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Whipple E85 Challenger Heavy Build

132K views 822 replies 61 participants last post by  WhipCat  
#1 · (Edited)
UPDATE: the car has undergone significantly more modications over the course of this whole build. There are more updates throughout the rest of thread.

Hello all, first post fun post. I have the pleasure of owning a 2017 challenger Hellcat. This car is loads of fun and Is absolutely beautiful to look at from every angle. But I am definitely not one to leave things stock for long. After owning it for about 4 months now is she has already undergone many modifications.

Started off with a upper and lower pulley swap and mid pipe pump gas tune. Made 780 to the tire. Had fun but wanted more power.

Went with upgraded driveshaft, differential brace, 3.09 gears, Triple pump fuel system, e85, heat exchanger thermostat etc. made 825 to the tire spinning on the dyno. Very fast car!

Motor went kaboom racing a local charger Hellcat shortly after. Sad day.

Now! The car is getting a beefier set of internals and a pretty whipple 4.5 on top of it.

Sooooo... here is the mod list.

New 6.2 block
Stock crank
Mahnley rods
Diamond pistons
Thitek Heads
Stock cam
Whipple 4.5
Fore triple pump fuel system
ID1300
Catch can
Stainless works complete exhaust headers to tips.
10% lower pulley
Torque converter
Aluminum drive shaft
3.09 gears
Diff brace
Bwoody control arms upper and lower.
All poly bushings for rear
Mopar lowering springs
Vossen GNS-1 wheels (hand brushed, with dark smoke transparent clear coat) 20x10.5 rear 20x9.5 front.
Nitto 315mm rears
E85 pillar gauge

Car will be a daily driver. Goal is 1100 street daily. No excuses. Nitrous is sitting in the garage wondering if it wants to be installed.

I would have done billet crank but I don’t want to wait 16 weeks. We will be running a tune with the 4.5” pulley which should be 20psi. The 4.25” pulley is probably what’s gonna be needed to break 1100 Hp. 23-24 psi should get that whipple to whine.

Looking to have a stealth tank in the trunk to carry an additional 20 gallons of fuel for extending E85 range. I want 350+ mile range min.

I’m used to whipple cars as I own a 2004 terminator with a built 5.3 and 2.9 whipple making 730 to the tire. Also a fun daily driver. The challenger will take over the heavy driving while the cobra becomes my weekend baby.

I’ll start adding pics of what parts have come in so far. Mario at gear head fabrications is doing the installation work.

What’s nice as this has been ongoing so the build will be done hopefully within next couple weeks.

UPDATE:

Dyno result and pics/videos on page 10 of this thread. Enjoy.
 

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#3 · (Edited)
Out of curiosity what the point of all those modes with 20 inch wheels ? Hope you use different tuner , 825 is nothing for hellcat stock engine .
Keep us posted , nice build sheet .
for the street I like to keep it 20”. They look great on the car. Will get some smaller wheels for the track.

Car went 10.66 with the pump gas tune at 780

At 825 on E85 tires would not hold up on the dyno. Should have made 880-890 was what I was expecting.

Threw a rod during a street race.
 

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#7 ·
for the street I like to keep it 20”. They look great on the car. Will get some smaller wheels for the track.

Car went 10.66 with the pump gas tune at 780

At 825 on E85 tires would not hold up on the dyno. Should have made 880-890 was what I was expecting.

Threw a rod during a street race.
Nice build plan. Do you know what caused the rod failure?
 
#13 ·
Yea, might of melted a piston prior to that I imagine or took a good chunk out of it from detonation. I'm the the timing the tuners put in to "real" e85 is not designed to take 50% ethanol.
 
#21 · (Edited)
Yes I am keeping them brushed like that, I selected hand brushed so I believe they will hand brush them to make the lines even. The transparent clear coat is in Dark Smoke. So you will see the machined brush lines through the paint. From what I hear these things glow when they are in the sun. Also, the GNS-1 wheels will be the first car these are going on for Vossen. So we will be doing a little photo shoot and send them over for the site.

This is one of only like 2 pictures I can find of the wheels that's not just a website photo. I'm not sure what color these are in. But this is the wheel painted.
 

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#19 ·
I have the stock upper but a 10% lower from my previous setup. The 4.25 upper pulley with a stock lower could give you a bit more boost than 24-25. Try it and let us know how it works out. Good luck on your goals I'm sure you will get there.
 
#20 ·
Thanks for the tip man.

Here is a couple of attempts when the car was at 780 to the tire on pump gas. These videos are strictly imaginary and are not real. Just good editing on my part. Turn the volume up and put on some headphones. This is beautiful music.



I wish I could figure out what's causing the screaming noise, I know it's wind but not sure if it's the trim on the window or the side mirror.
 
