1991 Chevy Crew Cab "R" / "V" Conversion

[mckustomfab]

Not a ton of progress from this weekend but I was battling the flu.

I was able to get the front end off, the big block pulled and sold, removed the factory engine crossmember and modified my core support to hold the innercooler and radiator.

 

[mckustomfab]

Here is the progress from today, I removed the powersteeing box because it needs to be replaced and I found one of the bolt holes has a few spider cracks running out from it... So I hopped online and ordered the weld in repair kit, it should be in on Thursday. While I am waiting on that I am going to get as much else finished as I can, so I clearanced the front crossmember and test fitted the engine with the core support to get a idea where the mounts need to be. Now I have to clearance the firewall some for the bellhousing bolts and it should be good. Here are the few photos I did take, sorry for the red haze, I had to put up a pop-up cover to keep the rain off.

 

[mckustomfab]

So Wednesday consisted of test fitting the engine about 15 times and persuading the firewall with a hammer. Thursday was mostly running around getting parts ect. Friday I painted the firewall and welded on the steering box brace, and swapped the Dodge NV4500 input into my Chevy NV4500. Today I landed the engine in its final location, installed the NV4500 and Np205, I had to take the driveshaft to be shorted. I was also able to wrap and hang my down pipe along with some other small things. I installed the core support and passenger side fender to see how the intake and everything would line up. Here are a few pics I got...

 

[obijuank5]

First picture makes it look really tight fit. How's the fan to front of engine clearance?

 

[LNielson]

How much does that engine weigh? looks good in there.

 

[Truckman4life]

Dry weight is between 855-906 lbs less the flywheel and electrical parts.

 

[6872xtc]

Looks good!

 

[mckustomfab]

First picture makes it look really tight fit. How's the fan to front of engine clearance?

Between the fans and the pulley there is about 1.5" without the fans there is 3". So yeah its tight but my engine could have gone back a little more but I didn't want to get too close to the firewall.

 

[Truckman4life]

Between the fans and the pulley there is about 1.5" without the fans there is 3". So yeah its tight but my engine could have gone back a little more but I didn't want to get too close to the firewall.

You would never be able to fit a mechanical fan and clutch would you? Does the dodge radiator kill a lot of space up front compared to a big block radiator?

 

[LNielson]

Dry weight is between 855-906 lbs less the flywheel and electrical parts. View attachment 257182

Wow those are heavy!

 

[mckustomfab]

You would never be able to fit a mechanical fan and clutch would you? Does the dodge radiator kill a lot of space up front compared to a big block radiator?

I know there are people who have run the mechanical fans, I am not sure if they put their engine closer to the firewall or what. I have heard that a 1st gen fan hub is shorter then the 2nd gen so it provides more room but I'm not 100% on the numbers...

 

[mckustomfab]

Looks good!

Thank you sir!

 

[mckustomfab]

Here are some pics of the progress from the last post. The weather has not been cooperating but I have got the innercooler and radiator hosed in and connected, fenders are on and ran the power and grounds for the battery.

Also got the exhaust in, I was surprised how well the 89-93 Dodge D250 kit fit. I had to add a 6" section so the bend over the axle would line up but other than that it was a good fit.

I also started running my fuel lines down the driver side frame rail. Here are the pics!

 

[mckustomfab]

Made a little progress on Sunday (rained all day Saturday), here is what I'm left with.

- Finish the wiring, need to hook up the electric fans, headlight relays, and maybe the grid heater.
- Make fuel line connections on fuel tank, and prime the fuel lines.
- Fill fluids, and check bolts
- Sort out my clutch mastercylinder issue
- All the little things I forgot...

Here are a few pics of the relay box and Buss bar I'm using.

 

[Truckman4life]

Looks good. Once you get that engine bay tidied up it will look almost factory. How do you like those military battery lugs? I've got 1000 CCA group 31 semi truck batteries with the 3/8" threaded studs in my 6.2L K5 but when I redo the cables and batteries in my Cummins/F350 I'd like to go that route.

 

[1-ton]

That is one tight fit. You seem utilizing every square inch of space you have as best as possible. Who would have thought a square body engine compartment would be tight on space for anything.

 

[ryoken]

just electric fans correct?

 

[mckustomfab]

Looks good. Once you get that engine bay tidied up it will look almost factory. How do you like those military battery lugs? I've got 1000 CCA group 31 semi truck batteries with the 3/8" threaded studs in my 6.2L K5 but when I redo the cables and batteries in my Cummins/F350 I'd like to go that route.

Thanks! I really like the military style lugs, the only issue i have run into is that I will need to get longer bolts because the cable lugs I used are really thick. Other then that they are great!

That is one tight fit. You seem utilizing every square inch of space you have as best as possible. Who would have thought a square body engine compartment would be tight on space for anything.

Yeah, i'm glad that there was a lot of room to start with! I don't have a photo of it but I removed the vacuum reservoir so that i could mount my blow-by separator/catch can right behind the drivers wheel well. I also have to figure out how to squeeze a windshield wiper reservoir in there, the battery and the tank try to occupy the same space but I cant move it too much or the hood spring hits it... Not too worried about that until its on the road though.

just electric fans correct?

As far as the wiring to run and drive, I have the fans and I am going to use two of the relays in my box to hook up to my headlights. I already have the fuel cut off solenoid hooked up and after I get it on the road I have a boost and EGT gauge to hook up. Getting closer!

 

[Truckman4life]

Mine is here.

 

[ryoken]

As far as the wiring to run and drive, I have the fans and I am going to use two of the relays in my box to hook up to my headlights. I already have the fuel cut off solenoid hooked up and after I get it on the road I have a boost and EGT gauge to hook up. Getting closer!

no i meant you aren't running a mechanical?