Yesterday we drove over to GM's Performance Build Center (PBC) in Wixom, Michigan to build an LS9 engine — the most powerful production engine GM's ever built — and the 638 HP beating heart powerplant underneath the hood of the Corvette ZR1 — all while being taught the tricks of engine assembly trade by the man who's built more LS9's than anyone else.

Here's how the magic's made.

Aluminum block, aluminum heads, forged crank, Forged pistons, titanium connecting rods, valves, and valve springs, a bespoke Eaton four-lobe roots-type supercharger displacing 2.3 liters of air per rotation blowing into an air-to-water intercooler, all backed by a twin-plate clutch. It's 638 HP of smack-you-in-the-face and it'll shove the ZR1 to a 0-60MPH time in 3.4 organ-crushing seconds. But first it has to be built

Each Corvette ZR1 engine is hand assembled at GM's Performance Build Center (PBC) in Wixom, Michigan, a purpose-built 100,000 square foot facility with the express intent of building the best motors in the GM universe. It's a mix of the latest thinking in lean manufacturing paired with the old world responsibility inherent in a one-man, one-engine build philosophy. The facility also builds the monstrous huge 7.0 liter LS7 for the Z06 and the hopped-up LS3 for the new Corvette Gran Sport, but when you're offered the opportunity to build an engine of your choice, you pick the LS9.

My guide through this most unique of looks into the guts of GM's baddest engine was Mike Priest, the man who's put more of these engines together than anyone in the world and some say he assembles the fastest ones. Good hands to be in. We start the day off by getting right down to business, cracking the connecting rods. Each piston comes sub-assembled complete with a high-moly top ring, a nodular iron lower, and a 3mm oil ring.We inspect each for nicks and scratches, make sure the wrist pin turns freely, and then systematically mark the bearing cap and con-rod to make sure they match up later. The bolts are then loosened and they're separated by a light tap or a cracking fixture.

The bearing journals are then laid in and everything gets placed in a tote and wheeled to the first station on the rolling engine stand.

The line is arranged into individual stations, each being fed by pre-kitted parts and a pull-type delivery system. The stations each have at least one Atlas Copco electric torque driver which torques fasteners based on a scan of the build sheet. Each data point is recorded and tied to the individual engine, and data can be reclaimed at any time. A naked engine block is sitting on the delivery fixture awaiting assembly, it'll be engine 10ZAN 322731901. In the very first step we install studs which will hold the engine to the rolling engine stand.

Once Mike gives the engine a good once, a water passage hole is plugged, then we move on to installing the first exciting piece, the camshaft. An assembly fixture is placed on the back of the cam and then a handle screwed onto the front, the journals are given a coat of assembly oil the cam slides in easier than any cam you'll ever touch. It's nice having factory tools. Mike then uses the overhead crane to hoist the block over to the stand where we bolt it down. Finally, the cam seal and retainer is installed.

Next we loosen the crank bearing caps and use a custom pry bar to remove them without damage and set them aside.

The bearing journals and main bearing are now snapped into place and liberally coated in assembly oil.

After inspecting the crankshaft, Mike expertly drops it into place with a crane fixture. He offered to let me do it, but the idea of marring such a critical piece wasn't something I was too excited about.

The crankshaft is gently turned to make sure there's no unexpected drag.

Next we assemble the other half of the journals into the bearing caps and oil, installing them as they were delivered in the block.

The caps are torqued down using a multi-spindle driver to simultaneously drive the inner then the outer bearing bolts. Those bearing blocks also get cross-bolted to the walls of the block, which increases the assembly's overall stiffness. As a validation, the torque to turn the crank is checked, to make sure there's no undue drag.

Next we stuff pistons. Assembly oil is applied to the piston bores, the edges of the piston and the connecting rod bearing. An assembly guide is slipped over the end of the connecting rod and a ring compressor slipped over the head of the piston. I' told to run the piston up and down to make sure it slides smoothly in the compressor then place it over its cylinder. When the bottom of the piston is seated in the bore, one strong push to the top of the piston and the entire assembly slides in smooth as silk.

The connecting rod cap is lubed and installed and the process is repeated down the line, then the bolts are all torqued. The engine is rolled to the opposite side and the process repeats.

Next up the engine oil baffle is attached to the studs on the crank bearing outer bolts.

Next, the timing is set. Piston number one, on the driver's side front of the engine, is raised to top dead center. The chain tensioner is then bolted into place.

The crank gear is then pressed into place with a pneumatic ram.

The timing gear for the cam is placed on, two timing marks on both gears are are aligned and the cam gear is removed, the chain is laid over top and then the chain is attached to crank gear as the cam gear is slid into place and bolted down. The pin in the tensioner is then removed.

The dry sump oil pump is then carefully positioned with a fixture to ensure its ports are flush with the bottom of the engine block, then bolted into place.

The back engine cover compete with rear main seal and the front engine cover are then installed

In the next station, the first step is to lay down RTV sealant beads at the front and rear covers.

The pickup and oil filter-equipped oil pan is now dropped into place carefully and torqued down.

A protective cover on the side of the pan is removed and set aside to be sent back to the supplier and the oil cooler is bolted in its place.

After a quick look we drop in one side of the cam followers living in their cam carriers.

Now it's time to for the aluminum heads. Here's a bit of information that'll be useful in garage trivia: The aluminum heads on the LS9 are exactly identical, there is no left side or right side, they are the same part number and on the engine one gets a screw in temperature sensor and the other gets a screw in plug, that's the only difference.

