1955 Pontiac LS upgrade
 

New project showed up for Modernization...…. Judy and Jeff's 1955 Pontiac Station Wagon.... A little background on the car....The car was purchased some years ago with a small block Chevy engine and trans for power...…. However it did not have A/C or power steering and since this is Judy's car it was a handful for her to drive...… and since they want to travel the country and enjoy Life...…. Well …… We are going to fix that...…They already added Disc Brakes and a 9" ford rear end...….. We will be adding a GM Connect and Cruise LS3 480hp/ 4L70E engine and trans assy along with Power Steering, new tilt column, A/C and rewiring the car and some interior sheet metal repairs...…..And whatever else pops up along the way....Anyhow here are some pic's to start the build thread....

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Jeff also sent the gauges out to Dakota Digital for them to work their magic on......


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What a unique project Ken...glad to see it here. :thumbsup:

Another cool project Ken. So what are your plans for the exhaust and mufflers?

Jim

Nice looking car. Going to be fun watching it come together.

Probably stock exhaust manifolds and regular mufflers. Just gonna be a driver

So…… The first thing that needed to be fixed was to install the new power steering box…….The new box will need the mounting holes modified in the frame for mounting the modern box conversion……… And as Luck would have it the Stock Pitman Arm spline was different from the first box we tried……… Gonna use a GM 605 box next as in a previous swap thread by others it was noted that the Spline in the 605 box is the same as the stock Pitman arm……. Thought we would try with a better box than the 605 but that didn’t work out too well…. Won’t be the last time things didn’t go according to plan…..

Got the #605 box today…… Pitman arm and the box have the same splines...... Amazingly two of the stock frame bolt holes lined up perfectly ……. I will just need to add 1 hole for mounting...… Got Lucky.....Aftermarket steering column on order along with universal joints allowing for any slight mis-alignment......and after getting the box mounted it looks like we will have room for Headers if required........


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The frame is not similar to the normal 55-57 Chevy Frames...… The box is now permanetly.in place...… The upper two mount holes lined up and I was going to drill a 3/4" hole thru the frame and weld in a piece of round rod with a bolt hole in it for the third bolt......After I started drilling the hole with a smaller size drill I noticed there was a frame gusset in the frame....... Ended up I just drilled the hole thru to suit the mounting bolt and everything cleared perfectly right next to the gusset so there was no need to weld the tubing in for support...... Too simple...… Just had to shim the box out about an 1/8" to clear interference between the box and the frame...…..

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Awesome project... way cool.
I’ll be anxiously awaiting updates on this baby.

JD

Did some more disassembly this morning........ Got all the wires that will be replaced with the rewire out...... Removed the make shift trans tunnel ……. There are some rust holes thru the front floor pans so we will be replacing them along with fixing the trans tunnel.....Lot's of parts showing up next week

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Got the steering column in and got the connection to the box finished ……… Going to put a Patch panel on the Passenger side Floor pan .....… I'll be welding that in today after treating the floor with some Rust remover to get rid of the surface Rust, then treating the floor with Boeshield to help prevent further surface rust...… Engine will be here tomorrow and then the real assy will begin

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What's the white stuff on the ground in the first pic ?

Not white sand...…… Darn !!!!!

Got the Floor patch panel welded in today and got the drivetrain delivered to the house...… I thought I was going to be able to save Jeff and Judy some $$ by being able to use the as delivered oil pan..…… Wrong...…. Luckily I have a new 302-2 Holley pan in the garage...….. It will have a new home shortly...….

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LS3 480H.P. 4L70E trans......

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Got the engine mount adaptor plates installed along with getting the pan changed ……..

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Getting ready for the Engine install soon.….

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Well..... Got the engine in and now that wide open engine compartment is getting full...… Mainly on the driver side....When Jeff had the car converted to 4 wheel disc brakes previously.....they used the space available with the SBC in place while changing from the floor pedal to the firewall mount power system.....So...… A couple of things popped up after getting the LS 3 in place...#1... I think we may have to change the power booster assy over to a Hydro-Boost system to gain needed space (Vacuum Booster and Coils are fighting for the same space) to provide the needed space and still provide Judy with the Braking she needs...…… #2...…. I installed a Holley 302-2 pan.....Thought there would be plenty of room...…. LOL....We will have to change the pan out to a 302-1...… (Centerlink hit's the -2 pan while going thru the steering range..... The -1 has an additional 1 1/2 clearance)…… The sump area is shorter on the -1 pan......Things you find out as the process continues.....Darn !!!!………. I'm making a new trans crossmember tomorrow so that with get the engine mounting completed...…Also it seems like there is going to be a major clearance issue with the driver side exhaust The next problem for another day...….. Two steps forward, one step back...…..

