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LT1 powered stepper
Hello all! Now that my very slow going project is almost complete, I figured it was time to post some pics and share my blood sweat and tears with the forum. All comments and (constructive) criticism are welcome!
My current project is a 1981 Silverado stepside. I bought it about 2 years ago in Victoria, BC. I have loved the look of stepside pickups for as long as I can remember, so when I saw this one listed for sale it was love at first sight. This is what she looked like when I bought her: http://i280.photobucket.com/albums/k...ol13/35164.jpg http://i280.photobucket.com/albums/k.../IMAGE_044.jpg Nice solid base to start with. Frame was rock solid, cab and front clip were in pretty good shape, but the rear stepside fenders were toast. Standard rot spot below the fuel fill doors (yes it has the dual tanks) Interior was well weathered and needed some attention. The biggest issue was the old powerplant. Tired ol' dog 350. Had an edelbrock carb and I was told it had an RV cam too. I figured the heads were shot or the cam wasn't enough for the carb because it was getting something like 200km to the tank. Pathetic even for a 350. So after many thousands of dollars of fuel later, I decided to pull the old motor and drop in a newer fuel injected motor. The old mill, nothing special: http://i280.photobucket.com/albums/k.../IMAGE_323.jpg So the search began. My build was on a budget (or so my wife told me) so I needed to find the best bang for my buck. I needed an engine, transmission (the TH350 screaming on the highway wasn't cutting it) wiring harness and ECU/PCM. I obviously wanted an LS1, but the cheapest combo I found was around 5k. I was looking into a TPI because I liked the look of the intake, but after reading up on them I didn't like the batch fire on the injectors and I had a hard time finding a 350 TPI. (all the wreckers had 305's) So I finally decided on the LT1 for the reverse cooling, fair choice of aftermarket goodies, etc. Now it was just a matter of finding one. |
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After a search through many a junkyard and CL ad I finally found a winner! I picked up a 1996 caprice 9c1 for a thousand bucks. I liked the fact that it was a 96 for the vented optispark, obd2 and the owner claimed that the engine was recently rebuilt. So with the deal sealed, the caprice came home to live with me having no idea the horrible fate that awaited it. *insert sinister laugh here*
Unfortunately I live in a condo, so all the work had to be done at my in-laws place. Thankfully my pop is mechanically inclined and still tolerates my projects. So over the next 3 or so days, my new aquisition turned from this: http://i280.photobucket.com/albums/k.../IMAGE_259.jpghttp://i280.photobucket.com/albums/k.../IMAGE_260.jpg into this: http://i280.photobucket.com/albums/k.../IMAGE_268.jpghttp://i280.photobucket.com/albums/k.../IMAGE_271.jpghttp://i280.photobucket.com/albums/k.../IMAGE_261.jpg and finally into this: http://i280.photobucket.com/albums/k.../IMAGE_274.jpg From all the carnage emerged an iron head LT1 engine, 4L60E trans, PCM and every scrap of wiring from stem to stern. I was also able to sell a bunch of parts from the shell and with the cash I got from the scrap, my net cost was about $500 for the powertrain. |
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You will like the swap. I had one in a '79 (aluminum headed version) and had no problems with it. It had good power, and got pretty decent mileage too.
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Time to pull out the old and busted and replace it with the new hotness.