After tapping in guide studs and laying on a crazy seven leaf gasket you just drop them on without fanfare.

Fourteen stainless steel bolts go into each head and get tightened down simultaneously with a multispindle driver.

Next up is the valley cover which seals up the 'V' between the cylinder banks.

The final process in this station is putting together the valve train. First, the pushrods are slid in place. (Aren't those old fashioned?)

A cam rail is placed across the inside of the head and the rockers are put in and the bolts are hand started. A pair of installation guides are then placed over both heads. These indicate the torquing order for the rockers, begin on the green number one and travel around the engine in order driving the bolts in, when you run out of greens, stop, manually turn the crankshaft 180 degrees to realign the pistons and then pick up the tightening order for the yellow numbers.

Once installed, a generous application of oil on the rockers finishes the station.

At this point, the line turns around on the other side and starts back the other direction. Here a set of guards are temporarily put in place to protect the lower intake as rivet-like cup plugs are popped into small holes in the water cavity.

Next, the valve covers are put in place and torqued down followed by the coil packs that aren't delivered preassembled for the sake of assembly access.

The water pump is installed along with a couple of hard vacuum lines and the alternator bracket.

The crankshaft damper is placed on the crank and a pneumatic ram presses it into place.

The next step is where happiness is made.

The supercharger comes largely preassembled and is lifted from a tote by crane and inspecting for the hoses, wiring, and gaskets.

It's gently placed into the valley of the engine. The entire unit is bolted into place and the supercharger gets a good spin to make sure it turns freely.

You can hear it pulling a lot of vacuum against the closed throttle.

Next we take a quick look at the intercooler, which incidentally is the only class-A surface underhood in any GM product, which means it must be protected from damage just like a fender or a hood. The intercooler gets a gasket, debris and paint finish inspection.

It's then dropped onto the supercharger, torqued down, then covered with a cardboard guard.

Next, Mike puts a lot of faith in me as he applies his name plate to this engine which I've had a dangerous amount of involvement in building.

Next up is an all-too-unsexy but entirely necessary step, a complete leakdown test of both the coolant and oil passages. All the ports and still open areas are sealed off with plugs and covers, then a controlled amount of air pressure is applied and the rate which the pressure drops is measured. The less leakage the better, this one passed with flying colors.

Once all the testing equipment is removed, spark plugs are put in place and the exhaust manifolds are installed as well as the manifold studs, the engine mounts are put in place and two temporary engine hoist loops are put on the front and back for transport.

In the final station, coil wires are installed and then the engine number decal is put onto the head.

The engine is then taken off the rolling engine stand and dropped into the flywheel and clutch installation fixture.

The holes in the flywheel are then numbered to make balancing engine easier later downstream,

The flywheel is installed and torqued down.

Next the clutch housing is picked up with an assembly reaction arm.

A mark on the twin clutch pack is then aligned with a mark on the housing to balance the assembled parts.

The clutch is then installed. And with that, the assembly process is complete.

The engine is weighed (530.6 lbs dry) and placed on a palette and an engine audit is completed another employee.

The palette is taken over to the final step in our process which would be running the engine through cold test.

In the cold test process, 2.5 quarts of oil is put into the engine after it's affixed to a test stand.

The stand is rolled into the test cell and hooked up to electric couplings, various sampling sensors, like noise vibration and harshness sensors, pressure sensors, etc. as well as a big electric motor. When the doors are closed, the motor spins up and turns the engine over after building up oil pressure. There are an array of tests done in the 90 second cycle time, but in the end all the lights were green and it passed everything very convincingly.

Since it was a shutdown week, we didn't proceed to the next step, but normally the engine would go to the balancing chamber. In the balancing chamber, the engine is hooked up to an isolation fixture which freely allows multi-axis vibration. It's then hooked up to a special ECM and a natual gas fuel source and fired. That's right, a Corvette ZR1 motors first breaths come from a clean fuel. During the engine's operation, sensors detect vibrations and calculate where to add weights on either the flywheel or the crankshaft damper to bring the engine into balance. The weights are installed and the process is repeated until it passes the test. The final step in the process is a second, intense inspection, from the assumed position of the customer at the Bowling Green Corvette factory. After it's gone over with a fine toothed comb it's off to storage awaiting the truck to Kentucky.

It wasn't really my engine, I did a lot of the installing and bolting down, but I was just a monkey following directions. It was, and is Mike's engine, and I have to pay him my respects on his level of care and attention to detail over even the smallest potential flaws in any part or element of the process. He's like a parent watching over a child. And yet, at the end of the day, it was gratifying to see the engine turning over, pumping air and passing all of its tests. Someday in the recent future, that motor will find its home in a ZR1 and it'll be rocketing some happy new buyer to delirious speeds. Kind of a surreal day if you ask me.

Hennessey's only producing 24 HPE700 Camaros for $109,000, but with 705 HP and 717 lb-ft of tire melting torque on tap, we could let go of some of the kiddies college fund. Don't judge. You're thinking the same thing.

Here's the specs on this Corvette ZR1-powered monster:

# Power: 705 bhp @ 6,400 rpm
# 717 lb-ft Torque @ 4,400 rpm

Performance (Estimated):
# 0 - 60 mph: 3.7 sec.
# 1/4 mile: 11.3 @ 125 mph
# Top Speed: 201 mph
# Skidpad: 0.96 g
# 60 - 0 mph braking: 105 ft.

