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Out in the Heat !
I took a little break from the Camaro because I was getting a little burned out (literally and figuratively). Hot weather sort of slows down things when I can’t open the garage door anymore. We have a pretty good summer going. So far the hottest day is 119F.
I had a week furlough so I got out and figured out where I left off on the exhaust system 4 weeks ago. I decided to keep this in smaller sections so that it is easy to remove, repair, and even modify in the future. Some V-bands were added directly behind the flex-couplings. I already like how easy it is putting this thing on the car. https://i.imgur.com/Wczx8aYl.jpg I had a little difficulty figuring out what I am going to do with the mufflers. I finally decided that everything fits best when the mufflers are angled outward. I modified the X-pipe to kick out and up a little just in front of the mufflers. I also finished tacking the front flanges on the cross-over so it now bolts into place. https://i.imgur.com/eqRb9zFl.jpg With the mufflers kicked outward, I had to modify the shape of the finished RH tail pipe. It is pretty much complete but still some minor tweaks. https://i.imgur.com/OlIycYyl.jpg Here is a photo of what I have completed all laid out. It will be 7 pieces in all. https://i.imgur.com/EoKJjMVl.jpg Next I will perfect the fit of the RH tail pipe, copy for the LH tailpipe, weld the LH muffler inlet flange and figure out what the tail pipe exits are going to look like. It sags a little due to the expansion bellows so I will probably also add another couple of X-pipe hangers up front. After that I can final weld this whole mash-up! I also started dreaming about getting the car down off the rotisserie so I can start playing with this thing! https://i.imgur.com/g4PAhsOl.jpg |
Nice work on the exhaust! Your desire to make the system easily removable will definitely pay off in the long run. I took the same approach with my system and am very happy I did. I was able to pull my transmission without removing the headers or even loosening them. All I had to do was pull the mid section of the system out of the car which was two band clamps and two vbands. Easy peesy.
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I love this build. Your fab work looks great in the raw. It's got me looking for more projects on my "finished" car.
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Thanks for the kind comments guys. Just shows you can do anything if you are slow enough :-)
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Wow, this project is insane - in a good way :-) Pro-level fab skills in a home grown project. Wish I had half that much skill and motivation.
I asked a question about your cooling fan over in the cooling section - trying to order the same thing myself and work with C&R on a custom radiator. You're right that you can never have too much cooling, even if you don't live in AZ. Scott |
Yes the part number in the cooling thread is the same one I show in the photos (23455465).
I think it looks like Mikels also confirmed over in the cooling thread. I bought the fan first and then had C&R draw up the radiator to make sure everything would match. This is probably a good idea because GM may make improvements to the fan at any time! The radiator I ended up with was similar to one for Stielow but I deleted trans/diff cooler in the RH tank and also the intercooler bracket in front of the radiator, leaving just the Vintage air condenser. C&R are good to work with so don't hesitate to contact them. I would make a couple of small changes if I had to do it over. 1. The condenser bracket is just a little more flexible on mine than I would like. You may want them to beef that up a little to make sure the condenser screws never flex into the core. 2. Also the VA outlet fittings are pretty close to the core support. If the bracket was moved up and forward slightly I would have had more room for A/C fittings. These are minor points you can see in my photos, but could save you some fab time if you fix them ahead of time. Don't hesitate to ask more questions. I know I asked a bunch ! Scott |
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I'm upgrading to an LT4 engine, so I'll have an intercooler in the stack as well. That will change the VA condensor location for me, as well as the core support. I'll end up modding the core support around the cooling stack a la Stielow in JA 2.0. Mine won't look as cool as yours, guaranteed :-) Keep the posts coming on the rest of your build, awesome car. Scott |
Happy New Year!
I took off some time last year because I was getting burned out. The last two weekends allowed me get started on the exhaust again, clean the garage and finally get the Mast engine out of the crate and on the engine stand. Not much progress to show but that mast 427 sure looks great, really nice piece of hardware. I threw the manifold on just for fun. It is easier to move around without that big engine crate in the way and the big block rests nicely on the small cradle. I am pretty motivated again!