#22 ·
i have read up on e85 some don't claim to be an expert. E85 is said to clean off the oil on the cylinder wall which causes excessive heat and friction. Excessive heat can burn a valve, cause piston to over expand, etc. I read the Demon had holes drilled in the rods that would spray oil on the cylinder walls to offset the cleaning action of the e85. I'm glad you guys have the $$$$$ and time for such fun. Old guy here is just enjoying the stock Charger. Still smiles by the mile. Screeching sound sounds like the supercharger belt/pully being pushed out of alignment. Replace the belt with a new one and repeat the test to see if the sound is any different.

Cheers.
 
#26 ·
View attachment 356217 View attachment 356209 View attachment 356201 View attachment 356193
Been there done that, went the same route with new motor ported polished heads more aggressive cam, Kooks headers, 2.65/10% Fore fuel system E85 with pillar gauges this time. Kept stock supercharger for now, been looking at the new KB 4.9 intercooled one. Mine let lose cause bad fuel in Iowa while on the power tour.
Wow! Looks like lightning struck that block! Sorry to hear about the motor, but that leaves room for improvement now. Your building a nice power plant, what pistons, rods and crank did you go with?

Go with the KB or the whipple, you've got everything else ready for it!!
 
#28 ·
i have read up on e85 some don't claim to be an expert. E85 is said to clean off the oil on the cylinder wall which causes excessive heat and friction. Excessive heat can burn a valve, cause piston to over expand, etc. I read the Demon had holes drilled in the rods that would spray oil on the cylinder walls to offset the cleaning action of the e85. I'm glad you guys have the $$$$$ and time for such fun. Old guy here is just enjoying the stock Charger. Still smiles by the mile. Screeching sound sounds like the supercharger belt/pully being pushed out of alignment. Replace the belt with a new one and repeat the test to see if the sound is any different.

Cheers.
Never thought it could be the pulley and belt alignment. I'll check into that.
 
#33 · (Edited)
i have read up on e85 some don't claim to be an expert. E85 is said to clean off the oil on the cylinder wall which causes excessive heat and friction. Excessive heat can burn a valve, cause piston to over expand, etc. I read the Demon had holes drilled in the rods that would spray oil on the cylinder walls to offset the cleaning action of the e85. I'm glad you guys have the $$$$$ and time for such fun. Old guy here is just enjoying the stock Charger. Still smiles by the mile. Screeching sound sounds like the supercharger belt/pully being pushed out of alignment. Replace the belt with a new one and repeat the test to see if the sound is any different.

Cheers.
Can you cite this anywhere?
Most GENIII HEMIs have oil squirters attached to the block which are intended to keep the cylinders and pistons cooled. Not holes in the rods, and absolutely not because of E85, which is not recommended for the Demon.
 
#35 ·
I am considering putting this in the trunk towards the back behind the seat. Based on the measurements I think it will fit.

https://www.summitracing.com/parts/...rese1-_-tanks-inc&gclid=EAIaIQobChMInJjjl5z-2AIVlFYNCh2UmwngEAQYESABEgIMtvD_BwE

Mount it, then have lines run to the main tank. I would think because of the elevation the gas cap would be blocked off and it would have to be filled primarily from the trunk.

Once mounted and plumbed have it wrapped in the same material as trunk lining for a clean look?

Or have it painted for a race look?

They have these phantom fuel setups for diesel trucks to extend range. So wanting it for my e85 beast. I plan on doing allot of driving with the car this year. My builder is also a fabricator and can make a custom fuel tank as well.

This is going to be done after everything and it is optional, just trying to think out side the box and have something unique.

Thoughts?
 
#195 ·
I am considering putting this in the trunk towards the back behind the seat. Based on the measurements I think it will fit.

https://www.summitracing.com/parts/...rese1-_-tanks-inc&gclid=EAIaIQobChMInJjjl5z-2AIVlFYNCh2UmwngEAQYESABEgIMtvD_BwE

Mount it, then have lines run to the main tank. I would think because of the elevation the gas cap would be blocked off and it would have to be filled primarily from the trunk.

Once mounted and plumbed have it wrapped in the same material as trunk lining for a clean look?

Or have it painted for a race look?

They have these phantom fuel setups for diesel trucks to extend range. So wanting it for my e85 beast. I plan on doing allot of driving with the car this year. My builder is also a fabricator and can make a custom fuel tank as well.

This is going to be done after everything and it is optional, just trying to think out side the box and have something unique.

Thoughts?
I've been thinking about adding a second tank also.
 
#37 ·
Thank you. I want this thing stealth. And the main thing is I want to be able to use stock gas cap and line to fill car. I wouldn't want to have to fill from the trunk every time.

Aluminum would work. How thick do you think?

Also do you wanna see something cool 04cobravert? Check out my 04 cobra vert!
 

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#38 ·
Nice. From what I hear the stock crank is good for 1400 hp. Is demon performance doing any flex tuning? And are they porting stock blowers?

They are only couple hours north. Should be a stout bottom end.
No Tim Barth is doing the flex fuel tune for me, black key 93 fuel 14 psi boost. Red key E85 fuel 19-20 psi boost. You will have to call Skip at Demon about the blower cause I am not sure.