91' Blazer 6.0 LS, 4l80e, Nose swap, Full Top Conversion, and Restoration

[Coontail]

Coontail submitted a new Build:

91' Blazer Build: Just LS Swap It

WELL here's a story about the time my wallet caught on fire...

This is my first build ever and I'm only 19 so take it easy on me. Just kidding but seriously.. lol

I got this hunk a junk with a 12 Valve Cummins a 47rh and an NP205 and I was going to reinstall it but I decided the swap would be too much and the "diesel phase" is starting to end for me so time to LS swap it!

I should be pulling the driveline out this weekend, a kids buying it for $2100 so that'll give me a good headstart on this.

I'm planning on using a 2004 5.3 a 4l80e and a np241c. I have read that this is the standard setup though it seems people opt for the 4l60e. I'm not falling for that though, my 02' silverado's 60e crapped out on me last year leaving me $700 in the hole and I only had $150... Doh!.

Not really too sure how often i'll be updating this

View attachment 263368

Read more about this build here...

 

[Coontail]

Well let's get down to business...

Last weekend I looked on car-part.com and found a NP241C out of a 1990 Burban 1500 in Methuen for a $185. Now I don't know if you've ever been to a salvage yard in Methuen but I had my belongings in a deathgrip. As one of the employees helped bring the T-Case over he gave a crooked smile and said "It's all yours". Naturally I felt reasurred...

Once I got home I snapped a couple pics for the before and after

https://drive.google.com/open?id=1syYTbkBYwF_m5TIVLKCsAyKuGO73dA9t

I tore it apart a few a days ago and discovered some good news! Someone had replaced these things with new things! Love it when that happens
https://drive.google.com/open?id=1d5h4DcaFqzujWaiZIQQtqNSkyZ5aimts

I stripped the cases, cleaned, sandblasted, and painted them. I decided to paint the T-Case a "dark forest green". The transmission and the block i'm gonna paint aluminum so it's nice and shiny. I didn't get any pics of some "befores' and some "afters" but you can use your imagination or ill upload the missing links at some point.

BEFORE:

https://drive.google.com/open?id=1AoC1slsE5_wUVHDT9fOR5OkwqvcDNwQA
SANDBLASTED:

https://drive.google.com/open?id=1ovqJU8E-ow-Ph3cAMYpf7GgzxxShItoD
PAINTED (AFTER):

https://drive.google.com/open?id=14gccA4wvkSWJYpdzVO9Kyr0ZuqDIHq2g
Can't wait to get this together, I just need a 32 spline input shaft and i'm all green... ha

 

[Chevy305]

Pics don't work... But happy to see another member in the New England area

 

[Coontail]

Pics don't work... But happy to see another member in the New England area

I'll have to figure out how to get them to work

 

[frankin5]

Follow the links to pictures.

 

[Coontail]

Question! What's everyone else doing with the old 91 computer? I'm getting a headache looking at these wires

 

[Coontail]

Nevermind I got it all figured out now

 

[Coontail]

Got around to assembling the transfer case today, I had to disassemble the whole thing after I got it all together because of ONE snap ring... I don't wanna hear the word snap and ring together ever again

How about these before and afters though!

 

[Coontail]

I bought a mildy built 6.0 and 4l80e from my brother for $1700 a couple weeks ago. It needed a cleaning and a little touch up so I did that today.

More before and afters!













I still have to clean and paint a couple other things but it's looking gooooooood

 

[Coontail]

I've been plucking away at the harness and I've been following Brendan from lt1swap.com's videos to a T and its been working out pretty good! Definitely a lot easier than I thought it would be and I enjoy wiring anyways. I'm going to be using a Littelfuse fusebox as it has a gasket around the lid for water

 

[Coontail]

The harness is nearly done, I got the fuse box wired up and in case anyone is wondering you can use the Delphi 8866 Relays from the OEM fuse box. They should be 30 amp and I think the horn uses one.

