me at 31st position for the event, which is in the range of Vipers(with exhaust/intake mods) and many of the larger displacement super bikes.
I believe that with a newer clutch and a little more fuel enrichment(maybe some propane) that I can hit the magic 175mph mark in the 5280foot run.
This event is held twice a year and is a great time, with unlimited runs over a 2 day period and a lot of very cool fast vehicles.

One of the biggest things I learned running the standing mile is that after the first 1/2 mile nothing happens fast but the second half. Pulling in 6th gear is long and tedious and once you are at 140-150mph(about 1/2mile) the car does not accelerate like it does in the first half. At those speeds the second half is a blink but the way the car is pulling it feels like forever!

I didn't get any personal pictures but there may soon be event picturex with the aerobody on their site.
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by Never_Lift »

Where are the next videos? :sclock

Corvette Life, are you going to pull the whole engine and take a look at things, or will you take a look at compression and leak down prior to disassembly? :wtf

Can you outline what we can expect? I like a TV guide to see what's on the next episodes, so it would be appreciated if you would :beer
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by SurfnSun »

He hasn't logged into this board in a month....doubt you'll get a response.
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Another video has been added to the process of sorting this Callaway Twin Turbo Corvette. This one is about painting the manifolds after media blasting them. The videos do seem to have slowed down from him, so hopefully that give him time to check-in with us and share the progress firsthand.

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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

The dude's been gone for a month, and finally posted a clip to say why...



Chris Draper, hope you continue the progress, and the parts you received sound like you're going to have some work laid out for you after the Holidays.

In the meantime, you might want to take note of this thread:
http://callawayownersgroup.com/viewtopic.php?t=1272

And thank you for your mention of www.callawayownersgroup.com in your clips. We are here to help on your journey :thumbs

Be sure to check-in though every once and a while, directly here :hi
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by Never_Lift »

Never_Lift wrote: Sat Nov 20, 2021 8:02 pm Where are the next videos? :sclock

Corvette Life, are you going to pull the whole engine and take a look at things, or will you take a look at compression and leak down prior to disassembly? :wtf

Can you outline what we can expect? I like a TV guide to see what's on the next episodes, so it would be appreciated if you would :beer
Is this guy ever coming back to answer anything ? I wander and lose interest easier than most so it’s been kinda boring with out regular posts. Where is the OP :pop
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Looks like this week, Chris Draper posted some more videos of his restoration of his 1990 Aero coupe.

Hope he's getting things back on track after his busy December. Chris, drop on by the site. In the meantime... :hi


Air Conditioning Compressor:

https://www.youtube.com/watch?v=IA5PF7DgAAo

Scavenge Pump Oil Tank:

https://www.youtube.com/watch?v=82UCdm4n_cI

Scavenge Pump:

https://www.youtube.com/watch?v=hoju2SQpLdo
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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

Two more videos posted by Chris Draper. Chris, if you drop by, say hello, let everyone know how things are going behind the scenes, thanks :hi


Intercooler Pipe Resto:

https://www.youtube.com/watch?v=4KFmMl5fvus




Starter Removal

https://www.youtube.com/watch?v=EKmY4xDIFEI

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Re: My Corvette Life: 1990 Callaway Twin Turbo Project

Post by *89x2* »

What's the latest, My Corvette Life? :wtf It's been a couple weeks since your last video. Keep your fans posted :cool

In the meantime, here's a couple pics of my aluminum parts which I had Hot Tanked and Bead Blasted. I think it cost a couple hundred bucks for this, maybe just under. Really cleaned up the aluminum like new, and left the finish raw/natural. On a Callaway, the runner and plenum should then be painted with the proper VHT Black: http://callawayownersgroup.com/viewtopi ... 2&start=10

Thank you for your continued mention of www.callawayownersgroup.com in your clips. :beer
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