This week I will try to finish tacking up the LH tailpipe and maybe start some of the final exhaust welding. Here is a quick photo dump. https://i.imgur.com/6IzqRfK.jpg https://i.imgur.com/UY64zD1.jpg https://i.imgur.com/YOJkyeT.jpg https://i.imgur.com/SEDNBTW.jpg https://i.imgur.com/WqNgsoDl.jpg |
That motor sure is pretty!!
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Wow, awesome skills here.
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DT69 Thanks for the compliment. I need to get more like Sonar Chief and just get-r-done. Sometimes I spend too much time on things. Ok I almost always spend too much time!! I sent you a couple PMs on the bracket question.
Scott |
Oil Pan Install
I put the oil pan on this weekend. It is a simple job but there are a couple easy gotchas with the LS style pan and pickup tube, also with the Mast pan. I thought I would post up a little bit of detail in case it helps someone else. Make sure to order the right windage tray nuts. My engine has aftermarket studs and they were M10-1.25. I should have ordered this type of nut but I didn’t plan well and ordered the stock GM nuts that were too small.
https://i.imgur.com/pUKjkqzl.jpg Rather than lose the weekend I just bought some all metal locknuts and used hardened washers underneath, more on that later below. The pickup tube only uses one bolt but I decided to install one the little braces from Improved. It is probably overkill but a nicely made product and satisfied my need to have a bolt in every pickup hole. It twas a little tight to get it installed but it fits even with the cover already on. https://i.imgur.com/pWCTF0pl.jpg https://i.imgur.com/X7YUQSvl.jpg https://i.imgur.com/nzhkbA8l.jpg Remember I said above that I used standard M10-1.25 metal locknuts. Well they are really big and here is where I had a clearance issue with the pickup tube. I could have removed it and made a little dent but I didn’t want to start over. I just worked the nut down slowly until I could tighten it with an open end wrench. This time waster could have avoided by buying the special flange nuts ahead of time! https://i.imgur.com/8UVHwdzl.jpg The Mast instructions reminded you to measure the pickup clearance. I have done this before on other engines, but it was a good reminder to set some clay on top and adjust it. I had to hit mine with plastic hammer to get it square and establish the right clearance, so I was glad I did take the time to do this. Mostly I just wanted to use Play-Doh! https://i.imgur.com/n8i9Dlkl.jpg https://i.imgur.com/Skduzm3l.jpg https://i.imgur.com/r21LOl2l.jpg The Mast pan comes with special fittings and a reminder to take the plugs out and check for debris before the final installation. I was glad I did this because the long fitting actually had cut the O-ring and there were two loose pieces in there. I am not sure where those little O-ring pieces would have ended up (probably the filter). Also Mast tech support told me not to use the small second O-ring. They apparently quit using it about two years ago, so I know I won’t have the cut problem when I re-install it. https://i.imgur.com/bhzkqDll.jpg After blowing out all the oil passages I put the final torque on the pan bolts and installed a filter to keep dust out. It really is an easy job, but I learned more than I expected since this is my first LS engine. https://i.imgur.com/9QC2Axyl.jpg Well that was a little long but hopefully it helps someone. Next week back to the stainless exhaust. I spent a few hours on the LH tailpipe today but still not quite ready for final welding. Pretty sure the exhaust is my worst subject. If it was school I would be earning a C- ! |
why did you have to replace the stock windage trey nuts? my mast instructions did not make any mention of that?
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never mind i just looked back, looks like your motor did not come with the stock oil pan or windage tray.
