1969 Camaro Transforms From Big Block to Supercharged LT4 V8 at V8 Speed & Resto Shop

[l2azorback]

Originally Posted by Jr

Beautiful car.

What are your plans for the heat exchanger?

This one will get a C&R LT Heat Exchanger. The LT heat exchanger has inlet and discharge on the driver's side of the car vs the LSA on the passenger side. This marries up nicely with the intercooler manifold on the top of the engine which discharges on the driver's side.

Regards,

Larry

[V8TV]

There are numerous connections off the back of the LT4 that require some space to access and make them look clean, as well as for serviceability.



The V8 crew lowered the engine into the bay just to get a visual of how things were going to fit. This car had a smoothed firewall, and A/C bulkhead fittings down on the passenger side. The motor mounts had not yet been chosen, this was just to get a bird’s eye view of any potential challenges.



It was obvious that there would be some clearance issues on the back side of engine as the assembly moved closer to the transmission.






The engine was lifted out, and the firewall was examined. At this point, the team noticed that the existing firewall was showing some cracking bodywork and would require a fix and repaint regardless.



The decision was made to modify the firewall to better accommodate the new engine and fix the surface issues. In order to do this, the front sheetmetal was to be removed.

[V8TV]

The team carefully measured and recorded the gaps, spacing, and fitment of the panels and the alignment so that everything would go back together properly.

[V8TV]

Front body panels removed.



Here you can see the bruised firewall. We decided to investigate further.



Hmm



Lots of cracks and filler are lurking below…



Putting the engine back in place on Dirty Dingo mounts in the Detroit Speed subframe, we could see the clearance from the head to firewall was a bight tight.



The accessory drive seemed to fit well, even with the increased diameter crank pulley.



There’s room for the A/C compressor as well.



But the decision was made to do some work on the firewall to repair the damage and make a bit more room for the engine, as well as to clean up the A/C bulkhead fitting holes.

[V8TV]

The Camaro was moved to the metal fabrication shop where the new firewall would be created.

Once the heater block off panel was removed, it became obvious that this car was originally painted blue. It was also obvious that because of the cracks and previous finish work, the heater block off panel was holding water and rusting the bottom of the firewall. Water literally ran out when we removed the panel.










The opening was ground smooth of rust and corrosion and a plan was made for the new firewall.



Fabricator John felt a large piece would allow him to start over cleanly.

[V8TV]

Stomping the steel on the Mittler Brothers shear…



A little trim to bring it to the firewall…









And off to the Mittler Brothers bead roller to add some strength and interest to the panel. John likes to draw out the pattern with a sharpie marker and “trace” it with the roller.







Keep in mind that with each contour, the panel’s overall size shrinks, so careful consideration needs to be given to the size along the way.





Quick test… looking good!

[V8TV]

The edges are tapped over with a tee-shaped rounding dolley.



Some shrinking helps tighten up the edges



The main piece seems to fit pretty well. Next, the tunnel portion is marked for an extension piece on the firewall. This will allow more clearance for the LT4.





A trip to the Pullmax starts the tunnel housing extension. A pointed die begins to “fold” a flat section.







The shape is roughed in.

[V8TV]

Some shrinking on the Mittler Brothers shrinker helps form the curves



And a bit more on the Pullmax to make the contours deeper.



And the corners are tightened up with a sharp-edged dolley.



A test fit with magnets and cleco clamps, things are looking good!



The section is tack welded to the firewall with the HTP Mig 200 welder, then test fit in the car.

[V8TV]

The firewall is cut back a bit to facilitate the install of the new panel.







The welding is completed and metal-finished, then the panel is cleaned and treated with an epoxy primer on the inside.



Any corrosion is removed from the firewall, and weld-through primer is applied before the new panel is welded in place.



The firewall is then welded to the car, and all welds are finished.

[V8TV]

This little corner requires a small piece to “connect the dots”.





Welds are all ground and metal finished.



The finished firewall will only require a touch of filler before epoxy and paint.