Stroker's Build (5.3/4L60E in a '69)
 

Well, I decided to finally set up a full build thread. I've had the truck for almost 3 months, and it's been in the garage for 4 weeks now. I hoped to have it done already, but it was plagued with rust that I just couldn't turn away from. So...I fabbed a new firewall that ran down the floorpans and also fixed some rocker panel rust and redesigned the cowl.

I took apart the whole front clip while I was at it and freshened it all up. I replaced EVERYTHING except the crossmember and control arms. The worst part of the build so far was finding a 1 11/16 socket to tighten the new lower control arm shafts. I didn't enjoy that at all. :( Also new up there are 3" lowering springs, 2.5" drop spindles with 11" disc brakes, new ball joints, tie rods w/ adjusters, idler arm, as well as polyurethane sway bar bushings and bump stops.

Then I primed and painted everything with Rustoleum rusty metal primer or bare metal primer, and then it got a couple coats of gloss white enamel everywhere. The suspension and steering parts got coated in Dupli-Color Cast Iron Grey Engine enamel.

Re: Stroker's Build (5.3/4L60E in a '69)
 

More pics of the rampant rust. Something not too noticeable from the previous pics is that the PO used fiberglass to patch the upper part of the firewall where it curves out about an inch. This is why I just cut it all out and started from scratch.

Also note the badass fix that the PO did to the rocker panel. Shop rags and expandable foam. Fun fun.

Re: Stroker's Build (5.3/4L60E in a '69)
 

New firewall!!

More of the PO's handiwork. A half-assed patch on the inner fender. Both inner fenders were covered in some orange rubber stuff, like thick seam sealer or something.

Stripped and primed.

Also a pic of the old running gear. 350/TH400 combo.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Finally, some good porn!

The 5.3 & 4L60E
Motor is from a 2003 Silverado 1500 w/ 113k miles. Tranny was pulled from a '97 Astro van. It is a 3-piece 4L60E, which wasn't made until '98, so it was obviously replaced at some point, which means it should be fresh-ish...I hope.

I modded the wiring harness with Brenden's great site: LT1swap.com and I sent my ECM out to him as well to have some stuff removed/added/tweaked a bit.

For the fuel system, I'm using the Walbro 255lph pump and Vette filter/regulator. 3/8" hardline with -6AN fittings throughout. For the return line, I thought this would work. I drilled a 1/2" hole in the sender and added a bulkhead fitting with a 90* fitting. I had to grind a little bit off of the nut on the bottom of the fitting to squeeze it into the tank, but it seems like it will work OK. I also flared the outlet and added the appropriate AN fittings.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Got the engine and trans in, but with drama. I wanted it 3" forward so that I wouldn't have to shorten the driveshaft, but there were too many clearance issues. The accessories would have been in the radiator, and the exhaust manifolds just did not fit. So, I moved it to where it is 1" back from stock, and since I was able to get the manifolds to fit, I called it good. I'll have to take about 4" out of my driveshaft now, but it's a good excuse to get it balanced, I suppose. The mount plates I used were like 3/8" thick or more, so I had to adjust the motor mounts outward a bit to get it in there. I drilled the frame holes to 9/16" and that gave me what I needed.

I had to grind some (a lot) out of my passenger manifold. I took a moderate chunk out of the EGR part, and shaved the bottom a bit. I also had to cut a clearance out of the motor mount and shave the top a bit. For the collector part, I had to notch the frame a bit, but I made it look good.
Driver's side fit fine.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Wiring ran through the firewall. The ECM, TAC, fuses and relays are all mounted under the dash. This seriously cuts down on visible wires under hood. Looking at the passenger's side of the motor, all of the wiring is hooked up and you can hardly see it. I still need to loom the driver's side, obviously. I like that there is just one 6" bundle connecting the engine to the firewall.

I will also be rewiring the entire truck with an EZ-Wiring harness. I plan to run all of those wires in/under the fenders and inner fenders so that it will be minimally visible as well. Once all of the sheet metal is painted bright white, this should be one seriously clean engine bay.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Well...that's it for tonight. I'll post some more pics after I kick some ass on it this weekend. My plan is to have the engine bay all wrapped up and put back together so that I can move on to the wiring, gauges, and interior. I have a torque converter on order that probably won't show up until the first weekend of May, so that is my tentative deadline for having all the pertinent stuff done that I need to start this pig and drive her out of the garage.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Nice....keep us up-to-date on your progress!!!

Re: Stroker's Build (5.3/4L60E in a '69)
 

What did you use for motor mounts, and what pan do you have on the engine?

