'Da Chief : 5.3 Gen V / 6L80 Swap

[cu4whln]

Updated Cost Today . . .

Costs :

So, if you haven't seen it, I have been keeping a running list of all the parts and what they cost in post #9. [page 1]
I update the list every so often. This is a little painful, but realistic.

Copied from post # 9 :Total As Of: 8/19/20 - $ 12,283 [So Far - edited 8/19]

Note: This cost was offset by the sale of my 401 drivetrain .. so subtract $2500 from the total.
So actual cost is now at $9,783.


EDIT: Oops.. and AC system !

Now, keep in mind I have bought all new parts, and am trying to build it right. I need a very reliable vehicle to do a cross country road trip.

I wanted to document this as build costs are often not discussed.
I think folks think this can be cheap.. it often is NOT.

Be prepared...

[SOLSAKS]

man this is a well done project.

wish I had your knowledge and drive,....

going to be a reliable beast.

good idea to keep track of cost

so when others ask, the info is there.

I currently have a newly rebuilt 360 that has tanked twice before driving it

1st cam lobes wore down during break in

2nd now coolant leaking from heads

(prob will have to pul again to fix correctly depending on what is found )

could have had a modern engine......

keep up the good work.

dave in NC

[cu4whln]

I currently have a newly rebuilt 360 that has tanked twice before driving it

1st cam lobes wore down during break in

2nd now coolant leaking from heads

(prob will have to pul again to fix correctly depending on what is found )

could have had a modern engine......

keep up the good work.

dave in NC

UGH !! Soo frustrating. I have been there with older engines I rebuilt, and it went bad. Very disappointing.
I hope your luck changes on that soon.
I really was torn about selling off the 401.. but in the end, i needed the reliability for the family.


As for persistence:
I have found the internet SOOO helpful in planning this build.
I planned for 6 months before jumping in. I had some idea of what was in store...
BUT - The unexpected kicked my butt a few times !

I am a one man show here.. doing what I can in a garage rebuild situation.
However, I hope my junk gives others ideas and hope as they venture into their own builds.

[cu4whln]

Light .. Camera .. ACTION !

Since I had the front end apart.. i installed my upgraded wiring to give direct batt voltage to the lights...

I bought these Cibe lenses and bulbs 2 years ago. Now I am finally installing them.
If you are not familiar with Cibe lighting, they are very well engineered lenses.
H4 bulbs as well. Huge upgrade over the old sealed bean units.
I don't want funky looking LEDs on this. Want better headlight performance, but keep the classic look.

[IMG][/IMG]

Testing... yuup. got high and low beams. Check.

[IMG][/IMG]

All lights up and running... Check.

[cu4whln]

In Da Hood . . .

My buddy Mark stopped by this am to help me get the hood installed.
It was kinda like a 3 Stooges routine.
Neither of us understands body panel adjustment very well. And it showed!



However, after 2 hours of trial and many errors.. we got it on.. not perfect, but close enough for driving.
Learned that the latch adjustment is not as easy as it seems. Hmmm . . .
. . .and sometimes jams in the down and locked position. Hmm.

Anyway, it's on

[IMG][/IMG]

Had to move the horns .. again. They were sitting too high. Sigh.
Will have to find another positive batt terminal as well... It sits too high as well... digging into the new hood insulation.

[IMG][/IMG]

Also threw on the rest of the bumper and grill of course...

[IMG][/IMG]

Now ?? Hmmm

[cu4whln]

Driving !

Well, after getting the hood and front end together, I decide to test drive it a "little"

Very little.. first thing was down the driveway in low range ... and the trans shifted ! Woot !!
Then backed up the drive.. reverse works too.

Next.. put it in 2wd and go around the block. It moves!
Trans seems to upshift as expected. Check.
Don't drive far as I have no exhaust.. only the cats up by the manifolds... but it's not too loud if you keep your foot out of it.

Anyway, stayed in the neighborhood just in case. But all went ok...
Kept it below 30 mph.. tested the brakes a few times.
After about a mile, I went back to the drive and let it idle for 20 minutes.
Kept an eye on everything.. looking for leaks etc. None so far.
It's strange to have a FSJ that isn't bleeding some sort of fluid at all times!

[IMG][/IMG]

Kept a very close eye on the oil pressure.. steady ay 40 psi at idle. Maybe 48 at speed.

[IMG][/IMG]


Coolant temps never exceeded 202. BUT - it was only 86 today. Shows 197 F in this pic..
The fan ramps up as expected.... Alls well it seems.
Now have correlated the digital tool temp with the gauge.. Note, the temp needle is right in the middle of the gauge here.

Idle rpm is a very smooth 550 or so. Very low, but OK. Note temp lower left bottom corner.. and batt voltage on lower right. All seems OK ?