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LH Tailpipe tacked-up
I didn't have a lot of time this weekend but finally got the LH tailpipe trimmed and tacked together. I have a lot of time in it and looking forward to being done with exhaust. Overall if fits pretty well. I still need to trim a few things, raise the differential and mount the tires to make sure there are no tight spots.
https://i.imgur.com/JNIaSdsl.jpg https://i.imgur.com/PHUbbawl.jpg https://i.imgur.com/4BVqpIjl.jpg A while back I sketched up a hanger bracket for the tailpipes. I need to get two of these made this week and start doing some of the final welds on the exhaust. The frame rails are really thin so these brackets will mount with Rivnuts, similar to the DSE sway bar bracket. https://i.imgur.com/VghXCFcl.jpg Not quite out of the exhaust business yet but getting closer! |
Finally got a chance to read through the entire thread. Love the fab work that you've done! I'll be looking back through this when I get to my VA system and exhaust.
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Hope there is some helpful stuff in there. I can say if you have a choice take the "git-er-done" approach like Sonar Chief (and others). Mostly just have fun because that is what it's all about!
Scott |
I think the tailpipe hangers came out about like I planned. It was fun to sketch something up and then make it and have it come out about like it was designed. We do that for a living at work, but mostly I just like to freehand and have fun in my garage. Here are the LH bracket rivnuts installed and the bracket in place.
https://i.imgur.com/TvjK0xpl.jpg https://i.imgur.com/PqFURmLl.jpg I was a little worried about drilling the one horizontal hole because there is very little clearance. I messed around with a few ideas and the first one took an hour or so experimenting. Since others may run into the same problem I decided to shoot some images on the RH side. I cut down a ¼ inch drill and used the angle grinder to start the hole. Then put the step drill in the air ratchet to get the size stepped up. I paint a stripe on the correct step so I don’t forget how far to go. After that just a little clean up with a drill held in vice grips. Seems clunky but it worked fast the second time. https://i.imgur.com/h81epHll.jpg https://i.imgur.com/saXfz07l.jpg https://i.imgur.com/rjHpEtbl.jpg I was thinking about using my rivnut tool to do all this work but I ended up buying fine thread inserts. Turns out they don’t have any fine thread adapters after I wasted a couple hours on the internet. I found a company that makes a little hand adapter that worked pretty well. I will admit I botched a couple of rivnut installs and had to cut them out and start over. Fortunately they fall out of the frame towards the back. https://i.imgur.com/MLTi8qdl.jpg I need to get some screw jacks because it is a lot of work to get the car at ride height because the differential is so heavy. I jacked it up and there are no interference points and the exhaust is at least ¾ inch away from everything on the suspension and 1-inch from the tires. I still need to weld the hangers but the mockup was good. https://i.imgur.com/O1rBssYl.jpg https://i.imgur.com/1qC2XB0l.jpg https://i.imgur.com/1uPUsghl.jpg It is starting to get pretty crowded under there and I still need to order a driveshaft and add some sort of travel limiter so the differential won’t drop so far, and add the fuel and brake lines, vents, etc! https://i.imgur.com/XzMYLUyl.jpg That’s if for now. I keep saying I am going to weld this exhaust up but little details demand attention. Hope to start that next week! |
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Finally welding the exhaust
I decided to take a week off and catch up on things around the house and really focus on the car. I have been stuck on the exhaust, so I decided to put in some serious hours this week. I started by practicing a lot and working out the back-purge settings. I figured if I practiced 4-5 hours it would really help. Well I figured out more like a 100 hours to get even moderately proficient. Finally, I just decided to jump in both feet and get something done. There is no better way to get experience than just get the experience