This future didn't used to be so far off, but thanks mostly to the failing economy and subsequent carpocalypse we may never see this bow tie warrior compete with the monstrous 2010 Shelby GT500. The top dog Z28 model would have received a version of the 2009 Cadillac CTS-Vs 556-horsepower supercharged LSA, which in turn is a variant of the 638 horsepower 2009 Corvette ZR1 LS9. A larger power dome hood would have made room for the intercooler-topped small block while a larger functional hood scoop would have drawn in cold air to feed the monster. A revised front fascia with large intakes would have been used for functional cooling of both the engine and the massive Brembo front brakes.

All bets are currently off in the high-performance pony car war, but we're extremely hopeful that we'll eventually see this historic nameplate make an official return. Until then, tuners like Hennessey Motorsport and Lingenfelter will continue to build tasty alternatives. [via Camaro5]

Out of 24 of these ultra-Camaros, only 13 are currently left which means you had better start making decisions on parting ways with your hard earned $109,000 or else you'll never get to feel the adrenaline rush of 705 ponies running through your long, luscious mulletard hair. What you're looking at here is just the first step in the process of turning the meager-Camaro SS into a supercharged and carbon-fibered UFC fighter. If the Corvette ZR1 is anything to go by, this swapped ride will come with a swift kick in the pants standard. We can't wait.

A few hours after we published our in-depth interview with Stile Bertone’s new design director Jason Castriota, I was standing by Lake Como with him showing me the secrets of his first Bertone design, the Mantide.

The front fenders melt into wings behind the front wheels then draw up into a single taut bunch—reminiscent of a calf muscle—which in turn passes under an archway similar to Castriota’s famous C-pillar for the Ferrari 599 GTB. The confluence of curves and LED’s in the back is, when viewed from a step back, a classic Kamm tail. While retaining the tried-and-true shape of the fastback, the Mantide is boldly futuristic.

But will anyone be able to drive it? There are plans to make two more examples, Castriota says, in white and green, to create an Italian flag with the addition of the first car. Then, in an email to the New York Times, he said: “We would not rule out producing as many as 10.” A price has also been quoted: €1,500,000

That's close to two million US dollars at the current exchange rate—almost two Veyrons worth of cold, hard cash. Not insignificant for a car built on a Corvette ZR1, which retails for 5% of the Mantide’s asking price. Let’s examine what you get for that kind of money, apart from the warm feeling of contributing to a company’s survival which has given us the Miura, the Countach and the Lancia Stratos.

Interior

While Jeremy Clarkson has named the Corvette ZR1 his car of the year for 2008 and our own road test editor Wes Siler called it “the best car ever made,” the fact remains: on the inside, it's all Corvette.

To whit, from our first drive:

In fact, the only thing detracting from the ZR1’s grand touring credentials is the interior. The only options on the $103,300 car are an awful set of chrome wheels and the 3ZR upgraded interior package, which succeeds in moving the interior from cheap and nasty into luxurious bass boat territory with more embroidered ZR1 and Corvette logos than my fragile mind could comprehend. We have a hard time accepting the “value” excuse; for this kind of money we’d no longer like to feel like a Jeff Foxworthy punchline. An automatic transmission is, thankfully, not an option.

Let’s see what the Mantide has to offer:

As you can see, it’s a modern European alcantara-carbon-fiber-leather affair, with the car’s hexagonal theme continuing as cutouts on the racing seats, themselves thin carbon shells. The instrument screen is the one used in the Ferrari FXX, the gearshift is a nice aluminum knob and it’s certainly got a snug racer feel to it. But it’s perhaps not as remarkable as the car’s exterior.

Certainly a major upgrade on the Corvette, though, but then that’s not saying much when you’re considering this is a two million dollar Italian super car.

Exterior

Here in Europe, the current Corvette is not liked much. It’s a big, brash American design, a brute amongst small European cars, but while it’s unarguably alien to these shores, I rather fancy its low, wide, flowing looks. In ZR1 trim, it’s a proper menace, with all the right vents, wings and scoops.

The Mantide gets rid of that all. Aside from the front-engined layout and the fastback silhouette, you would be hard pressed to tell there’s a Corvette underneath. And there is: the Mantide is not like the Italian-American cars from the 60s like the Iso Grifo or the De Tomaso Mangusta which paired an Italian chassis with an American V8. Beneath the red carbon fiber is a Corvette ZR1: LS9 engine, aluminum chassis, the works.

But what carbon fiber! It’s all sharp Bertone creases which turn into subtle arcs as you examine them up close, dihedral Enzo doors, smatterings of hexagons everywhere. The angular rear wheelarches—straight off the M577A armoured personnel carrier which transported the space marines into the doomed reactor core in Aliens—frame black Transformer wheels.

It’s dramatically new, so shockingly new that it’s actively disconcerting to take a few steps back and see its classic berlinetta profile. In person, it creates the sort of time warp the iPhone did when it first went on sale in the summer of 2007. You felt as though you were holding a sliver of 2011 in your hands.

The Mantide? I’d say it’s from 2017. Similar vehicles are on their way to leave the inner Solar System.

But then is it worth the price of 20 ZR1’s? There is, of course, no rational answer to such a question, as even the ZR1 is not an entirely rational purchase, being, as Dan Neil put it in his article The rapture of the hypercar, a big needle to deliver the combustible heroin of petroleum.