[IMG][/IMG]

Pretty excited as it seems to be working!

Now, i have to build the air intake system and tackle the AC system.

Also, the custom exhaust guy is booked for a couple of weeks. Ugh.
Can't get it in until Aug 5th or so. Guess this will let me address the minor issues.

Today was a WIN !!

[Full Size Jeeper]

Beautiful job, thing is Bad A$$!!! Great looking rig.

[bkilby]

Had to move the horns .. again. They were sitting too high. Sigh.
Will have to find another positive batt terminal as well... It sits too high as well... digging into the new hood insulation.

[IMG]

That battery terminal is goofy tall. Can it be put on a side post of the battery.....if you had a side post? I can send you a few sets of these milspec battery terminals if you'd like too.

https://s.yimg.com/aah/yhst-59523690850641/battery-terminal-clamp-mil-spec-positive-terminal-ms75004-1-8.jpg

[cu4whln]

Beautiful job, thing is Bad A$$!!! Great looking rig.

Thank You!

It's a 20 ft rig, trust me. But I am only worried about drivetrain this year.

[cu4whln]

That battery terminal is goofy tall. Can it be put on a side post of the battery.....if you had a side post? I can send you a few sets of these milspec battery terminals if you'd like too.
https://s.yimg.com/aah/yhst-59523690...s75004-1-8.jpg

Send a pic of terminals...

The tall one in the back is the negative GM connection. That one clears.. just had to rotate it away from the hood reinforcement bar.

The front positive one.. worried that might ground out against the hood with wear. Can't have that.. so I have to change it to something else

[bkilby]

I did send you a pic. Click the link!

[cu4whln]

I did send you a pic. Click the link!

Oops - I did see it after all. I need at least 3 terminals to feed the various systems. I'll find something!
__________________________________________________ ______

Now, I am waiting on exhaust work, so not much going on... Sooo -
After sitting in my drive for 2 years, then my garage for a year or so.. The Chero got it's first bath in 3 years!
I need a ladder to reach the roof.. I am not tall!

[IMG][/IMG]

[IMG][/IMG]

Then a "small" project that needed to be done. After cleaning out the cowl vents, which were full of stuff... I added some screen material to the underside of the cowl inlet vents.

I thought this would be quick and easy.... NOPE. It was kinda a pita.
BUT, I got it done. I have a lot of trees on my property so this was a MUST!

Backside.. you can see the glue. Had to be careful not to get it on the open areas as you can see it.
( Figured that out quickly ! )

[IMG][/IMG]

Top view, ready to go back on now. I washed inside the cowl as well since this was off . . . Only found one leak at the driver side wiper pivot.

[IMG][/IMG]

Oh, I HAD to drive it around a little to dry off the body.. of course! Can't wait on a "real" test drive with exhaust and an air intake with filter.

[Full Size Jeeper]

Do you have any idea where I can buy some of those V8 401 stickers like on your side glass?

[cu4whln]

Do you have any idea where I can buy some of those V8 401 stickers like on your side glass?

They were on the Jeep when I got it.. actually had a checkerboard pattern in the square part of it, but that has worn off.

As for custom decals.. I had Frank Sanborn make the valve cover ones for me.. Maybe contact him?
He is a graphics guy by trade.. does nice work.
Will be having him make me some custom Chero stripes when I get this painted.

[cu4whln]

In Today's News . . .

More parts showed up today.. yea !

Today was rigging up a mount for the air filter and intake runner. I am mixing and matching some parts from 2 separate cold air intake kits.
Hmm.. nothing is easy and neither works well.. Sooo -

[IMG][/IMG]

I ordered some good reinforced silicone parts to cut up/modify.
After some mocking up, I found a rough configuration that should work.

I had to cut out the section from the alum tube that mounts up the MAF sensor...

[IMG][/IMG]

OK - cut out part ready to mate up with modified 90 degree parts.
Note to self: Will have to add a port for the valve cover vents to connect to the intake air.

[IMG][/IMG]

Roughed in air intake system.
Not super happy as it almost sits on the upper rad hose.
BUT - I can't raise it as it's almost against the hood insulation already.
I plan to add some cold air "chambering" to help cool the intake air a bit.
Not a lot of options at this point.

[IMG][/IMG]

Now.. I will make a bracket that attaches to the water pump bolt that you see under the elbow. this will locate the hose and let it move with the engine.

[IMG][/IMG]

I will make some kind of cold air baffling in the near future.
Exhaust shop next week...
WHEN the exhaust is complete, I can actually drive it safely and start the debug process.
I do have a couple of fault codes that show up... need to figure those out. Seems to run OK though.

Slow progress, but coming along.