Part 4! I feel like I am finally starting to close the gap on this project! With Part 4 we are going to button up a bunch of small stuff and order a bunch of parts.
So we left off part 3 with me having just completed building the motor mounts and installing them. Next needed to clean up a bunch of little issues.
I had been meaning to install this heater core shutoff for months, possibly years. Since everything was already drained, I figured now was as good as ever. This will keep the hot coolant from circulating through the heater core in the cab during the summer.
I also bolted the alternator and truck intake back on, there is a specific torque sequence and spec to prevent intake leaks. Below is a screenshot of the instructions I followed in a post on the www.LS1tech.com forum.
Next challenge! the LS power steering pump had some kind of electronic solenoid on the output. Not sure what it does and I didn’t really care enough to research it, all I knew is that I don’t need it and it won’t accept my current high pressure hose. I went out on a limb and assumed that Chevy hadn’t changed the basic pump and got lucky. I had an old pump in the basement that I went and stole the valve off of, and it bolted right in. Somewhere in the late 70’s early 80’s Chevy went from an inverted flare fitting to an O-ring style fitting. Turns out my steering box and lines are the flare type but the spare valve that I just put in the steering box is the newer O-ring style. So after some more Googling, I found an O-ring to inverted flare power steering adapter at Speedway Motors online.
The more you work in your shop, the more you will want to start buying in bulk. 5 trips to the auto parts store gets old FAST. I bought this cheap Metric O-Ring Assortment a couple of years ago and it has saved my butt many times @ midnight when all the stores are closed.
I also got a chance to install my wiring harness.
Ran into an issue with the drivers side manifold hitting the frame, I needed to remove a stud so I could bolt the manifold on. Easy right?
I also got to spend a lot of time researching all of the miscellaneous parts, bits, and pieces that I am missing to complete this project. Below is a list of what I ordered. (disregard the PF3144 fuel filter, though this one would work with the right fittings, I ended up going with a different filter covered in Part 6)
If I was counting actual man hours in this truck, I would be way deep. Not so much in how long the actual work takes, but the amount of time spent researching, finding, and ordering parts adds up quickly.
For example, I have probably spent at least 2 hours researching how to connect exhaust to the LS truck manifolds. The drivers side has a different bolt pattern and gasket than the passenger side which is weird to me. After getting frustrated I finally decided that I have 3 exhaust options:
- Go to the junkyard and try to find some factory exhaust stubs that are probably 10″ long before a catalytic converter.
- Buy some exhaust flanges online ($25 each plus shipping for a piece of plate with 4 holes…) to connect to the factory flanges then make custom exhaust for the rest
- Cut the factory collector flanges off and replace everything with V-Band clamps (ding, ding, ding, we have a winner!!!!!)
So, having decided that started Googling until I found the cheapest ones available. Turns out somebody on eBay was selling them for ~$15 a set including shipping with no tax, so I ordered 6 sets.
I ended up going with 2.5″ v-band clamps which I have read about other people using and verified with my own measurements (approximate size observations posted below in case you need them).
I also got the passenger side manifold removed. After having broken a bolt off in the head on the drivers side, I was extra careful this time. I took a punch an hit the head of each bolt (in theory) to break it loose, then tightened each bolt ever so slightly (~1/8th turn), then soaked everything in WD40, and carefully removed them with a ratchet by hand. No more broken bolts!!
Digital calipers are another handy tool to have around the shop. Let’s face it, a tape measure isn’t all that accurate. You can get a digital caliper for around $12 bucks now-a-days, so you don’t have an excuse for sloppy measurements: 6 Inch LCD Digital Caliper
So now, I wait…for a bunch of parts. Turns out my 2.5″ exhaust tubing that I ordered from Summit Racing is backordered, so it might be a couple of weeks before I make considerable progress.
- Ol’ Blue LS Swap LINK INDEX:
- Part 1: Removal of the 496 BB and wire harness
- Part 2: Initial install of LS motor and adapting to TH400
- Part 3: Custom motor mounts and EGR blockoff plates
- Part 4: Power steering adapter and LS ECM installation
- Part 5: LS manifold V-band and exhaust installation
- Part 6: Coolant/fuel system installation – First Start!
- Part 7: Throttle Cable/Intake/DIY ECM mount
- Part 8: Painless wire harness install and LED conversion
- Part 9: Reconfigure the exhaust…again and finish LED’s