If you have space-faring ambitions on the public road, set to the soundtrack of a pushrod V8 with titanium bits, then by all means get in touch with Stile Bertone and put down whatever deposit they ask. The car geeks of the world need you to enable them to carry on the traditions of coachbuilding.

And then I saved the best part for the end. If you open the gigantic hood and peer inside, what you’ll see is exactly what you'll see when you open the hood of the ZR1 — a grinning, black Corvette Racing skull named Jake.

So even though this is not a race car, your Le Mans ass-kicking heritage is right there. And who could ask for more.

Photo Credit: Alex Conley (Corvette ZR1), Natalie Polgar and the author (Stile Bertone Mantide)

Sure, we could drop the LS9 V8 crate engine, normally found under the hood of the 2009 Corvette ZR1, in a Chevy Aveo or a GAZ-51 custom truck. But aren't those kind of obvious? If we had the monster crate engine, capable of 638 HP and 604 lb-ft of torque, we'd want to put it into something completely incongruous. Can you say Tesla Roadster Sport?

In it's current form, we doubt the LS9 would actually fit behind the cabin, so we'd have to make it a Tesla Roadster Sport shooting-brake, an idea so exciting if we put it on the Weather Channel it would blow up your television. It would eschew both the Tesla concept of electric motivation and the Lotus concept of lightness by dropping a big, honking V8 in it. Glorious. What about you?

(QOTD is your chance to answer the day's most pressing automotive questions and experience the opinions of the insightful insiders, practicing pundits and gleeful gearheads that make up the Jalopnik commentariat. If you've got a suggestion for a good "Question Of The Day" send an email to tips at jalopnik dot com.)

GM PERFORMANCE PARTS SET TO UNLEASH THE SUPERCHARGED LS9 CRATE ENGINE

LAS VEGAS - The LS9 6.2L supercharged V-8 is the power behind the most powerful and fastest production car in GM's history - the 2009 Corvette ZR1. In the third quarter of 2009, it will be available as a complete crate engine package from GM Performance Parts. It delivers a stunning 638 horsepower (476 kW) and 604 lb.-ft. of torque (819 Nm).

The LS9 crate engine will be the ideal all-in package for enthusiasts and racers who want the ultimate LS power plant for their project cars, from resto-modified vintage Corvettes, muscle cars and street rods to late model F-bodies and "shoebox" Chevys. The supercharger and charge cooler are integrated in the engine's valley for a lower profile, allowing creative builders to fit the engine in a variety of applications with plenty of hood clearance.

The engine's 6.2L displacement is shared with the LS3, but the LS9 is built for high-revving power with a supercharger. It uses stronger cylinder head castings and steel cylinder liners that are honed with a deck plate installed to maximize performance and cylinder sealing.

High-rpm-validated lightweight reciprocating parts, including titanium intake valves, are used, along with high-flow cylinder heads that draw the charge forced on them by a sixth-generation supercharger. A new, four-lobe rotor design delivers greater power at the low end and sustains it longer through the rpm band for broad, on-demand power, whether off-idle or at speed. A dual-brick charge cooler is integrated on a unique manifold system that mounts the "blower" in the engine's valley, with charge cooler on top.

GMPP's LS9 crate engine assembly comes fully dressed, including the ignition system, supercharger assembly, exhaust manifolds and more. It also includes the production dry-sump oil pan and provisions for the charge cooler's liquid cooling system. Builders will need an external oil tank, external coolant tank (for the charge cooler) and an ECU/wire harness.

[GM Performance Parts]

[AutomobileMag]

CHEVROLET ANNOUCES CERTIFIED POWER RATINGS FOR THE NEW CHEVROLET CORVETTE ZR1: 638 HP FROM THE SUPERCHARGED LS9 V-8

PONTIAC, Mich. - When it was introduced at the North American International Auto Show in Detroit earlier this year, the 2009 Chevrolet Corvette ZR1's power was estimated at 100 horsepower for each of its 6.2 liters of displacement. GM Powertrain has completed SAE certification of the ZR1's supercharged LS9 V-8 and the results exceed the estimate: 638 horsepower (476 kW) and 604 lb.-ft. of torque (819 Nm).

The LS9's output is nearly 103 horses per liter, or just about 1.7 horses for each of the engine's 376 cubic inches. It is unquestionably the most powerful automotive production engine ever manufactured by General Motors and enables the Corvette ZR1 to achieve a top speed of more than 200 mph (322 km/h).

"One of the most amazing things about the Corvette ZR1 is the level of refinement that our designers and engineers have attained. Even with all that power, this car has road manners that will allow our customers to enjoy it on the streets as a daily driver, and on the track," said Chevrolet General Manager Ed Peper.

The Corvette ZR1 goes on sale this summer. Its 638-hp supercharged engine is complemented in the chassis by heavy-duty components not offered in any other model, including a six-speed manual transmission with race-hardened gears and dual-disc clutch technology that delivers exceptional clamping power and lower inertia, as well as strengthened axle components.

Fuel economy testing has not been completed, but engineers are confident the ZR1 will be the most fuel-efficient 600-plus-horsepower car on the market.

The LS9 engine is hand-built by specially trained technicians at GM's Performance Build Center in Wixom, Mich. It is a unique, small-volume engine production facility that also builds the Chevrolet Corvette Z06's LS7 engine and other high-performance GM production engines.