https://i.imgur.com/EJoZl3Ll.jpg You can see there is no sugaring on the inside of the tubes after welding with a purge. This was my main goal and I was happy about that. https://i.imgur.com/sgelKnwl.jpg Here is an assortment of photos showing the in-process work. You can see the Kapton tape used to seal the un-welded joints in some photos. I got this idea off the Burns stainless website and it was a good idea. https://i.imgur.com/b4CWOqCl.jpg https://i.imgur.com/gie7B61l.jpg https://i.imgur.com/AX9nU0ql.jpg https://i.imgur.com/xI9aqqol.jpg https://i.imgur.com/YLL2sQtl.jpg https://i.imgur.com/8TVeA5Ol.jpg https://i.imgur.com/IIVTkiel.jpg Overall my technique is improving but I told someone I go between skillful welder and 5 year old at the drop of a hat. Here is a photo showing the welds are more-or-less OK but the technique isn’t consistent. I think I also need to work on my patience. I need to slow down and let things cool to minimize the oxidation, which definitely wasn’t done in this photo. https://i.imgur.com/tpPaEQJl.jpg Tomorrow I start on the X-pipe. It has about 150 inches of welding, so I will probably empty the second argon bottle and move to the third. Next up I am going to add a door in the trunk floor. I spent a little time on the computer figuring out what it might look like. For simple things I am finding a 3-D model really helps because you can rotate it around and play with the design. I still need to drop the tank to start on this after the exhaust is finally welded. https://i.imgur.com/7mLNeDOl.png I am going to try to get out to Goodguys this Friday but hope to get more done over the next couple days and the weekend and post up some more images. Thanks for looking! |
Looks better than my stainless TIG welding !
I think you're doing great. |
Exhaust is welded finally!
Having a week off helped a lot. There were so many things to do around the house, but I focused mostly on getting the exhaust welded so I could move on. I had a couple of small breakdowns on the welder that I had to stop and fix. The gas solenoid was leaking and the post flow timer was shutting off early. The solenoid was a trip across town to Grainger and the timer was a couple of hours trying to figure out how to wind up this little clock spring and get it all put back together without pieces flying out. Afterwards the welder purred like a kitten. I should have fixed those long ago but the expensive argon back purge finally motivated me!
https://i.imgur.com/1ldRtjjl.jpg I laid down some clean paper to keep my rusty table away from the stainless and taped all the joints with Kapton tape. Then it is just remove the tape and weld one joint at a time. I still have a lot to learn but I feel like it came out fine as far as strength goes. https://i.imgur.com/efJgbLUl.jpg https://i.imgur.com/NejvtANl.jpg https://i.imgur.com/qIRNWwWl.jpg https://i.imgur.com/FrxVy5ol.jpg https://i.imgur.com/fVPlKs3l.jpg https://i.imgur.com/RobV7mel.jpg I ended up using almost two full tanks of Argon for the whole exhaust, partly the solenoid leaking and also I just move slower than a real welder! The overall setup is fairly heavy and I don’t think my original muffler hanger idea is strong enough. I am planning to copy this idea from Detroit Speed, but didn’t get the parts, or get it properly figured out yet. https://i.imgur.com/eNmg1dYl.png I moved on to the fuel pump access cover. After lowering the tank I realized I had to grow the size a little bit and that took some time. I have it figured out now, but didn’t have a wide enough piece of metal to cut it from and the metal store was closed. I will pick some metal up on Monday. https://i.imgur.com/bTtzRhdl.png https://i.imgur.com/o1MMz08l.jpg I have this old lathe I use for spacers and whatnot. It has always had a bad gear in the change box. I took a short diversion to get that removed and the gear on order. It was sort of a simple/fun way to wrap up the weekend. https://i.imgur.com/qor99X0l.jpg https://i.imgur.com/lY1x1b1l.jpg Next week work on the fuel pump access panel and think more about the muffler hanger final solution. Scott |
You're welding looks good to me, Scott. I'd be happy if I could lay down welds like that. Good job on the exhaust!
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I agree great fab work and maybe taking a week off is a good idea to get some stuff done around the house and car.....maybe just the car:yes:
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Looks great :hail: Is that a corvette sway bar link on the DSE exhaust pic? huh?
Michael |
Thanks for the kind words guys.
Chief I think you are correct that looks like a C5 Corvette link. I know there are other designs but that seems like a good place to start. Thanks for spotting that. Scott |
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Thanks, great info. I will pick up a couple and see how they work out.