Re: Stroker's Build (5.3/4L60E in a '69)
 

nice! that motor looks good in there...ill be keeping up with this one!

Re: Stroker's Build (5.3/4L60E in a '69)
 

Meee toooo !

Re: Stroker's Build (5.3/4L60E in a '69)
 

I got some mounts from ebay seller !!tj!! http://cgi.ebay.com/ws/eBayISAPI.dll...m=260973734885

I drilled and tapped 2 additional holes so that I could use them as 3" forward mounts, but that didn't pan out too well for me. So I used them as designed, and am pretty happy with them. They are 3/8" thick, so I had to widen the frame motor mounts so that it would fit all the way in place. Easy fix.

I'm using the stock 5.3 truck oil pan. It fits with loads of room, but hangs down past the crossmember a bit (~2"). I'm probably going to make a skidplate to protect it, since the truck is lowered 5.5" up front.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Thank you for the info, have a rad picked out yet? What are you doing for gauges?

Re: Stroker's Build (5.3/4L60E in a '69)
 

I'm going to push my luck with the stock radiator for now. If it lets me down, I'll throw in a universal aluminum dual row 1" tube rad from Summit or Griffin. Those seem to be the lowest priced, and since I have an external tranny cooler and won't break 400HP, it will suffice. BUT, I think the stocker will be fine. I'm using an electric fan from a '96 Ford Thunderbird. This is nearly identical to the famed Mark VIII fan. It has the Mark's blades, but a 2-speed motor from a Taurus. It's sort of a hybrid, but still moves mountains of air...and at less than $30 from pick-n-pull, you just can't beat it. I'm wiring them up with Volvo fan relays. If you haven't seen these little beauties, you should jump on this train. I like them so much, I got 5 of them my last trip to the pick-n-pull. :metal: I'll post some pics of that when I get to that part of my build.

Oh, and I'm glad you asked about gauges...this is going to be a fun migraine of a project. :lol: I'm using a cluster from a '89 Trans-Am GTA. They are all electric gauges, so will be compatible with the LM7 ECM (I hope). I hacked the GTA cluster into 3 pieces and with enough cutting and trimming, I'll be able to orient them neatly into a spare glovebox door. Half of the wiring goes through a PCB that I have also cut and trimmed, and the other half I can connect directly to the gauges via their mounting screws. Sounds complex, and it is. I'll post a couple preliminary pics of this later tonight after I get home.

Re: Stroker's Build (5.3/4L60E in a '69)
 

As promised, here's a few shots of the gauges. It's still in the R&D stages, but I'll make it work...trust me. :lol:

Re: Stroker's Build (5.3/4L60E in a '69)
 

nice

Re: Stroker's Build (5.3/4L60E in a '69)
 

With the 1" back adapter plates, the A/C doesn't fit, but that isn't news to anyone. So...I chopped it all to hell, and hey, it fits. :devil:

Re: Stroker's Build (5.3/4L60E in a '69)
 

I tapped the water pump for the steam return. Seemed like a quick, easy, clean way to do it.
I used the EQUUS adapters for Auto-Meter senders that should work with my GTA gauges.
Wiring on the motor itself is 99% done. (only need to hook up starter solenoid wire) With it all loomed up and tucked away, it's a pretty neat setup.

Re: Stroker's Build (5.3/4L60E in a '69)
 

I finally found some good use for those German 'Driving Machines'

Which do you prefer? The one that is all connected, or separate? I'm thinking the separate one, because I'm going to use emblems from a new Burb on the tailgate as well.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Yipes!

It's a good thing I'm an electrician in my normal life, so this is actually fun & easy for me.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Nice progress!

Re: Stroker's Build (5.3/4L60E in a '69)
 

Your just sick!!!:lol: Things are moving along....nice work!

Re: Stroker's Build (5.3/4L60E in a '69)
 

I got some good stuff done in the last 2 days. I made some brackets to mount the PCM under the dash as well as my fuse block, TAC, and other wiring goodies. I either welded the mounts to the firewall or found a way to mount it on the brake pedal bracket. Doing it this way meant that I did't have to drill any holes in the firewall. Well...I did drill 2 holes to mount the gas pedal, but that had to be as secure as possible.

I also worked on my gauges as well. I didn't know how well things would work out if I tried to solder wire to the PCB, but it worked flawlessly. I must admit I was surprised. So I continued to do that and heat shrink what I soldered. Easy day.
I also cut the inner half of the spare glove box door out and then lined things up and cut out the holes for gauges. The pic is a very rough look at how they will be. I'm going to pretty it up a bit, but you get the idea.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Dang that glovebox turned dash cluster is gonna turn out really nice....may need you to write up a "how-to" so i can post it over in the FAQ section!!!