my pal chaining up the block http://i280.photobucket.com/albums/k...p/IMAG0028.jpg http://i280.photobucket.com/albums/k...p/IMAG0030.jpg and out she comes! http://i280.photobucket.com/albums/k...p/IMAG0034.jpg and dropped my sexy purple TH350 http://i280.photobucket.com/albums/k...p/IMAG0037.jpg buddy looking like he's ready to crap himself lifting the old engine (ignore the hoist) http://i280.photobucket.com/albums/k...p/IMAG0035.jpg EWW! http://i280.photobucket.com/albums/k...p/IMAG0040.jpg time for some scrubbin' http://i280.photobucket.com/albums/k...p/IMAG0049.jpg puttin' the old man to work http://i280.photobucket.com/albums/k...p/IMAG0082.jpg and then some paint: http://i280.photobucket.com/albums/k...IMAG0066-1.jpg In with the new: http://i280.photobucket.com/albums/k...p/IMAG0078.jpghttp://i280.photobucket.com/albums/k...IMAG0079-1.jpg |
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I lucked out with the transmission situation. I had a long nose TH350 so I didn't need to modify my driveshaft when the 4L60E went in. I did however, need a new crossmember to accommodate the dual exhaust and catalytic converters. Here's what I came up with compared to the stock mount:
http://i280.photobucket.com/albums/k...r/IMAG0463.jpghttp://i280.photobucket.com/albums/k...r/IMAG0464.jpghttp://i280.photobucket.com/albums/k...r/IMAG0467.jpghttp://i280.photobucket.com/albums/k...r/IMAG0470.jpg Now the exhaust is nice and happy. Speaking of exhaust, I wanted to re-use the old headers that were on the old engine. I sandblasted them and welded the AIR injection and O2 bungs, and a nub for the steam trap from the back of the intake: http://i280.photobucket.com/albums/k...s/IMAG0068.jpg then wrapped them up with DEI header wrap: http://i280.photobucket.com/albums/k...s/IMAG0069.jpghttp://i280.photobucket.com/albums/k...s/IMAG0070.jpghttp://i280.photobucket.com/albums/k...s/IMAG0071.jpg and finished them off with a spray of high heat silicone spray: http://i280.photobucket.com/albums/k...s/IMAG0076.jpg Then the real nightmare began - wiring up this pig |
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Wiring! Normally I don't have a big issue with 12v systems, but this - this was not fun. Until I finally fired it up of course. To wire up the new engine, I used the orignal harness from the caprice. Here it is laid out:
http://i280.photobucket.com/albums/k...p/IMAG0086.jpg A few pals were ragging on me for not buying a painless harness. Yes, it would have been a bit easier but I kept the original harness for a few reasons. 1) I didn't have a spare thousand dollars to buy a painless harness 2) The painless harness only covered the engine compartment wiring 3) The caprice harness already had a HD headlight relay wiring harness, and provisions for power door locks and windows (which I added later) So, with the FSM for my truck and the caprice in hand with a pair of wire cutters and soldering iron, I began the 2 week journey into madness. I stripped all the wiring from the cab and engine compartment. While I was at it I added a layer of peel n' seal and stuck a layer of water heater insulation down with some 3M spray adhesive. My carpet underlay was rotted and smelled pretty bad, so I decided to pull it out and replace it with something a little more resistant to moisture. http://i280.photobucket.com/albums/k...p/IMAG0089.jpg While I had the access, I cut a hole in the firewall and mounted the a/c heater box I scavenged from a part-out on CL. http://i280.photobucket.com/albums/k.../IMAGE_312.jpghttp://i280.photobucket.com/albums/k.../IMAGE_311.jpg Once I got the critical wiring connected under the hood, I had to try a test fire. Needless to say I was happier than a pig in mud when she fired up. http://s280.photobucket.com/albums/k...=VIDEO0011.mp4 The other thing that was pretty important was to keep all the factory gauges and switches intact. Especially because I scored on a tach dash for 40 bucks! I ended up doing a pinout of the headlight switch and instrument cluster and tied them all in. I also picked up a mechanical speedo conversion kit for the 4L60E to keep the original speedo. After the interior was in order, I connected the headlight relay to the H4 and H1 headlight conversion that was installed. Needless to say, a wiring harness from a luxury size 4 door sedan is considerable larger and longer than what would be found in a regular cab pickup. Thankfully I was able to shrink the harness by deleting unnecessary items like ABS, airbags, DRL, back door/trunk wiring, etc. I was also able to discard about 6 feet of wire from each harness so things started to clean up pretty quick after I had everything connected and working from this: http://i280.photobucket.com/albums/k...p/IMAG0427.jpg to this http://i280.photobucket.com/albums/k...p/IMAG0437.jpg to finally this http://i280.photobucket.com/albums/k...p/IMAG0460.jpg |
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Okay, all looks good. Wiring, that doesn't look like fun.
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Thanks - yeah wiring was a little daunting, but what a payoff when it all worked.
No updates tonight - gotta take care of the trick-or-treaters! |
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Okay - so in the process of wiring up the cab, I scored a pair of rust free power doors from an 87 suburban. The only issue with them was the giant speaker holes cut in the bottom section of the doors. This proved to be an advantage on the passenger side as the connector for the window motor was missing and there were just the two wires siliconed into the motor. Needless to say that a new connector was soldered in.