I found in the lt1swap videos there are a couple wires that weren't mentioned, the ignition 1 voltage wire ties in with your switched wires so I just put that with my injectors on a 15 amp fuse. I thought I would be able to use the blazers fuel pump relay instead of putting in a relay for it in the fuse box but the way he wires it the fuel pump relay pretty much powers the wholes fuse box... If I worded that correctly lol

There are also two pink wires that came from the neutral safety switch to the c2 connector, after much searching i finally found to delete them so I did.

Hopefully this helps someone

 

[Coontail]

After too long I'm finally able to start working on the Blazer again and go figure, we have a humid heat wave this week in new england

I cut what was left of the old crossmember out with a torch and accidentally grazed the frame a little so I gotta weld a strap there so it doesn't crack

I also installed the ORD Big Block crossmember, it went in fairly easy. The 3 bolts on each side had to be tightened before anything else lined up and I did have to give the engine mounts a couple wacks with a hammer but it's in!

I also split the clamshells and replaced the very broken black rubber mounts with Energy Suspension poly mounts.

I ALSO installed the ORD bolt in steering box kit which was very easy. I realized I forgot to plug the hole to steering box while it was sitting

Tomorrow I wanna get the engine, tranny, and t case in so I can figure out where to move the transmission crossmember and I'll be able to figure out where some lines are go and such.

Maybe tomorrow I'll be able to wake up the bald eagles for the 4th

More pictures!

 

[Coontail]

So good news:



It's in!

Bad news:



Remedied by a torch and hammer:




Everything went smoothly but my only problem was the ORD Crossmember wouldn't clear. I had a good 3/8 on the driver's side the whole time but the passenger side was a constant battle. I even fabbed up some 1/4" spacers for it but still no luck. So I had no choice other than the good ol' hammer torch combo.


The transmission crossmember needed to be moved about an inch and no longer needed the spacers that were there.

Tomorrow I'll be seperating the body to figure out a couple little things then it's ready for paint

 

[Coontail]

The body is now seperate, it went fairly easy




The previous owner had a few engines in and out of this so the fuel lines are mostly already setup and I found out the tank is already setup for an inline pump




Tomorrow's a really good cleaning of the chassis and draining the tank then hopefully I'll start priming and painting it very soon

 

[Coontail]

So I spent all day yesterday day power washing and priming the frame. I still have a bit more to do but the factory paint underneath the grime looks like brand new!.. in some spots

 

[Coontail]

A question to anyone that reads this

I'm trying to figure out a radiator and fan combination and I think I know what I want to do but I just want to make sure.

1991 6.2 diesel radiator with engine and transmission cooler

Ford Windstar fans

This is gonna be on a 73' radiator support as I plan swapping the nose out for the IMO far better looking body style

 

[Abusfullofnuns]

Windstar fans work great, as does the two speed Taurus fan. I've got the Taurus fan wired up through a Volvo relay pack, and used HP Tuners to set up the on points. I very rarely hear the second speed, and that's in the south at well over 100 degree road temps in traffic. My 6.0 runs at 194 all day and night, with the second speed coming on at 197. The high speed is set to come on when the A/C is engaged as well.

 

[Coontail]

Windstar fans work great, as does the two speed Taurus fan. I've got the Taurus fan wired up through a Volvo relay pack, and used HP Tuners to set up the on points. I very rarely hear the second speed, and that's in the south at well over 100 degree road temps in traffic. My 6.0 runs at 194 all day and night, with the second speed coming on at 197. The high speed is set to come on when the A/C is engaged as well.

I've heard nothing but good about them, thank you for backing that up further

What are you running for a radiator? I wanna run the diesel radiator mainly because the tranny cooler and engine cooler is built in but I'm open to suggestions

 

[blazinzuk]

I would run the big block radiator.

The diesel radiator is wider so the Windstar fans dont fit as good. I'd run a complete separate oil cooling system and run the trans through a seperate cooler too

 

[obijuank5]

I would run a big block radiator and use OEM radiator mounts and everything for a clean install. Then use external coolers that are more effective at cooling.
As said earlier the fans fit the smaller radiator better.