Scott |
Fuel Pump Access Door Progress
I got a pretty good start on the fuel pump access door this week. I decided I liked the shape of the sketch and rough cut the opening. I put the tank up to make sure I have access to everything and it looked pretty good.
https://i.imgur.com/Y6kBGjyl.jpg https://i.imgur.com/2ZeKiSrl.jpg Using the sketch I cut my template out of 11 gauge material for the door frame, hacked it out and sanded it to shape. I pre-drilled the .125” pilot holes for later. https://i.imgur.com/bhoFj3yl.jpg https://i.imgur.com/G3n215ul.jpg After trimming the frame, I cut the cover out of 18 gauge and rolled some stiffening beads, then match drilled the cover so everything will line up. I don’t know what I was thinking, this door has 24 fasteners. My friends were joking that it will be easier to take the gas tank out than take out all those screws. After taking it apart a couple of times they may be right. https://i.imgur.com/oIzljBul.jpg With all the holes drilled and tapped, I put the door frame in the trunk and started final sanding the trunk floor to shape until it fit pretty well. I only had time to get it tacked in place this weekend. I put the door on just to see how it fits and I think it will fine. After looking it over I may wait and weld this from the bottom while it is still on the rotisserie. I think that will be easier and will provide a better looking result. https://i.imgur.com/KTEutazl.jpg https://i.imgur.com/7MS2BtXl.jpg I spent a little time figuring out how far to cut down the trunk hinge braces. The height is about right but the angle is wrong so I need to work a little more on those. https://i.imgur.com/BXUHkCVl.jpg Next week I will be working in the trunk area to finish up some of the fuel system and differential vent system ideas. I will move back to the exhaust hangers when the fuel line, and brake lines are worked out. |
Amazing job on the exhaust,can I bring you another one?
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Thanks but the exhaust almost single-handedly killed my project progress. If you take it on I will give you pointers though. Number one buy a powerful belt sander. I wasted way too much time hand trimming everything.
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Hing braces, clutch pedal and Finch vent.
I messed around in the trunk until I got tired of it then worked on the clutch linkage for a while, then back to the trunk.
I finally installed the Finch vent for the diff. and gas tank. It came with a nice metal template so just put that down, drill the holes and use the step drill to get everything enlarged to size. https://i.imgur.com/iRd10kVl.jpg https://i.imgur.com/jJC6m13l.jpg https://i.imgur.com/X44LWzUl.jpg I think it looks really clean from the bottom. Still don’t have the hoses yet. https://i.imgur.com/1Mm87fjl.jpg I decided not the cut the cultch rod shaft down like DSE recommended. By fabbing a tab if I ever need a new one it will be easy to find at any dealer. I just tacked it in place for now. When I get the clutch in I can check the travel and feel. It looks pretty good so far. https://i.imgur.com/lr3hhcel.jpg https://i.imgur.com/ehRrUXfl.jpg https://i.imgur.com/AEEHsl9l.jpg https://i.imgur.com/4fd89Wdl.jpg I also picked a spot for the clutch master reservoir. I just clecoed it in place for now. When I get everything else positioned and it still looks good I will permanently mount it. https://i.imgur.com/BAVUf8wl.jpg I have had the trunk hinge braces hanging around for over a year and still haven’t fit them up. I decided I may lose them at this pace. They get cut down about ¾ inch but the angle is all wrong with the new tubs and also one of the feet is at the wrong angle with the wider tubs. After I cut the first one down and it didn’t fit I was wondering if there is a better way to get them to fit. This weekend I just gave up on thinking and cut and pieced them back together so everything lines up. It was probably a waste of time for such a simple non-visible component but I think they came out OK. https://i.imgur.com/4e5tCnKl.jpg https://i.imgur.com/DwlIxNAl.jpg https://i.imgur.com/wK4QYApl.jpg They are ready to weld. Next time I crawl back in the trunk I will plug weld them in. https://i.imgur.com/u61ceAll.jpg https://i.imgur.com/fDm4NyTl.jpg Next week work on the fuel line for sure! |
Finishing braces, starting fuel line
I didn’t get that much done this weekend, some progress last weekend and a little during the week. I finished up the trunk braces. Tried something new and cut some slugs with the Rotabroach to fill in the large holes from drilling the spot welds. I am not sure it was worth the effort, but it is always good to try something new. The braces came out OK.