"Developing the LS9 involved more than simply striving for a great horsepower number. Endurance and reliability testing have shown the engine to be robust and low-maintenance, just like other engines in the small-block family," said Sam Winegarden, executive director, engine engineering for GM Powertrain. "That it is distinguished as the most powerful engine ever from General Motors is a source of immense pride among everyone involved with the LS9."

Supercharged aspiration
The key enabler of the LS9's performance is the industry's first production application of a new, positive-displacement Roots-type supercharger that has a unique four-lobe rotor design. Its design promotes quieter and more efficient performance, while the large, 2.3-liter displacement ensures adequate air volume at high rpm. Maximum boost pressure is 10.5 psi (0.72 bar). It is teamed with an integrated charge cooling system that reduces inlet air temperature for maximum performance.

"The combination of large displacement and the new, four-rotor design broadens the effective range of the supercharger, allowing the engine to make more power at lower rpm and sustain it throughout the power band," said Winegarden. "The low-end torque is tremendous and the high-rpm charge from the supercharger is simply amazing."

A raised hood provides adequate clearance for the LS9, while a polycarbonate window in the hood provides a view of the engine beneath it.

LS9 details
The LS9 features many unique design and manufacturing details that support its high-performance nature. They include:
Aluminum cylinder block with iron cylinder liners that are finish-bored and honed with a deck plate installed
Forged steel crankshaft with a nine-bolt flange
Titanium connecting rods and forged aluminum pistons
Stronger, rotocast cylinder heads with 2.16-inch (55 mm) titanium intake valves and 1.59-inch (40.4 mm) hollow-stem, sodium-filled exhaust valves
Camshaft with 0.555-inch (14.1 mm) lift for excellent idle and low-speed driving qualities
A dry-sump oiling system with 10.5-quart (9.9 liters) capacity
Integrated oil cooler and piston-cooling oil squirters
Intercooler cover visible through the hood window that features ZR1-unique blue accents and "LS9 SUPERCHARGED" embossed on the left and right sides

General Motors Corp. (NYSE: GM), the world's largest automaker, has been the annual global industry sales leader for 77 years. Founded in 1908, GM today employs about 266,000 people around the world. With global headquarters in Detroit, GM manufactures its cars and trucks in 35 countries. In 2007, nearly 9.37 million GM cars and trucks were sold globally under the following brands: Buick, Cadillac, Chevrolet, GMC, GM Daewoo, Holden, HUMMER, Opel, Pontiac, Saab, Saturn, Vauxhall and Wuling. GM's OnStar subsidiary is the industry leader in vehicle safety, security and information services. More information on GM can be found at www.gm.com.

# # #

Specifications

LS9 6.2L SUPERCHARGED V-8
Displacement (cu in / cc):
376 / 6162
Bore & stroke (in / mm):
4.06 x 3.62 / 103.25 x 92
Block material:
cast aluminum
Cylinder head material:
A356-T6 rotocast aluminum
Valvetrain:
overhead valve, 2 valves per cylinder
Fuel delivery:
SFI (sequential fuel injection)
Compression ratio:
9.1:1
Horsepower / kW:
638 / 476 @ 6500 rpm
Torque (lb-ft / Nm):
604 / 819 @ 3800 rpm
Fuel shut-off (rpm):
6600
Recommended fuel:
premium required
Exhaust manifolds:
stainless steel
Main bearing caps:
forged steel
Crankshaft:
forged steel
Camshaft:
hollow steel; 0.555-in (14.1 mm) lift
Connecting rods:
forged titanium
Valves:
intake: titanium
exhaust: hollow steel
Valve lifters:
hydraulic roller
Supercharger:
R2300, four-lobe "Roots" type (2.3L)
Additional features:
piston oil-spray cooling; direct-mount ignition coils; 11-rib accessory drive

SPECTER WERKES/SPORTS ANNOUNCES NEW C6 CORVETTE GTR

TROY, Mich. - Specter Werkes/Sports announced the all-new, C6-based Corvette GTR - the successor to the limited-edition C5 GTR program that helped forge the company's reputation as a Corvette performance and styling specialist a decade ago.

Retaining the intrinsic character of the Corvette, the GTR enhances its appearance, performance and luxury quotient. It is available on all C6 Corvette models, including the base coupe and convertible, the Z06 and even the forthcoming ZR1.

"The GTR is the Corvette for enthusiasts who want an exclusive, distinctive automobile," said Jeff Nowicki, Specter Werkes/Sports president and founder. "It's an uncompromising combination of great looks and racetrack-capable performance."

Featuring the use of exposed carbon fiber details on the exterior, the GTR package includes:
∑ Unique GTR bodywork, including: front fascia, carbon fiber splitter, extractor hood, front fenders, doors, rocker panels, rear fenders, rear fascia, carbon fiber rear diffuser, Cleartastic paint protection, paint and assembly
∑ Headlamp bezels with exposed carbon fiber appearance
∑ Unique tail lamps and CHMSL
∑ Michelin Pilot Sport 2 Zero PressTires; 335ZR2520 (rear) and 285ZR3019 (front)
∑ Forgeline or HRE wheels; 19-inch in the front and 20-inch in the rear
∑ Carbon fiber fuel rail covers and carbon fiber, low-restriction air box
∑ Hotchkis stablilizer bar kit
∑ GTR-embroidered seats and serial-numbered dash plaque
∑ Stainless steel performance exhaust system
∑ GTR badges
∑ Mobil 1 Synthetic Fluids

The Corvette GTR package carries a base price of $34,995, with a variety of high-performance powertrain options available for additional cost. Production is expected to begin this spring, with each vehicle hand-built, numbered and fully documented for the customer.