I replaced the motors after I did a weatherstrip replacement as the old motors wouldn't roll the glass up all the way in the new rubbers. I followed this procedure: http://www.73-87.com/7387garage/interior/winmotor.htm I haven't had the truck out on the highway yet so I'm hoping that resealing the vent windows will eliminate the whistle that was driving me insane. Here's the write-up I followed for the vent windows: http://67-72chevytrucks.com/vboard/s...=514602&page=2 A big thank-you to 1425956 for the excellent instructional! *** NOTE - if you have a 1981-1985 chevy truck and are planning to rebuild your vent windows and have the 2 piece seal - DO NOT order from LMC. They have a one-piece seal listed for 81-87. This incorrect and will not work. I found out the hard way. I got the correct seals from Brothers truck parts *** I didn't want to cut holes in the new carpeted sections I ordered from LMC to put door speakers back in the holes cut by the PO, so I followed an article I found on custom classic trucks: http://www.customclassictrucks.com/t...l/viewall.html I didn't like the ghetto plumbers putty way they sealed the speakers, so I did mine a little different. I cut out a surround similar to the article and mounted my 6X9's in each. Then I bought a pair of foam 6X9 backers: http://i280.photobucket.com/albums/k...lBay_VXT69.jpg Siliconed them to the frame and bolted them to where the crossflow vent was in the door. 6X9 sound, no more holes. :D With the guts of the doors up to snuff, I had to do something about the interior - The door cards were pretty badly sun damaged and the tops were flaking off. Also the dash was cracked in 4 places (sorry - no pics). I nabbed an entire interior from the same guy that I got the a/c from. The pieces were in great shape - Best of all, the truck still had it's headliner! (mine was gone when I bought the truck) Needed to be recovered but it was intact! Yeah! So after I pulled my original black carpet and gave it a mega scrub, it got laid back in with my new sparkly interior panels. The instrument cluster bezel was going to pose a bit of a problem. It was an original, uncut bezel. With how hard some of these parts are getting to find in good condition, I couldn't bring myself to cut that bezel. The only recourse was to install a knob radio. I found the Concours USA-630 radio on fleabay and ordered it. Getting it into the dash would be another story. The PO had cut the steel dash to get a late model head unit in. After a stop at the local wreckers I came home with a donor dash plate. Here's what I started with: http://i280.photobucket.com/albums/k...o/IMAG0438.jpg The new side tabs welded in, and painted: http://i280.photobucket.com/albums/k...o/IMAG0449.jpghttp://i280.photobucket.com/albums/k...o/IMAG0450.jpg The new radio installed - looks almost factory http://i280.photobucket.com/albums/k...o/IMAG0453.jpg and powered up: http://i280.photobucket.com/albums/k...o/IMAG0452.jpg The pros: looks original, deters theives, has USB and AUX inputs, has subwoofer and cd changer outputs The cons: underpowered - pre-amp sucks balls. Needs an amp for the internal speakers |
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Bodywork - I hate bodywork! I hate it with a passion.