Re: Stroker's Build (5.3/4L60E in a '69)
 

I might do that. I guess that means I'll have to take more pics of that as it comes together.

Re: Stroker's Build (5.3/4L60E in a '69)
 

I threw down some sound deadener. It's RAAM mat BXT II. Seems like some good stuff. I covered that with RAAM's PS Ensolite, which really helped. I'm going to be hitting most everything else with this combo, but under the dash needed to be done before I started loading it with wires, dash, A/C, etc. As stated before, my overall intention for this rig is to make it a comfy daily driver.

In the 2nd and 3rd pic, you can see how I mounted the PCM. I just bent up some channels out of 16ga sheet and welded it to the firewall. It fits snug. I'm not going to be worrying about it, that's for sure.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Uh Oh...somebody got a Hydroboost!!

This is working out great for me so far. I didn't want to screw around with any adapter plates, so I just lined it up on the firewall with the stock pedal assembly, and marked some holes to be drilled so that I can just mount them together. There is some minor drama with the top holes, because they ended up so close to each other. I think I will weld some tabs to the very top of the bracket so that I can use the stock studs that come through the firewall. Another great fitment is that one of the holes for the steering column mount will be shared with the HB plate. Score one for me!

Since I chopped about 2" out of the brake pedal mount because of the smooth firewall, the brake pushrod went together great as well. As you can see, the stock pusher was just a bit too short. I chopped it back to the rod portion, and the stock clevis slid right over it without much wiggle room. I'm going to wait until I get it fired up and operational to weld it together so that I get the adjustment set up just right.

For the hydraulic lines, I'm going to be replacing those busted-ass rusty Astro lines (which are too short anyways), but I'm not going the Earl's powerflex route like everyone else does. I have something else in mind that is about 10x more cost effective and proven to work. Of course, like everything else, I'm not 100% sure it will work for this application. I'm going to keep a lid on this until I can prove that it works or not. If if does work, I'll be into this HB setup for about $80 total, and I'll let the cat out of the bag so that you all can save a few pennies as well.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Believe it or not, the wiring is coming along very well. It looks like crap, but is almost done.

Here's a quick shot of where all of the wiring for the front end comes out of the cab. It's going to run inside the top of the fender, all tucked away nice and sound.

Re: Stroker's Build (5.3/4L60E in a '69)
 

I got my floor shifter and e-brake installed.

Shifter is a B&M Unimatic. E-Brake is from an early '90s Honda Civic Hatchback. Cables aren't hooked up yet, but will be by the end of the week. I'll have to do some tweaking under the truck to get them fitted up right.

Ooh, and steering column is back in with new turn signal switch.

Re: Stroker's Build (5.3/4L60E in a '69)
 

I did a write-up for my Hydroboost setup. Ch-ch-ch-check it out: http://67-72chevytrucks.com/vboard/s...42#post5359142

Re: Stroker's Build (5.3/4L60E in a '69)
 

I've gotten a lot done since the last time I posted. I got my return line squared away for the HydroBoost, got brake lines fitted up, and the exhaust is fitted, welded, and installed. I also fitted the front sheetmetal so that I could run my front end wiring. I found out that 5.5" of static drop is no joke when you would like to run inner fenders. I will be doing some chopping, that's for sure. :devil:

Since I will be running a cold air intake from a silverado, as well as using the 5.3's battery cables, I needed to move the battery to the driver's side. My original battery tray was rusted and crapped out anyhow, so I fabbed a new one. Here's some pics:
1) Measure and draw a scale model
2) Make a full-size model out of posterboard
3) Cut posterboard and make bends to verify fitment
4) Cut out of 16ga. I added kerfs to aid with bending, since I don't have a brake.
5) Bent using a 4" vise, hammer, and ingenuity. Fits OK.

Re: Stroker's Build (5.3/4L60E in a '69)
 

1) Mounted in driver's side to core support
2) Battery seems to fit
3) The battery isn't fully inserted in this pic. It's a really tight fit, so I won't fully insert it until I'm sure I don't want to get it out again. LOL

Part of the reason I had it wrap around the top is because I'll be mounting distribution blocks to the top of it for power and grounds, in case I add some high-power stuff in the future.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Great job. I have a similar setup that I am working on now and I'm also trying to keep the wiring low key. Keep it up.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Well, I was supposed to go to VIR and race my Supermoto all weekend, but Thursday morning, it blew the water pump impeller shaft's water-side seal, and of course nobody had parts locally, so I couldn't fix it in time. :waah:

So that left me with an entire weekend with nothing planned. Hrmmm...seems like a legit time to work on the Burb.