The Specter Werkes/Sports GTR was first launched a decade ago and saw the creation of nearly 30 specialized cars that were delivered across the country - including the two most notable GTRs, which were created for Dale Earnhardt Sr. and Jr., in 2001.

Specter Werkes/Sports was founded in 1990 by Nowicki, a Corvette racer and car designer.

Arash, formerly known as Farboud, hasn't yet decided on a powerplant for the AF-8. Both a smaller capacity GM V8 or a turbo diesel are under consideration. Expect either option to give a top speed in the low 200mph range, with a sub 3.5 second 0-60 time.

It's expected that the AF-8 will share the steel-and-carbon composite construction of the AF-10, but will undercut that model by about £50,000, with a projected price of £120,000. [Via Arash Cars]

2009 Corvette ZR1 Powered By The Most Powerful Production Engine Ever From GM: The Supercharged LS9 Small-Block V-8

PONTIAC, Mich. - When it arrives next summer, the 2009 Chevrolet Corvette ZR1 will be the most powerful and fastest production car ever produced by General Motors, with performance enabled by a new, supercharged 6.2L LS9 small-block V-8 engine.

Incorporating the engineering experience already found in the Corvette Z06's LS7 engine and the new-for-2008 6.2L LS3 of the Corvette, GM Powertain is targeting 100 horsepower per liter for the LS9, or 620 horsepower (462 kW), and approximately 595 lb.-ft. of torque (807 Nm); final SAE-certified power levels will be available in early March 2008.

It is, indeed, the ultimate small-block engine for the ultimate Corvette.

"When you experience the LS9 in the Corvette ZR1, the terms performance and refinement take on a new meaning," said Tom Stephens, group vice president for GM Powertrain and Quality. "The LS9 demonstrates an outstanding performance range, with smooth driveability at low speeds, and surprisingly fierce performance when the customer wants more power."

The enabler of the LS9's performance is a new, large positive-displacement Roots-type supercharger - with a unique four-lobe design - developed for the engine by Eaton. It is teamed with an integrated charge cooling system that reduces inlet air temperature for maximum performance. The LS9 represents the first of several new, supercharged small-block engines that will be introduced in GM vehicles in the near future, each using superchargers of similar design.

"The small-block V-8 once again demonstrates it boundless horsepower potential, versatile design and an architecture with proven quality, durability and reliability," said Stephens. "We haven't yet realized the small-block's performance potential."

Performance range

More than just its tremendous peak horsepower and torque numbers, the supercharged LS9 makes big power at lower rpm and carries it in a wide arc to 6,600 rpm. GM Powertrain testing shows the engine makes approximately 300 horsepower (224 kW) at 3,000 rpm and nearly 320 lb.-ft. of torque (434 Nm) at only 1,000 rpm. Torque tops 585 lb.-ft. (793 Nm) at about the 4,000-rpm mark, while horsepower peaks at 6,500 rpm. The engine produces 90 percent of peak torque from 2,600 rpm to 6,000 rpm.

Heavy-duty and lightweight reciprocating components enable the engine's confident high-rpm performance, while the large-displacement Eaton supercharger pushes enough air to help the engine maintain power through the upper levels of the rpm band.

"The sixth-generation design of the supercharger expands the 'sweet zone' of the compressor's effectiveness, broadening it to help make power lower in the rpm band," said Ron Meegan, assistant chief engineer. "To put it simply, the low-end torque is amazing."

The LS9 is assembled by hand at GM's Performance Build Center, a unique, small-volume engine production facility in Wixom, Mich., that also builds the Corvette Z06's LS7 engine and other high-performance GM production engines.

Cylinder block and reciprocating assembly details

The LS9's aluminum cylinder block features steel, six-bolt main bearing caps, with enlarged vent windows in the second and third bulkheads for enhanced bay to bay breathing. Cast iron cylinder liners - measuring 4.06 inches (103.25 mm) in bore diameter - are inserted in the aluminum block and they are finish-bored and honed with a deck plate installed. The deck plate simulates the pressure and minute dimensional variances applied to the block when the cylinder heads are installed, ensuring a higher degree of accuracy that promotes maximum cylinder head sealing, piston ring fit and overall engine performance.

Nestled inside the cylinder block is a forged steel crankshaft that delivers the LS9's 3.62-inch (92 mm) stroke. It features a smaller-diameter ignition-triggering reluctor wheel and a nine-bolt flange - the outer face of the crankshaft on which the flywheel is mounted - that provides more clamping strength. Other non-supercharged 6.2L engines, such as the base Corvette's LS3, have a six-bolt flange. A torsional damper mounted to the front of the crankshaft features a keyway and friction washer, which also is designed to support the engine's high loads.

Attached to the crankshaft is a set of titanium connecting rods and forged aluminum pistons, which, when combined with the cylinder heads, delivers a 9.1:1 compression ratio. This combination is extremely durable and lightweight, enabling the LS9's high-rpm capability.