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So.… The Pontiac has a "X" frame unlike Chevy's.... and with this conversion with the 4L70E being longer I had to make a new trans crossmember...….. The existing one was just a piece of 3/8" thick flat steel...…… Didn't like that so I wanted to make one out of "C" channel to resist the bowing from the weight...… I searched around the shop and couldn't find what I needed and didn't want to wait for a piece to be delivered so I found a piece of 2 1/2" 1/4" wall square tubing and ended up with what I wanted ….. LOL......Pic's will show the process...… Got it done and transferred the holes thru to the "X" member and Bingo...…. Finished.....Made a quick sketch of where I wanted to end uphttps://i13.photobucket.com/albums/a...34CA87DA90.jpghttps://i13.photobucket.com/albums/a...26556AABBD.jpghttps://i13.photobucket.com/albums/a...6F5B436F26.jpghttps://i13.photobucket.com/albums/a...DED1E2E962.jpghttps://i13.photobucket.com/albums/a...60BB7B03_1.jpghttps://i13.photobucket.com/albums/a...F8CD9875BC.jpg

Swapped put the pans today...…. If you are doing a LS swap into a 55-57 Buick, Olds, or Pontiac the 302-1 Pan is the one you need...…. Fits perfect.....https://i13.photobucket.com/albums/a...14E91A809E.jpghttps://i13.photobucket.com/albums/a...72B8F45554.jpg

The pieces are falling together...…. After getting the Exhaust manifold issue resolved (hopefully)………. The next thing that could have become an issue was the power brake booster positioning...…. Was thinking of changing to a Hydra-Boost to get more room between the Coils and the vacuum booster...… But.... After taking some time to think about it I took the last coil off and the coils and bracket assy fit right on...…. So... I have to add some clearance in the booster mounting bracket and make a offset mount for the last coil...… Just saved Jeff and Judy a lot of $$$$…… And..... Another concern was the positioning of the upper control arms on the Pontiac suspension in relation to the front drive assy...…. I got all the dimensions from Donnie at Frame-up and made a cardboard template of the power steering pump position...…. Bingo.... Looks like a winner...…. (those famous last words)…..LOL.....Tomorrow the steering column will be permanently mounted to the firewall and the cable shifter will be installed in addition to getting the last coil repositioned.....

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It’s going to fit in nice.

So.…… Jeff and Judy decided to go with a Hydra-Boost braking system ….. Good Choice !!!!!...… Ordered...… The exhaust on the drivers side was going to be a problem...… We ordered a set of Holley S-10 manifolds and when they came in.... I test fit them and due to the #605 steering box placement and the actual shape of the manifold it just wasn't going to work......I ended up trying the stock manifold again and noticed that if I ground of a portion of the steering box it would work...… we will be returning the Holley units as this odd combination just didn't work...….Spent the morning today pulling the steering box in and out grinding and fitting.....https://i13.photobucket.com/albums/a...1DF821EC_1.jpgAlso I received the Hydra-Boost system, and while the person who installed the Swinging pedal assy did a great job....Guess what...…. It mounts with completely bolt pattern..... LOL...…. I removed the old stuff and will be making a new mounting plate and reworking the firewall to suit.....It never ends...…. LOLhttps://i13.photobucket.com/albums/a...77B56E35C2.jpghttps://i13.photobucket.com/albums/a...18921030ED.jpghttps://i13.photobucket.com/albums/a...6490EBCA55.jpg

Ken now that your putting 4 wheel disc brakes you will need to remove the residual valve in the line, Correct?

Don't know …….. I need to check that out...… Getting conflicting info....Need to find out from someone a lot smarter than me...LOL

Today was a good day...…. No steps back.….LOL..... We are putting on a Holley front drive set-up...….Very well engineered kit..... But..... The hardest thing to do on a LS engine is to change the Harmonic Balancer...… Need I say any more..... Got that changed..... Installed the coils, Plug wires, passenger side exhaust, then installed the Holley system…… Waiting for the new power steering pump to show up for completion……. Here are some pic's from today

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Ken stopped in this morning and asked about a Prop valve and I said he would still need that.

If he is changing the rear brakes to disc, then the 10 psi residual valve will have to go.

That's what I figured.

Got the shortened driveshaft back and installed...…… Took the old firewall bracket and modified it to accept the existing Brake swing pedal assy and the new Hydra-Boost assy........ I also moved the assy 1" further away from the engine...... Had to cut out some of the contoured area of the firewall to get everything to fit correctly.......so I have some sheet metal work to do but it fits perfectly and was worth the effort.......

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Got the firewall patched and sealed around the Hydra-Boost...….. Got the ECM and Trans modules mounted along with the GM connect and Cruise Fuse panel...…. Waiting for more parts to show up ………. Still waiting for the Rick's Tank assy that was supposed to ship on Jan 29th.......... Time to figure out what A/C system to get that will fit this application also...….https://i13.photobucket.com/albums/a...154CB17B43.jpghttps://i13.photobucket.com/albums/a...F6A5463F97.jpg

It looks like that spot was made for that ECM.