The reality is I hate it only because I'm no good at it. I mean diasterous. As mentioned in my first post, the stepside fenders were toast. I bought a new pair from the same junker I got the radio plate from. A little surface rusty and a couple of dents, but no rust holes. http://i280.photobucket.com/albums/k...213343_o-1.jpg Thankfully the bedside was in great shape underneath, so it just needed new fasteners (from the bed kit I foolishly bought from LMC. Had no idea it was going to be home depot bulk bolts . . .:dohh: I also got a new front driver fender - the original one had a couple of holes around the wheel well. http://i280.photobucket.com/albums/k...85206175_o.jpg The worst of the damage I only found out about when the truck sat out in the rain. I thought the carpet was wet because of water coming in from the kick panel vent. Boy was I wrong! After the windshield was pulled this is what was left of the windshield corners: http://i280.photobucket.com/albums/k.../IMAGE_241.jpghttp://i280.photobucket.com/albums/k.../IMAGE_242.jpg Thankfully, the body guy patched it all back up and no leaks! Once I get the wiring finished, I'll be posting about the install of (in my opinion) the mother of all aftermarket accessories! A NOS power-lite power rear window! :metal: |
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Okay - still working on the wiring for the rear window (forgot what a pain in the a$$ running wiring into the doors was) I did however get my new temp/compass mirror installed and wired. For anyone interested in doing the same, the writeup is on gm***************/forum/showthread.php?t=3547. Unfortunately, no pics as I foolishly tightened the hold down screw too much and popped the metal tab off the windshield :dohh:
Also, finished fabbing my new traction bars: http://i280.photobucket.com/albums/k...3/IMAG0905.jpg I'll take some more once I have them bolted to the truck. |
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Finally got the rear window in and wired, and it is fantastic! I'm sure that some of you know about the old school powr-lite kits released in the early 80's by CR Laurence:
http://i280.photobucket.com/albums/k...0Co20Inc01.jpg As soon as I saw pictures of it on this forum, I knew I had to have one. Obviously, not the easiest part to find, so decided to build my own using the same design. I built the frame based on the shape of the original slider window so I could use the factory gasket to mount it. http://i280.photobucket.com/albums/k...w/IMAG0672.jpg I got some U-channel and cut and welded it to match the contour of the steel frame and fit some universal window track inside. http://i280.photobucket.com/albums/k...w/IMAG0673.jpghttp://i280.photobucket.com/albums/k...w/IMAG0674.jpghttp://i280.photobucket.com/albums/k...w/IMAG0675.jpg I bought a blazer tailgate motor/regulator so move the glass and I was just about to get the pane of glass cut when the unbeliveable happened. I came across a guy selling a NOS kit on CL. The price was right, so we made a deal and I headed down to pick it up. I hadn't realized how long of a drive it was from Vancouver to Idaho, but it was totally worth it. :D http://i280.photobucket.com/albums/k...w/IMAG0886.jpg Unfortunately, when I popped the old window the frame was a little crunchy: http://i280.photobucket.com/albums/k...w/IMAG0798.jpghttp://i280.photobucket.com/albums/k...w/IMAG0799.jpg I've seen worse, and I probably could have fixed it myself, but as mentioned in previous posts - I hate bodywork. So off to the shop it went to get fixed up: http://i280.photobucket.com/albums/k...w/IMAG0894.jpg So cracking open the box, here's what I got - http://i280.photobucket.com/albums/k...w/IMAG0889.jpghttp://i280.photobucket.com/albums/k...w/IMAG0888.jpghttp://i280.photobucket.com/albums/k...w/IMAG0890.jpg http://i280.photobucket.com/albums/k...w/IMAG0887.jpg http://i280.photobucket.com/albums/k...w/IMAG0891.jpg My neighbour who helped me put it in doing his best Vanna impression The gasket was slipped on the window frame, the rope was put into the gasket flage and slid into the truck: http://i280.photobucket.com/albums/k...w/IMAG0898.jpg http://i280.photobucket.com/albums/k...w/IMAG0900.jpg It was a tight fit on the bottom corners and needed a bit of massaging to get the gasket sealed to the body, and other than the rope getting stuck on the driver side (which I almost herniated myself trying to finally pull the rope out) http://i280.photobucket.com/albums/k...w/IMAG0901.jpg it went in well over all. A quick bench test later, and voila! http://i280.photobucket.com/albums/k...w/IMAG0902.jpg As for the wiring, I would like to meet the person who designed the pass-through for the power door wiring and punch him in the nose. Idk why they couldn't have lined up the hole in the cab with where the wires come through under the dash. Anyone who has had to fish wires through there knows what I'm talking about. After removing the rubber accordion and cutting a few fingertips and knuckles, I got the wires in. The switch that came in the kit didn't really impress so I decided to use a factory GM window switch to keep things as stock looking as possible. http://i280.photobucket.com/albums/k...w/IMAG0908.jpghttp://i280.photobucket.com/albums/k...w/IMAG0909.jpg So the order of the switches are: locks, side windows then rear window. I wish there was a GM switch that has “REAR” printed on it like the lock switch. If anyone has seen one or knows where to get something like that, please let me know. |
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I'm afraid those pictures are a little on the small side.
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its an awesome back window. if i remember right they stopped making them like 10 years ago.
was thinking of makin a kit for my CC |
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keep going
awesome |
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Does it use it's own glass? It looks like the factory just smaller on the corners. I wish they would start making these things again. I see some of the new Toyota's with them and I'd love to have something like that on mine.