Cylinder head details

The basic cylinder head design of the LS9 is similar to the L92-type head found on the LS3 V-8, but it is cast with a premium A356T6 alloy that is better at handling the heat generated by the supercharged engine - particularly in the bridge area of the cylinder head, between the intake and exhaust valves.

In addition to the special aluminum alloy, each head is created with a rotocast method. Also known as spin casting, the process involves pouring the molten alloy into a rotating mold. This makes for more even distribution of the material and virtually eliminates porosity - air bubbles or pockets trapped in the casting - for a stronger finished product.

Although the heads are based on the L92 design, they feature swirl-inducing wings that are cast into the intake ports. This improves the mixture motion of the pressurized air/fuel charge. The charge enters the combustion chambers via titanium intake valves that measure 2.16 inches (55 mm) in diameter. Spent gases exit the chambers through 1.59-inch (40.4 mm) hollow stem sodium-filled exhaust valves. The titanium intake and sodium-filled exhaust valves are used for their lightweight and high-rpm capability.

To ensure sealing of the pressurized engine, unique, four-layer steel head gaskets are used with the LS9's heads.

Camshaft and valvetrain

The broad power band enabled by the LS9's large-displacement supercharger allows it to make strong low-end torque and great high-rpm horsepower, which allowed engineers to specify a camshaft with a relatively low lift of 0.555-inch (14.1 mm) for both the intake and exhaust valves. This low-overlap cam has lower lift and slower valve-closing speeds than the Z06's 505-horsepower (377 kW) LS7, helping the LS9 - with its approximately 620 horsepower - deliver exemplary idle and low-speed driving qualities.

The camshaft actuates a valvetrain that includes many components, including the lifters, rocker arms and valve springs, of the LS3 engine. However, LS7 retainers are used to support the engine's high-rpm performance.

Supercharger and charge cooler details

The LS9's R2300 supercharger is a sixth-generation design from Eaton, with a case that is specific to the Corvette application. The supercharger features a new four-lobe rotor design that promotes quieter and more efficient performance, while its large, 2.3-liter displacement ensures adequate air volume at high rpm to support the engine's high-horsepower aspiration. Maximum boost pressure is 10.5 psi (0.72 bar).

The supercharger is an engine-driven air pump that contains a pair of long rotors that are twisted somewhat like pretzel sticks. As they spin around each other, incoming air is squeezed between the rotors and pushed under pressure into the engine - forcing more air into the engine than it could draw under "natural" aspiration. The rotors are driven by a pulley and belt that are connected to the engine's accessory drive system.

Because the pressurized air is hotter than naturally aspirated air, the LS9 employs a liquid-to-air charge cooling system to reduce inlet air temperature after it exits the supercharger - reducing the inlet air temperature by up to 60 degrees C (140 F). Cooler air is denser and allows the engine to make the most of its high-pressure air charge. The charge cooling system includes a dedicated coolant circuit with a remote-mounted pump and reservoir.

The design of the supercharger case and its integrated charge cooling system was driven by the space and dimensions afforded under the Corvette's hood. To that end, the charge cooler was designed as a "dual brick" system, with a pair of low-profile heat exchangers mounted longitudinally on either side of the supercharger. Coupled with the supercharger itself, this integrated design mounts to the engine in place of a conventional intake manifold and is only slightly taller than a non-supercharged 6.2L engine. The air inlet and rotor drive pulley are positioned at the front of the supercharger.

Additional engine details

Oiling system: The LS9 uses a dry-sump oiling system that is similar in design to the LS7's system, but features a higher-capacity pump to ensure adequate oil pressure at the higher cornering loads the ZR1 is capable of achieving. An oil-pan mounted oil cooler is integrated, too, along with piston-cooling oil squirters located in the cylinder block. The expanded performance envelope of the Corvette ZR1 required changes to the dry sump system also used in the Z06. System capacity is increased and scavenge performance improved to meet the demands of Chevrolet's highest-performance sportscar.

Water pump: To compensate for the heavier load generated by the supercharger drive system, an LS9-specific water pump with increased bearing capacity is used.

Accessory drive system: In order to package the accessory drive system in the Corvette's engine compartment, the supercharger drive was integrated into the main drive system. This required a wider 11-rib accessory drive system to be used with the LS9 in order to support the load delivered by the supercharger.

Fuel system: The LS9 uses high-capacity 48-lb./hr. fuel injectors with center-feed fuel lines. The center feed system ensures even fuel flow between the cylinders with less noise. In order to ensure fuel system performance during low speed operation as well as under the extreme performance requirements of wide open throttle (WOT), a dual pressure fuel system was developed. This system operates at 250 kPa at idle and low speed, and ratchets up to 600 kPa at higher-speed and WOT conditions.

Throttle body: An 87-mm, single-bore throttle body is used to draw air into the engine. It is electronically controlled.

Rocker covers / ignition coils: Unique rocker covers with new, direct-mount ignition coils are used. Other Gen IV engines, such as the LS3, feature coil packs mounted to a bracket. The LS9's direct-mounted coils offer a cleaner appearance and a shorter lead between the coil and spark plug.

Beauty cover: A special engine cover is attached to the top of the LS9. It surrounds the intercooler, which is visible through a hood window, accenting the supercharger while simultaneously reducing noise. The cover has "LS9 SUPERCHARGED" script on the left and right sides, along with a debossed Corvette crossed flags emblem on the front.