Moving along...…. Had to make a Firewall spacer for the Hydra-Boost to get the linkage to work out with the brake pedal...…. Got the steering column mounted to the firewall also...…. waiting for some other parts to show up to finish the shift linkage...…. Decided to put the Radiator back in and see what problems were going to come up there...… Bolted it in and everything worked out, enough room for everything to fit...…… Just have to run dual fans to clear the water pump (ordered)…… Time to start on the rewire....https://i13.photobucket.com/albums/a...9881DFCC27.jpghttps://i13.photobucket.com/albums/a...AB260968F1.jpghttps://i13.photobucket.com/albums/a...E9C52D4271.jpghttps://i13.photobucket.com/albums/a...4E3F1DAEB9.jpghttps://i13.photobucket.com/albums/a...27AD688751.jpg

Got the Lokar cable shifter and the Dakota Digital GSS-3000 installed today …… Just about ready to neaten up the trans tunnel opening and get the new tunnel installed.... Time to start researching out what A/C system we are going to install and then wiring...….. Moving along.....https://i13.photobucket.com/albums/a...7CF56C436A.jpghttps://i13.photobucket.com/albums/a...6EEC51C1D1.jpghttps://i13.photobucket.com/albums/a...35207B31C8.jpghttps://i13.photobucket.com/albums/a...59468C53A9.jpg

That's funny you post that GSS3000 mine got delivered Friday along with their PAC-2800BT Electronic Fan Controller . I hope this fan controller works. Your moving along nice!

Went over to Frameup and Donnie gave me some mock-up A/C units to see what would fit...….. Ended up figuring it out and got everything ordered...… Got a condenser for the radiator that they had in stock …….and got it and the electric fans mounted...….. Got all the fittings and lines for the Transmission cooling system...… also started plumbing the A/C lines...….. Waiting on more parts to come in to continue...….https://i13.photobucket.com/albums/a...39FCD100FB.jpghttps://i13.photobucket.com/albums/a...531EF490E6.jpghttps://i13.photobucket.com/albums/a...A744486F13.jpg

Well..... The car had a small block Chevy installed in it some time in it's past....When the frame mounts were welded in at that time it, ended up that the engine was off-center about 3/8" towards the drivers side......… Fast forward...… After installing the #605 box and grinding some clearance on it to clear the exhaust manifolds (seemed like a good idea and a simple fix at the time)…… Anyhow...… After moving on from that point, I noticed some fluid on the floor below the steering box but I wasn't too concerned at the time because after cutting the brake lines in that same area after removing the old braking system I thought it was brake fluid...… Wrong.... Darn..... So, after removing the box and looking closely at it I seen where the leak was coming from.... Ground a little too much off the box..... Double Darn !!!!…… So we get back to basics...… LOL..... I'm making some new mounts (Pic's to follow) to correct that issue which will remove the steering box clearance issue and center the engine...… This car stuff is hard sometimes...… Should have this corrected tomorrow Also.... The Rick's Tank showed up today.... They built it for this conversion as a passenger style tank as we requested and I will have to remove the spare tire well in the wagon to allow for it's installation...… More Fun...… LOL...…https://i13.photobucket.com/albums/a...C67947B766.jpghttps://i13.photobucket.com/albums/a...7721D36032.jpghttps://i13.photobucket.com/albums/a...2EB310D63C.jpgGot the old tank out...https://i13.photobucket.com/albums/a...8C1A3D004A.jpghttps://i13.photobucket.com/albums/a...2546B5C958.jpg

Made new mounts and welded them in...… The engine is now about 3/16 towards the passenger side, so I picked up a good 1/2" of clearance on the drivers side..... The new steering box (ordered) will have plenty of room without any clearance issues…. I also leveled the engine as it was down about 1/4" on the drivers side...… Now I can sleep at night.... LOL...… Still waiting for parts to complete the final needs of the engine compartment...…… Time to get rid of the spare tire well and get the new Gas Tank installed

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Continuing with the process..... Not gonna miss some of this old sheet metalhttps://i13.photobucket.com/albums/a...6DDF3D94_1.jpghttps://i13.photobucket.com/albums/a...251845EB63.jpghttps://i13.photobucket.com/albums/a...C58FB8507B.jpghttps://i13.photobucket.com/albums/a...B906655E54.jpg

Started the day with a big hole in the floor where the spare tire well was....Got the rear mounts for the Rick's tank installed..... and got the tank installed..... And I have to make some new side mounts for the tank to get that part of the build finished up...…. https://i13.photobucket.com/albums/a...C53977390E.jpghttps://i13.photobucket.com/albums/a...107F138AB9.jpghttps://i13.photobucket.com/albums/a...E4E15DC8F1.jpghttps://i13.photobucket.com/albums/a...F077DCC151.jpghttps://i13.photobucket.com/albums/a...8FB4B8BB41.jpg

When we are finished we will fabricate a storage compartment above the gas tank...….. Also the power steering pump came in today so I got that all finished up along with the belt installation...…. I also got the front tank mounts fabricated..... Tomorrows project is to get them installed...…https://i13.photobucket.com/albums/a...309076BD84.jpghttps://i13.photobucket.com/albums/a...9FC816318B.jpghttps://i13.photobucket.com/albums/a...09292AEA74.jpg