I got so much done, it is crazy. I would have been driving this thing weeks ago if I could have had this intensity in the past. :sumo:

Some stuff I got done:
- Made a fan support/mounting bracket/radiator filler panel
- Fabbed up some mounting tabs for my Cold Air Intake
- Mounted my A/C condenser and trans cooler
- bent up some hard lines for trans cooler and external filter (also mounted said filter)
- cut/hammered clearances in my inner fenders so I can alleviate some tire rub
- revamped the mounts for my battery box to clear inner fender
- fabbed mounts for my fan relay/circuit breaker/distribution block assembly
- mounted all my front sheetmetal (need to remove fenders at least one more time though, as I ordered new lower cab/fender brackets)
- added connectors to rear section wiring so I can plug into stock harness that runs through headliner
- Disassembled taillights to clean/restore them and sort wiring. (a trailer harness was butchered into the stock wires some time ago, so I had to fix that mess)
- replaced fuel sender & license plate wiring beginning at connector
- placed new gasket on fuel sender
- ran wiring to fuel pump
- cleaned interior and began laying down more RAAM Mat BXII

I also cleaned the garage and stowed ALL my tools about 6 times throughout all this, as I have OCD and get pissed when I can't find a tool. :lol:

There were a lot of detail things that also got accomplished, but weren't really worth mention.

I am taking Tuesday-Thursday off of work to tinker with the Burb, so maybe I'll get this thing fired up and running by the end of June. :metal: I'll take some pics throughout the week and post them as well. Sorry I don't have any from the weekend.

A bit off topic, but last weekend I was putzing around on my Harley and saw a gathering of bikes. I stopped by, and a few dudes encouraged me to enter my bike in the show they were having. They talked me into it, and I took 1st place!!! The bike was all dirty and didn't even have all the parts on it! :lol: Hopefully I'll have this same kind of luck with the Burb once it's on the road.

And on a bright note...my supermoto parts come in Monday, so I'll be out racing on Saturday in North Carolina. :devil:

Re: Stroker's Build (5.3/4L60E in a '69)
 

great job on your burb.Could you post more close up pictures of how you mounted you gas pedal?Did you make a bracket for it?Keep up the great work.

Ed

Re: Stroker's Build (5.3/4L60E in a '69)
 

I did't really put a lot of thought into the gas pedal, it just seemed to fit right in. I had to drill the holes out just a tad to 1/4" because they were metric, but it fits like a glove. Of course...I have that custom-ish firewall, so that might be why it was so easy for me. :ito:

(the pictures look like it's tilted, but it's totally vertical. I must have held the camera crooked...)

Re: Stroker's Build (5.3/4L60E in a '69)
 

And now some of the pics from the rest of the crap I've been doing to it.

1) External trans filter, because I don't trust auto trannies worth a damn.
2) Trans lines with -6 AN hookups throughout. Also shortened trans dipstick.
3) A/C condenser and 26,000 GVW trans cooler
4) Battery box finished with dual distribution block. Also seen is the circuit breaker and Volvo 2-speed fan relay for Mark VIII electric fan.

Re: Stroker's Build (5.3/4L60E in a '69)
 

Some pics of my nearly finished custom gauge panel. This truly turned out to be the biggest PITA of the whole build. It's not even close to 100% done, but the gauges sit in there and they are wired, so I'm calling it good for a while. Someday I'll remove it all and actually finish it.

1) The rocker switch on the left of the column is the master power for cruise control.
2 & 3) The 2 pushbuttons are for cruise as well. one for set/coast, other for resume/accel

Re: Stroker's Build (5.3/4L60E in a '69)
 

And finally some beauty shots of the whole engine bay, about 95% done. I need to paint a few more things gloss white (inside of fenders, fan support, etc.) and then add coolant hoses and fluids, and she will be ready to start!!

Note the absence of most wiring. That took a considerable amount of time to get right.

Re: Stroker's Build (5.3/4L60E in a '69)
 

I got all the little wiring problems finished up, primed the fuel pump, and was ready to fire her up for the first time. BUT...the starter seemed to crap out on me. It just clicks, but it turned over several times when my fuel pump wasn't primed. I'll get a new one tomorrow and maybe fire this pig up once and for all!!!!