Conversions

Mallett Performance Cars headed to SEMA with 2015 700+HP Chevy Colorado

The Mallett Performance Cars team returned to SEMA this year to promote the launch of our 2015+ Chevy Colorado/GMC Canyon supercharger system. We showcased this highly-modified 2015 Colorado with our friends from Magnuson in their booth this year.

This bad boy makes over 700 rear-wheel horsepower, putting out Corvette-equivalent horsepower with four seats and a truck bed.

We swapped the stock engine for a 3.6L V6 from a 2016 Cadillac ATSV. This engine is already built for boost.

The engine features a forged crank, titanium connecting rods, and forged pistons.

Bolted to the top is a Mallett Colorado Intercooled Supercharger Manifold assembly complete with a Magnuson 1.9L supercharger, custom 64mm C&R intercooler, custom CNC-machined upper and lower 8-rib pulleys, front engine idler pulley, tensioner mounting plate, drill-less mounted aluminum intercooler tank and water pump, and C&R heat exchange.

We used a C7 LT1 throttle body to open up the intake side and crafted a custom air intake box. It’s outfitted with a highly custom-fabbed, high-flowing true dual exhaust to polish off the performance mods. This mean machine was fueled with 109 race fuel.

Behind the V6 is a modified stock transmission that turns a narrowed Moser nine-inch rear-end with WaveTrac and aluminum center section. We added Forgeline custom MS3C concave wheels-19x9x.5 front and 20×13 rear, wrapped in rear 315/35/20 BF Goodrich G-force Rivals.

A lot of custom work was put into the chassis and suspension for drivability and stability. We adjusted the ride height to lower the center of gravity. Custom drop spindles were fabricated with custom lower control arms up front. Custom Penske coilover shocks were also installed.

The rear frame section was raised and narrowed, and a custom three-link ladder system with center frame crossbar and driveline hoops were fabricated and welded in.

We installed a custom rear sway bar and adjustable panhard bar were installed to fine tune the truck’s balance. With the size of the rear tires we tubbed the truck bed four-and-a-half inches wider on each side.

The brakes got an overhaul to make sure we could stop this beast. A big thank you to Mike Mecina and Danni Jacobs of Brembo brakes. They came to the rescue with custom Brembo brakes, 6 piston front calipers and 4-piston rear brake calipers with floating rotors.

On the exterior, we removed all the plastic trim, added a custom front grille, and a custom fascia. We added a custom carbon front spoiler for an aggressive look.

Contrast stitching was added to the seats, and Water Buffalo seat inserts. Some trim panels were hydro dripped, and a six Kicker speaker with sub stereo add to the pleasure of driving.

A very sincere thanks to all of our sponsors, vendors, and team members who helped make this vision a reality.

Here is a complete list of modifications:

Powertrain and Performance

2016 Cadillac ATSV 3.6L V6
- Engine Block
- Forged Crank
- Titanium Connecting Rods
- Forged Pistons
Mallett Colorado Intercooled Supercharger Manifold Assembly
- CNC Machined Manifold/Intercooler Base and Cover Plate
- Magnuson 1.9L Supercharger
- Custom 64mm High Efficiency C & R Intercooler
- Custom CNC Machined Upper and Lower 8-Rib Pulleys
- Custom CNC Machined Front Engine Idler Pulley and Tensioner Mounting Plate
- Custom, Drill-Less Mounting, Aluminum Intercooler Tank
- Custom Fabricated, Drill-Less, Frame Mounted Intercooler Water Pump
- Custom C & R Heat Exchanger
- C7 LT1 Throttle Body
- Custom Air Intake Box
- Custom High Flow Dual Exhaust
- Custom Dyno Tuned 750+ Horespower
Suspension
- Penske Coil-over Shocks
- Custom Drop Spindles
- Custom Lower Control Arms
- Narrowed Moser 9” Differential with WaveTrac and Aluminum Center Section
- Raised and Narrowed Rear Frame Section
- Custom 3-Link Ladder System with Center Frame Cross-Bar and Driveline Hoops
- Custom Rear Swaybar and Adjustable Panhard Bar
- Brembo 6-Piston Front Brake Calipers and 4-Piston Rear Brake Calipers w/Floating Rotors
- Forgeline Custom MS3C Concave Wheels – 9.5 x 19 Fronts, 13 x 20 Rears
- BF Goodrich G-Force Rival Tires – 285/35ZR 19 Front, 315/35ZR 20 Rear

