Turbo 5.3 Silverado Build Aims For 1,000 HP Sleeper Status

A rusty, 200,000-mile 2005 Chevy Silverado is the latest project to get the sleeper treatment, and the team behind it is documenting the entire transformation on YouTube. Creator Dom Tracy, working alongside a partner under the newly formed D&J Motor Swaps banner, pulled the truck’s factory engine and replaced it with a junkyard 5.3-liter V8, then added a single-turbo kit from On3 Performance in pursuit of a 1,000-horsepower goal.

From Camshaft Shop To Motor Swaps

Before tackling this build, the pair had already lowered the truck, added an exhaust, and detailed it after buying it about five months earlier. They also launched a camshaft business that, by their own admission, did not go according to plan. Rather than stepping back, they pivoted into motor swaps and turbo installations exclusively, opening D&J Motor Swaps and using this Silverado as the shop’s first project.

Pulling The Original Engine

The build started with a full teardown. The team drained the coolant, disconnected the battery, and removed the alternator, water pump, and air conditioning components before dropping the crossover pipe and headers to free up the motor mounts. Once the factory engine was out, they set it next to the replacement 5.3-liter long block and began transferring components, including the valve covers, timing cover, crank pulley, and a new oil pan with a welded-on drain plug, to prepare the fresh engine for installation.

On3 Turbo Kit And Cooling Overhaul

With the engine mocked into place, the team bolted on the exhaust manifolds required for the On3 turbo kit, then clocked the turbo and ran the oil feed and drain lines before the motor went into the chassis. Fitting the intercooler meant removing the front bumper and grille and trimming the core support for clearance. A smaller aftermarket radiator, at about 28 inches versus the stock 34-inch unit, created the room needed for the turbo piping, though it also required new cooling fans and additional wiring work.

A Built 4L80 For More Power

Knowing the factory 4L60 transmission would not survive the power increase, the team sourced a built 4L80 from Trans Pro Service Center, complete with a master overhaul kit, a shift kit, and a 3,600-stall billet torque converter. The swap also required a new transmission harness, a 4L80 brace, and a custom-measured driveshaft to match the longer transmission. The team estimated the combination could initially make 550 to 600 horsepower on the way toward the truck’s larger goal.

Before buttoning up the top end, the team also installed a set of larger fuel injectors, which had been flow tested and resealed, to support the added boost. The current injectors are sized for pump gasoline, though the team plans to add an E85-capable fuel system down the road as the build progresses toward its horsepower goal.

After wiring the new engine and transmission, the team hit a snag when a set of starter wires were found touching each other, preventing the truck from starting. Once corrected, tuner Fonz Performance flashed a base tune, and the Silverado fired up and idled on its own power for the first time with its new combination in place. Before any dyno pulls, the team noted several loose ends still need attention, including tightening boost clamps, addressing a transmission pan leak, and rerouting oil away from the hot turbo.

There’s still plenty of work standing between this 200,000-mile Silverado and its eventual 1,000-horsepower goal, but that’s also what makes the project interesting. Dom Tracy and the D&J Motor Swaps crew aren’t starting with a spotless show truck or an unlimited parts budget. They’re taking a rusty old Chevy, stuffing it with junkyard 5.3-liter power, and working through the same fitment problems, wiring headaches, leaks, and unexpected setbacks that come with building something like this in the real world.

For now, the combination of the On3 turbo kit, built 4L80, larger injectors, and supporting hardware should provide plenty of entertainment at the planned 550-600 horsepower level. From there, an E85-capable fuel system and additional upgrades should give the team room to start turning things up.