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Thats awesome. looking great!
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I'm no fan of bodywork myself. I'm quite untrained in the skill. I think a lot of these guys on the auto enthusiast forums like this one, are bodymen by trade and they just don't mention that when they show what they did at their house in their free time. And it comes out looking great. Or the computer screen does well at hiding any small flaws they might have.
But also, where did you get that thing if they don't make them anymore? Seems like its going to take up the already limited space behind the seat. |
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Thanks EasySteve!
Skunksmash - I agree with you there - I've seen some impressive bodywork skill displayed on this forum and a lot of it does seem a little more than backyard hobbyist level. As far as where I got the kit from - It was actually thanks to this site. The member Liddy71 to be exact. http://67-72chevytrucks.com/vboard/s...d.php?t=538362 I happened to be browsing the forum while I was stuck in a work camp in northern BC, and came across Liddy71's post. Just the right place at the right time - and yes, it takes up pretty much all the space behind the seat. I'm definately going to have to get an underseat woofer for the stereo when I start work on it. I can fit my jumper cable bag behind the seat, and that's about it. |
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Cool build! You will love the efi and overdrive... Back window looks awesome - I've never seen one of those before...
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A few small victories today - reattached my rear view mirror and the temp and compass work like a charm!
Attachment 1013272 I also pulled my instrument cluster for a couple of things - first, I painted the inside frame white to increase the lighting Attachment 1013278 Attachment 1013279 and added some new bulbs Attachment 1013285 I mixed and matched some gauges to make up this instrument cluster, and I noticed that some of the needles were faded and didn't match, so I figured that it was a good enough time to do somthing about it. Here's a comparison: Attachment 1013287 The speedo was the most vibrant of the oranges. I went to the local hobby store and used that to match the closest orange I could find. |
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This is what I came up with as the closest match:
Attachment 1013289 Here's a comparison of the painted (right) and the old faded needle (left) Attachment 1013290 I also had been meaning to add a check engine light for some time - I found one out of the clusters used to put together what I have now: Attachment 1013291 All put back together: Attachment 1013292 For the check engine light I had to run a separate power lead and the ground was provided on the LT1 harness via the PCM. I soldered two leads on the orignal peanut bulb holder and connected them to the power and ground separate from the cluster. Tested and it's all good! Attachment 1013293 Now I just have to wait until it's dark to see if painting everything white did any good. |
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Yeah painting those needles can be a bit of a pain. They're so old and brittle that they're easy to snap.
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Yay! Christmas came a little early this year:
Attachment 1017062 I signed my wife's name to the card and I was okay with that. She called me an idiot. She's probably right. It's a 3-4 drop spindle/shackle kit that I can't wait to bolt up to the truck. Here's how high she sits now: Attachment 1017063 I bought the kit for the 1 1/4" rotors as I'm going to upgrade to the HD rotors. I was going to wait until I saw the condition of everything behind the wheels before I started buying parts. Boy was I shocked! Attachment 1017064 Look at that balljoint! - You can't see it under the layer of grease, but it's RIVETED to the control arm! If I'm not mistaken, that means that it's the original factory unit. From 31 friggin' years ago! WTF? So the teardown began - and stopped quite abruptly. I got as far as stripping the rotors off. Attachment 1017065 The tie rod and shock came off pretty easy, but the work ended for the day when I ran out of daylight fighting with the lower balljoint on the drivers side. I have always removed ball joints but giving the spindle a couple of good strikes with a hammer and the ball joint has always released. Not this time! After almost mushrooming the side of the spindle with my 4lb sledge, the ball joint was still stuck in the spindle. So off to the outlaws house to borrow the old mans pickle fork. That'll get it loose right? Wrong! That fork went in at every angle and after beating the hell out of it - yup - the ball joint is still stuck. :cuss: Tomorrow the big guns are coming out. Unfortunately, I don't have a torch available to me in the condo's carport outside, but I have power there so the trusty zip-cut will make short work of that bastard ball joint! |
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Wow. That was one tough nut to crack. The grinder wouldn't get all the way through the stem but thankfully it broke once I gave one last swing with the sledge.