Interior and Exterior

Exterior
- Tubbed Truck Bed with Rear Roll Pan and Lexan Spoiler
- Smoothed Bed Top Rails with All Plastic Trim Removed
- Custom Front Grill
- Custom Front Fascia
- New Mallett Colorado Front Splitter
- New Hood with Air Extractor
Interior
- Contrast Stitching Seats with Water Buffalo Leather Seat Inserts and Grommets
- Formed Aluminum Door Panel Inserts Wrapped in Water Buffalo Leather with Contrast Stitching and Grommets
- Formed Aluminum Dash Panel Top Wrapped in Water Buffalo Leather with Contrast Stitching and Grommets
- Custom Dash Top Gauge Pod Wrapped in Water Buffalo Leather and Contrast Stitching
- Custom Center Console Arm Rest Wrapped in Water Buffalo Leather, Contrast Stitching and Grommets
- Hydro Dipped Plastic Trim Panels
- Kicker Speakers (6) and Sub-Woofer Enclosure

professional pic green colorado interior

Mallett Staff In Client's Rides, Conversions

Mallett Team Delivers 900RWHP 2013 ZL1 Camaro

For some people, the 580 crank horsepower from a stock ZL1 Camaro is enough.
Not for Mallett Performance Cars.

Chuck and the team took this stock 6.2L and completely reworked it to make more than 900hp at the wheels. Mallett-spec internals, valvetrain, and cylinder head increased the displacement to 454ci, and a 2.3L Magnuson Heartbeat supercharger with modified intercooler system provided 15lbs of boost.

The exhaust was routed through Mallett long-tube headers with Kooks Hyflow cats and collectors leading to Corsa mufflers with ZL1 cutouts. The fuel system and clutch were also overhauled to manage double the factory output. The fuel system now features upgraded pumps, injectors, and braided lines with AN fittings. The “Mallett Magic” clutch can handle punishment at the drag strip without the punishing feel of a typical high-torque clutch.

The monster drivetrain would be uncontrollable without the complete Mallett suspension package, including custom Mallett/Penske double adjustable coil-overs and a custom drop kit with control arms and upgraded rear springs.

The 20″ Mallett forged split-spoke rims were polished and powdercoated, then wrapped in Michelin Super Sport tires. The factory option Brembo brake package is surprisingly capable and was mostly left alone. The pads were replaced with a Performance Friction offering for aggressive bite with no sacrifice in comfort.

To make this machine look as good as it performs, the team installed a performance hood, a Mallett custom carbon engine cover to complement the polished and powder-coated blower, a Mallett custom carbon splitter, side air dams, spoiler, and framed perimeter grills.

The end result is a car that’s as pleasant to drive as it is to look at. It’s quiet, composed, and comfortable around town, but the drivetrain and suspension deliver stunning acceleration and grip when called upon.

Mallett Staff In Awards, Conversions, News

800hp 2014 Retro Chevy Silverado1500 Mallett Super10 Heads to SEMA

The Mallett team headed to the annual SEMA show in Las Vegas Nevada this year. We showcased our 800hp, retro-designed Chevy Silverado in the Kooks Headers and Exhaust display booth.

It all began with a phone call to General Motors to order a ’14 Silverado 1500 Z71 4WD double cab in factory red. The plan was to build a lowered truck, but the only way we could get the larger Silverado motor – the 6.2L V-8 – was to get a 4WD version. We would have to fabricate needed parts in-house at the shop. We were going for a ’70s-themed truck that would have the classic two-toned look, combined with modern luxury and performance.

Lowering this 4WD was a challenge at first, since no one made a lowering kit for the new body style 4WD and the 2WD version wasn’t an option for us. We took a McGaughys 2WD front drop kit and machined it to fit the 4WD truck.

In order to get a retro-looking wheel to complement the look we were going for, we chose a set of 22-inch Centerline Smoothie wheels that were painted red to match the truck and wrapped in 285/40/22 Yokohama tires.

A set of ’55/’56 Chevy repo hubcaps were machined by Bob Temple to fit the new wheels and were mounted on custom tabs. Under the truck, the entire frame was cleaned and sprayed with Dupli-Color bedliner.

Now that the truck sat in a lowered stance and the rolling chassis was ready to go, it was on to the body. First we removed the plastic caps on top of all the bedrails and the top of the tailgate. Jim Callaro at Metal Masters in Mooresville, North Carolina, welded in metal replacements for the plastic panels. This gave the bed a smoother look and allowed the paint to carry over the top of the bed. The next step was to completely rebuild the front and rear bumpers to remove all the plastic pieces and make them match the look of a ’70s Chevy.

There were more than 200 hours in custom fabrication in both of the bumpers. Sun Stoppers Chrome Wrap and Window Tint in Cornelius, North Carolina, wrapped both bumpers in chrome. To continue, the Mallett team built custom side trim moldings to resemble the old Chevys. We used 3003 sheer aluminum that was bent on a break, welded and hand-filed to mimic the ones from 1972. Then, they were masked off and a black center was sprayed to complete the look.