New six-speed manual transmission

The Corvette ZR1's LS9 engine is backed by a Tremec TR6060 six-speed manual transmission, with a twin-disc clutch system. It is based on the proven T56 six-speed, but upgraded to handle the LS9's torque output and delivers improved shift quality

The twin-disc clutch system provides exceptional clamping power, while maintaining an easy clutch effort. The system employs a pair of 260-mm discs, which spreads out the engine's torque load over a wider area, enabling tremendous clamping power to channel the LS9's torque. It also dissipates heat better and extends the clutch life (in normal driving).

Thanks to comparatively small plates, the twin-disc system enables similar disc inertia to the Corvette Z06, which has a 290-mm single-disc system, contributing to low shift effort and providing exceptionally smooth engagement and light pedal effort. In fact, the more powerful ZR1 has a pedal effort similar to the Z06.

ZR1-specific gearing in the transmission provides a steep first-gear ratio that helps launch the car. The car's top speed is achieved in sixth gear - a change from the fifth-gear top-speed run-outs in the manual-transmission Corvette and Corvette Z06. The gears also are designed to balance performance with refinement. The angles of the gear teeth are optimized to provide both strength and quietness.

Oh, and in case you forgot what the engine sounded like — remember who brought you the first video of the Corvette ZR1 — that's right, who loves ya, baby?

The allegedly-LS9-powered 'Vette has been spotted yet again on the mean streets of the town that's close to Wert's suburb, shot by a man with a cam who saw the camo'd up C6 and a bunch of guys typing on laptops in a manufacturer-plated Suburban. Sadly, dude was too intimidated to shoot more because he didn't want to get busted. Note to dude, if you happen to be reading this: they cannot bust you for taking photographs of cars they're driving around on public roads. Just carry a Glock in case they decide to get rough. They're engineers, not the Geheime Staatspolizei. Shoot all you want, they'll make more Corvettes. – Davey G. Johnson

[AND AGAIN] SS SPY PIC - Exclusive! [DigitalCorvettes]

Related:
Spy Photos: More on the 2008 Corvette SS, Stingray, Mako Shark, "Blue Devil," etc. [Internal]

Unsubstantiated tips come and go, but some stick around like relatives. If there's anything right in the world, this tip — which adds to the broadening legend of the "Blue Devil" Corvette — sticks. It's from a guy who knows a guy who's been to a master-mechanic's seminar on fixing the supercharged mill that will allegedly power the Dodge Viper-smoking 'Vette. According to the guy's guy, 700hp is in the works.

"My VERY RELIABLE source tells me the new Corvette is going to come with 700+ N/A HP!!!! I didn't believe him until he said he went to the class that shows them how to repair the engine. My source has been a Master Chevy mechanic his entire career.

He also mentioned there will be 2 new supercharged CTS-V and the convertible (forget the name) Caddy's. The design of the supercharger actually puts the intercooler inside the intake manifold, cooled by a front end radiator.

Whoa, mama. [Thanks to Kurt for the tip.] [UPDATE: Catch of the day goes to Frank, who points out that N/A could mean "naturally aspirated," mitigating rumors of supercharging. Can anyone say LS9?]

Related:
Over the Back Fence: Blue Devil Corvette Coming in Spring 2007? [internal]

The following cryptic message showed up today on Digital Corvettes. Apparently penned by a Chevrolet dealer, it may offer new insight into the upcoming "Blue Devil" Corvette. Not a hell of a lot of insight, mind you, but just about any is welcome.

"A SPECIAL LIMITED EDITION IS BEING PLANNED FOR NEXT SPRING - NO HARD DETAILS UNTIL 1st of THE YEAR OR SO...."

[*Name that reference]

Related:
More on the "Blue Devil" Corvette [internal]

Chevrolet's long-rumored ber- monstrous Godzilla Vette, alternately referred to as the Blue Devil or SS, is slated for reality. According to GM performance cars honcho Tom Wallace. And yes, it will have 600hp. According to Wallace, the biggest problem is figuring how to make that horsepower usable. Still, we have no hard data on whether the car's long-debated LS9 mill will be naturally-aspirated or supercharged.

To Hell and Back [AutoWeek]

Related:
Over the Back Fence: Corvette LS9 for 2008 [Internal]

One of our sources, now in deep cover somewhere in the Detroit area, reports the long-speculated "Blue Devil" corvette's "LS9" engine will be a supercharged LS7, not a spanky new DOHC mill as had been rumored. So does this rumor trump the earlier rumor, or will a a third rumor the same as the first trump them all? D'oh.

Related:
Over the Back Fence: Corvette LS9 for 2008 [internal]

We've been getting a bunch of tips regarding the rumored Corvette LS9 motor allegedly in development. Unfortunately, they've all come from some guy trying to promote his Corvette community site using false information. We took the bait somewhat, posting on an alleged drawing of the engine in question, but this time he's gone way too far. He's posted a shot of a chrome LS2 fitted with a Roots-type supercharger along with some cock-and-bull about a "reliable source" indicating it's a prototype of the LS9 Corvette engine. Of course, anyone who's seen the retro-rod concept recently shown in Australia, the Holden EFIJY Custom Coupe would know right away where that motor is from. There's your link, now f-off. [Update: In our tipster's defense, he says, he was just showing what he felt was a very closely related engine, and that the Efijy uses other Corvette components in its build. He also says he'll soon have even more supporting evidence of the "Blue Devil Corvette's" existence.]

Related:
More LS9 Intrigue [internal]