Attachment 1017524 Attachment 1017525 I got the front end stripped down (all by hand - @#&%$) I was even able to give the passenger side wheel well a coat of gravel guard. Attachment 1017526 Tomorrow I'll start on giving the control arms a varsol bath. Once they're clean, I'll get them blasted, primed and painted. Then I'll have the new poly urethane bushings pressed in. |
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Okay - so I've found my new favorite product! Rustoleum rust paint. This stuff is awesome! I brushed on a coat on my LCAs after I gave it a good go over with my wire wheel - Attachment 1024070
Stuff goes on so thick it dries with a finish like powdercoating. Also laid a coat on the crossmember with semi-gloss Attachment 1024071 Here's the new upper arms, belltech spindles and new springs all put together: Attachment 1024072 and a quick comparison between the stock spindle and the drop spindle (for those who haven't seen them side by side) Attachment 1024073 Got both sides installed - now I need to get new rotors, pads, calipers (upgrading to the 1.25" rotors) need new tie rods and I'm going to try to track down a one ton swaybar to upgrade |
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Driving it with the LT1 yet? Curious on the drivability and power.
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I've had it out a few times around town since the swap. I don't quite trust it yet for a long haul, but I've been pleasantly surprised each time I've had it out. The 4L60E has quite a kickdown when you put your foot into it. So far I'm happy with the acceleration and overall power with it (although there's always room for more power - lol) but I still need to chase down a few things, most electrical bugs. There's an annoying parasitic draw somewhere that flattens the battery overnight, but when I did a draw test there was only 20mA coming off the battery. I'm going to have to fully charge the battery again and retest.
Right now it's feeling out the truck and getting used to the new sounds and smells of a different engine, but so far so good. Once the truck is lowered and I can get her rolling again, i'll make a quick vid of it in action. |
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I have an LT1 in my 77 SWB although it is carbed. I just recently swapped the TH350 to a 700R4. I love it so far. Plenty of power and fair gas mileage. What did you do for a radiator? Mine has one from a 95 Z-28 Camaro in it and is is laid back to wards the motor like they are in the Camaros.
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I guess I need to do that. Mine kinda looks like hammered crap!
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Doesn't look bad. Just needs a plate to cover the mounting bracket and you're golden. Hell, I had to fab my rad hoses out of 2 or 3 different stock ones. I used exhaust pipe as a coupler and hose clamped them down.
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Merry Christmas and Happy New Year to all!
It was a great Christmas this year - flew my Mom out from the other side of the country to spend Christmas with my wife and I and her side of the family. She had a great time and (not sure if it's a good thing or bad) she and my Mother-in-law got along swimmingly! Needless to say, not a lot of progress over the Christmas season. I did get the brakes finally assembled: Attachment 1034835 The final tally for the front end was belltech 3" drop spindles, repainting the lower control arms, new upper control arms, control arm bushings, ball joints, tie rods, I upgraded to the HD brakes, so new rotors, bearings, calipers, pads, and SS hoses. I also scored a 1.25" sway bar from a C30, so new bushings and shackles for that too. While I was under there, I took the opportunity to swap out the intermediate steering shaft with the jeep one I grabbed from the pick-a-part. Once the truck gets an alignment, we'll see if it makes a big improvement with the steering. I noticed a bit of slop in the steering box (not sure how much is normal) so we'll see. Also installed an amp for the dash and door speakers today. The head unit has no pre-amp so the amp should help things a bit. No pics, because I'm sure everyone and their cousin knows how to install an amp. With a lot of wire tucking, the interior looks just as it did 2 days ago. Just sounds a little louder. In the (hopefully) near future I'll be getting an underseat subwoofer. My work contract finished a week before Christmas and I go on vacation in the middle of Jan, so I have two weeks of complete free time to try to get some work done. I'm going to start on the rear end tonight. All the bed bolts are rusted solid so they're getting cut off. Tomorrow I'll raise the bed off the frame to get at the shackles and mounts to grind the rivets off. I'm also hoping I have enough time to buy some new wood for the bed floor and get started on sanding/staining. I'm also going to have to replace the front bulkhead on the bed. Theres a huge dent that looks like it was caused by something heavy in the bed sliding when the driver hit the brakes too hard. |
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Looks good and glad you had a good holiday! JL audio makes a great little pickup enclosure with an 8w3. I think there are some pics of it in my build thread. Seat goes within a click of all the way back, and with buckets it's a passenger problem anyway... Keep up the good work!
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