For the tailgate, a retro “Chevrolet” center plate was made. Then, the truck was off to Lake Norman Paint & Body in Cornelius, North Carolina, where Mike Pelusi painted the center of the truck PPG Summit White and painted over the new bodywork on the bed, finalizing that ’70s look.

Once painting was completed, final touches like the custom egg crate grille insert made from welded aluminum plate and the chrome bezel taillights from Razor Auto were bolted on.

Now it was on to bring the retro look into the interior as well. The factory black leather seats and door panels received houndstooth inserts, thanks to Robert McCarter in Harrisburg, North Carolina, which mimics early ’70s Chevy. All of the dash and door trim pieces were sprayed chrome to complete the retro look.

Saving the best for last on this build: the performance add-ons.

Starting with the factory 6.2L V-8 engine, the block was fully race-prepped, balanced, and blueprinted. A Callies billet crankshaft, 6.152 Ultra I-beam billet rods, Wiseco Gen 5 LT1 10:1 pistons and JGK 4.065 rings made the bottom end of an already beefy engine bulletproof.

A COMP Cams custom cam was ordered to allow better fuel flow. The motor was ported by Advanced Induction/Cylinder Head Development in Concord, North Carolina. ARP head stud kit and wrinkle black valve covers wrap up the top end of the motor.

To spit out the spent exhaust gases, a set of Kooks long-tube headers and a complete Kooks 6.2L cat-back 3-inch exhaust with custom tips were bolted on.

Next we added a Whipple 3.0L supercharger with 13 pounds of boost along with a custom ECM tune that was done in house. A set of Accel Extreme 9000 Ceramic plug wires round out the performance additions.

A 6L80/6L90 was built by RevMax in Charlotte, North Carolina, to get all that power to the ground. Speaking of power, with all the internal upgrades along with the blower and new exhaust, this truck puts down right at 800hp to the rear wheels.

All the attention to detail in the build was rewarded, we were very proud to win the highly sought after GM Design Best Truck award at the 2014 SEMA Show. This truck is now at its new home, and we have already started on our ’15 Chevy Colorado project for the 2015 SEMA Show. Stay tuned for more!

Inside the Build
Year/Make/Model: 2014 Chevrolet Silverado 4WD Double Cab Z-71
Owner and City/State: Chuck Mallett; Cornelius, NC

Chassis
Suspension: McGaughys 2WD drop spindles custom milled to fit the 4WD

Drivetrain
Engine: 6.2L V-8, Callies billet crankshaft and Ultra I-beam rods, Wiseco Gen 5 LT1 10:1 pistons, JGK rings, Calico-coated bearings, custom COMP Cams camshaft, race-prepped block that was ported and polished, Whipple 3.0L supercharger with 13 pounds of boost, custom tune, Kooks long-tube headers, and 3-inch cat-back exhaust

Body
Mods: Two-Tone PPG red/white paintjob, custom bumpers, custom aluminum grille insert, custom trim molding, shaved bed caps and tailgate cap

Interior
Houndstooth inserts by Robert McCarter in Harrisburg, NC, dash and door trim pieces sprayed chrome

Wheels & Tires
Wheels: 22×9.5 painted Centerline Smoothies with custom milled Chevy Repo center caps
Tires: 285/40/22 Yokahama Parada
Special Thanks: Tom Garner, Dr. Jamie Meyers, Robert Chabless, Mike Malicoat, Robert McCarter, PPG Paints, Metal Masters, Lake Norman Paint & Body, Advanced Induction, Bob Temple, Dupli-Color Paints, and the crew from Mallett Cars, Carol Reichert, Randy Cowan, Josh Mills and Damien.

Mallett Staff In Conversions, News, Projects

Mallett Performance Cars Heads to SEMA 2013 with 2008 803rwhp Solstice

Mallett Performance Cars headed to the annual SEMA show in Las Vegas Nevada held Nov 5- Nov 8. The team transported the 2008 803rear-wheel horsepower Solstice cross-country to display in the Quick Time Performance Exhaust Systems booth.

This is not your average Solstice.

Under the hood it boasts a heavily-modified LS9 V8, 454 cubic-inch Corvette engine. It has ported cylinder heads and 15/1 compression. The body was modified to the “Pitbull” wide body style in which the body was widened 4″ in the front and 5″ in the rear. Underneath are Michelin Super Sport 295/35/19 fronts and 315/35/20 in the rear.