https://i.imgur.com/M4DvTXsl.jpg https://i.imgur.com/PetFI08l.jpg https://i.imgur.com/QMUYTc5l.jpg https://i.imgur.com/ZNXJDkjl.jpg https://i.imgur.com/FNGfMOYl.jpg I decided to lay the old fuel line in there to see where the new stainless one will run. I already knew I was going to have to notch the subframe connector. https://i.imgur.com/xF472lAl.jpg I had this old tube laying around so I cut it in. I will weld it and cut the top off probably this week. I may fab a cover also. https://i.imgur.com/K9xEJPDl.jpg https://i.imgur.com/fv98Zaql.jpg I started bending the fuel line. The bends came out OK even though I am not really happy with the overall fit yet. I made a couple of small mistakes and a tighter bend radius would have been helpful. https://i.imgur.com/GG7mJzGl.jpg https://i.imgur.com/wFTdsMgl.jpg I will tweak the bends some more and see if I can improve the fit. If not, I may cut and weld to improve, or maybe start over, still not sure. I will keep plugging away on the fuel line this week. |
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Car is looking great! Mad skills! |
Looking good! I approve of the notch for the fuel line. It works well in my opinion if you're not having to make a radical fuel system. Keep up the great work1
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Nice fix, that will definitely stiffen that up. The plate will be icing on the cake.
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This thing is really starting to take shape.
Nice work, attention to detail. Outstanding. |
Finished Fuel Line (mostly)
I got the ½ fuel line all hacked into shape. It has some warts and bruises but looks pretty good overall. Here are a few photos of the progress.
I had to make a couple of brackets to support the flex tube and keep pressure off the plastic gas tank fitting. https://i.imgur.com/kybNWxnl.jpg https://i.imgur.com/H2fIKVsl.jpg https://i.imgur.com/UWDFAhyl.jpg https://i.imgur.com/UEb4NKbl.jpg https://i.imgur.com/a8RRlgml.jpg I made a couple of stupid mistakes bending the first line and it was too close to the exhaust. So I started over and the second one came out much better. https://i.imgur.com/tOlVCbwl.jpg Here is the flex line all connected between the brackets. https://i.imgur.com/3YvgTQ0l.jpg I put in rivnuts where there was double wall and they wouldn’t poke through the inside. I may have to add a couple more later. I haven’t decided if I will stick with this style line clamp? https://i.imgur.com/OKyNf2Nl.jpg https://i.imgur.com/kCPebLul.jpg https://i.imgur.com/Hp5ovdll.jpg The fuel strainer needed some support but there was no place to put a rivnut without going through the inside. I just made a little box and spotted it in place for a support clamp location. It worked out well the filter is secure now. https://i.imgur.com/EOk7W65l.jpg https://i.imgur.com/KRgEVUdl.jpg I just routed the line into the engine bay but it isn't finished until I know more about where the flex line will be https://i.imgur.com/4e9YEsel.jpg One thing I was thinking I should have kept all my paper patterns. It would have been fun at the end to hang all those on a nail as a reminder how far I have come. Too late now but I think it is a good idea for someone just starting. I dug the old brake lines out to give me ideas and next week I will start on the stainless brake lines. I have my brake tubing on order from Classic Tube. This weekend I will just do a little clean-up and planning, maybe prepare the old tubes as patterns so I hit the ground running when my stainless is here? |
I love all the custom touches your doing, It's looking really good. Nice work.
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