Given were talking about the 1.6L I don't think it will be possible to run those kinds of numbers with the stock pistons.
Bascily the compression needs to be bumped down a little.... the easisest method is a thicker head gasket.... but the most reliable is new low comp pistons.
Personally I would bet on a solid 150whp and call it a day.... the car will be very quick at this level of power.
Keep in mind this is nearly double the power you currently have in your Aveo
Trust me on this.... my Lemans with the stock C20GET turbo is probably very close in weight to the Aveo and it is a real handfull to keep on the road with the torque steer.
Here is the dyno of the completely stock engine....
http://www.daewootech.com/forum/viewtop ... emans+dyno
I'm going to say it's roughly 140whp and 175lbft
I have a hell of a time keeping the car from spinning it's tires in first and second.... it's only when I get into third that I can use full throttle without tire spin.
You really have to keep in mind the power to weight ratio when figuring out how fast the car is.
Lets just say your around 2400lbs..... and lets guess that 150whp translates to roughly 180hp at the crank.
That mean your car is running about 13.3 lbs for every horsepower
Now..... lets look at a few other cars to see where they are at.
My Mazdaspeed3 weighs in at a heavy 3150lbs but I have 263hp at the crank giving it about 12lbs for every horsepower.
So... the aveo with 150whp would be slightly slower than my Mazdaspeed3.... which is one of the fastest "stock" production FWD cars on the planet.
Now.... the Dodge SRT-4 is rated at 215hp at the crank (which is low) and it weighs about 3000lbs
So it should have a power to weight ratio of about 14lbs per horsepower but since they rated the car low I'd guess it's closer to 12.7 lbs per horsepower.
Needless to say you probably know where I'm going with this........ an Aveo with 150whp would probably keep up fairly well with an SRT-4
If you start pushing past 150whp your going to have to worry about upgrading the transmission and engine components.... which will cost you a significant amount of money.... were talking about something in the $5000 range if your getting a shop to do the work for you.
So.... I would suggest you start out with something more realistic.... it may be possible to push the engine to 250whp but it will be next to impossible to get that power to the ground unless significant upgrades (including a limited slip) are installed.
I'm just going to guess here..... I'm thinking your going to need to run about 12psi to 15psi to get into the 150whp range.
In my opinion you would be better off dropping in a 2.0L/2.2L and turboing it if you want something above 200whp.... the 2.0L (25% more displacement) or the 2.2L (37.5% more displacement)
Don't get me wrong.... the 1.6L is a good little engine but you will be asking quite a bit if you want that much power.