This car was previously race-prepped for FIA GT4 European race. Most of the mods remained, such as the full FIA-approved roll cage and fuel safe fuel cell. The doors and hood were changed back to the factory steel from the carbon fiber that were added for the FIA competition.

Other modifications include:

Custom titanium red devil brakes
Mallett/Penske triple adjustable reservoir shocks
A stripped-down, seam-welded chassis
Windshield and greenhouse were moved rearward
A T56-6060 close ratio transmission
Fully-custom suspension with the roll center changed and the wheelbase made longer for better handling

Lest you think this car is only about speed, throw a few cones in front of it and the car comes to life. To achieve superior agility, the car is ballasted such that a 200-pound person sitting behind the wheel gives it perfect 50:50 lateral weight distribution. And with a full tank of gas, the weight split fore and aft is near that, at 52:48.

Achieving such good balance involved shoving the engine rearward to within millimeters of the tolerances set by GM for crash- worthiness.

This Solstice is truly one of a kind, a Mallett-ized, track-tuned, race-ready, 803rwhp monstrously-fast machine.

Mallett Staff In Conversions, News

Mallett Cars Preps 2008 Solstice to Race in GT4 European Cup

In early 2009, the Mallett team had the opportunity to prep a 2008 Solstice to race in the FIA GT4 European Cup.

Organized by the Stephanie Ratel Organization (SRO) and sanctioned by the Federation Internationale de l’Automobile (FIA), The GT4 European Cup follows a formula similar to the FIA GT Championship (GT1 and GT2), with races held across Europe. The vehicles used are generally factory-built with extensive modifications to meet strict safety and performance requirements.

The FIA, based in France, sent inspectors to examine the Mallett Solstice for homologation. There was a language barrier as Chuck and Lance spoke no French and the inspectors spoke little or no English. The French professor from nearby Baldwin Wallace University came to the rescue and translated the proceedings for both parties. After a six-month process, Mallett Cars was fully certified as an official FIA constructor and the Mallett Solstice was homologated to participate in the GT4 series.

Other cars in the class include the Aston Martin Vantage N24, BMW Z4 coupe, C6 GT4 Corvette, Lotus Exige Cup GT4, Maserati GranTurismo Trofeo Light, and the Porsche Cayman.

FIA rules state that the car’s dimensions and shape must remain true to the original, as must the front and rear overhangs. The car is required to have catalytic converters and must carry enough fuel to race for one hour.

For safety and weight reasons the interior of the car is gutted, then fitted
with a roll cage, fire suppression system, fuel cell,racing seat with harness, and netting on the driver’s window and interior. Every aspect was carefully scrutinized by the FIA inspector.

The standard four-cylinder drivetrain was replaced by a Mallett modified LS3 V8 which produces 400hp at 7700 rpm, a race-spec clutch, close-ratio 6-speed trans with Mallett shifter, 3.73 differential, and uprated axles. The dry-sump oiling and Aeromotive fuel system are designed to withstand Extended track sessions. Engine, transmission, steering, and differential coolers were added. Modified suspension components with Mallett/Penske Double adjustable coil over shocks provide the performance and adjustability required in a race car. All GT4 cars must run spec tires on fixed rim sizes. Since only the size was specified, this car sports custom ultralight wheels. Brakes are also fixed in size but not construction, so Brembo provided racing rotors, pads, and calipers to complement the modified factory brake system.

The factory steel hood and doors were reproduced in lightweight carbon fiber but were deemed illegal, so the factory parts were modified and replaced. The hard top, required by the series, was replaced with a carbon fiber SCCA-approved top with lexan rear window. The bodywork is subtly modified throughout to improve on-track performance while still adhering to series rules.

List of modifications below:

Mallett LS2 V8 Race Conversion
Zero Tolerance Balance & Blue Printing of Rotating Engine Components
Exedy Racing Clutch Assembly
8300 Mallett/Penske Double Adjustable Coil Over Shock Set
Mallett Custom Race Application Radiator
Mallett Body Graphics
Mallett Custom Number Plaque & Badging
6-Speed Performance Transmission
(Cryogenic Enhanced & Hardened Race Gears)
3.73 Differential
Race Prep Shifter with Delrin Knob
Mallett Custom Built Race Application Axle Shafts w/Aeromotive Fuel Rails and Regulator
Mallett Custom Sway Bar kit
ARE Dry Sump Oiling System
Engine Oil Cooler
Differential Cooler
Power Steering Cooler
ARP Long Wheel Stud
Race application Hood Latches
Poly-Urethane A-Arm/Differential Bushing Kit
Pontiac Solstice GXP Front Fascia Option
Pontiac Solstice Jazz Vented Race Fenders
Pontiac Solstice GXP dual rear Exhaust Fascia Option