My Build Thread - The stuff actually works

[AZ79K5Project]

Well today was a great day. I pulled the intake completely cleaned both surfaces, checked to make sure the face was flat on the intake. (I bought the intake from CL last year for $50.) Almost forgot - the alternator I pulled off had a 1993 date sticker on it. 15 years before dying - not too bad.

Put some new gaskets in and bolted it back up.

It was very strange. No smoke initially, but then I got heavy blue smoke for about a minute, cleared out, and then a 2nd and 3rd round of blue smoke then it cleared out. I let the thing idle for about 20 to 30 minutes. I ran it and put about 20 miles in it. No more smoke. Normal?????

Anyways - The pics on the left are what it looked like when I bought it three years ago and the ones on the right are today. I bought a POS!!!!!

 

[BGKYK5]

Purdy.

 

[Kenny78]

What methods, sealants did you use on the intake istall? I have only done one and that was before I knew much. Now, reading around has me spooked and that is tomorrows project.

I like the build and especially the bumpers.

 

[AZ79K5Project]

Thanks -

For the most part - dry. I used a couple of very thin spots of RTV - just to hold the gaskets in place while I set the intake on. I mean a smear - no real thickness.

This was my first time around doing anything like this.

I first put in the Felpro and had problems. I threw in Mr. Gasket the second time round.

http://www.partsamerica.com/ProductDetail.aspx?MfrCode=MRG&MfrPartNumber=5820&PartType=102&PTSet=A


Anyone else with info - post up.

 

[supersize75k5]

for the rear and front i just use the rtv, not the rubber piece, I do use rtv along with the intake gaskets on the sides. Ive never had a leak since I was shown this way!

I hate intake leaks and those damned rubber pieces.

 

[MetalGrand]

Wow, very nice looking!

 

[AZ79K5Project]

I finally got to do Martinez Cabin run last weekend with a couple of friends. I was really happy with the way my junk performed.

The only problem was the PCV sucking oil. I thought it was the new intake, but then (DUHHHH) realized I changed the valve covers at the same time. I finally pulled the PCV, but by that time the line was already oil soaked. It sucked blowing smoke in that gorgeous area. I was getting oil splashed up through the baffles.

Fix is in the garage. I bought new valve covers on the way home.

The on-board air rocked. I copied a design from another post (CLICK) for air hoses and air chucks. I can connect two tires at a time to air up or down. Aired back from 20 to 35 psi in a few minutes.

I peeled the bottom edge of the rear diff cover. No leak, but close. I ordered BFW diff cover kits that should be here Tuesday.

Here are some pics:

 

[GsxrMike]

EDIT: I am an idiot...again.

 

[Kenny78]

Try reading his post

 

[AZ79K5Project]

I've got some more stuff done. I replaced my valve covers and all the oil finally burned off. No more smoke.

I got my electric fans in and Blue Torch Fab diff covers on. I screwed those covers up when I welded them up. Too much heat and slight warpage. Garage fix and no leaks.

Cooling Fans





I used a couple of bolts with the heads cut off to hang the dif cover while I bolted them up.

 

[AZ79K5Project]

I got a lot done over the last few weeks. Been doing a lot of work, but no posts.

I installed my pusher fan for the AC and extra relay. The extra relay turns off the pusher fan when the cooling fans turn on high.

I changed my electrical setup as while I was at it. I put a 500A fuse on my winch. A 150A fuse for the accessories

I went from this:


To This:


I tried to do a fiberglass enclosure with circuit breakers. It was great in theory, but I didn't plan the space to well. The existing wires were a little too short to run them in and mount it up. First attempt at fiberglass:

 

[AZ79K5Project]

I also swapped my 94A alternator to the CS144. I upgraded to 8ga wiring and a semi-serpentine set-up from an 86 Monte Carlo.

I cut the vertical tab that bolts to the water pump and welded up a longer piece to raise it up. I also welded a small 1/4" thick metal to the horizontal tab that bolts to the intake.

I used a grade 8 bolt rather than trying to open up the bracket slot. It seems to be working OK.

I also fabbed up the rear bracket and bolted it to the center bolt of the rear of the CS144.

The semi-serpentine belt gives me one more belt possibility. I may install either a york compressor or a welding alternator in the center.

I still have to swap out the pulley on the alternator to a 5 spline pulley.

 

[AZ79K5Project]

Passed Smog and the fans work

I finally got to see if the fan set up was going to work. I sat idling at the smog inspection station for 30 minutes with AC on. The 10" pusher fan along with one of the dual fans running on low kept it cool. It's wired up so the AC pusher fan turns off when the dual fans turn on high. Dual fans kicked on, on the way back home.

The outside temp was about 103.

More importantly - I passed smog!!! First smog test since the Edelbrock intake install. No adjustments made.

HC Loaded - 25 and Idle 35 (220 allowed)
CO Loaded - 0.00 (1.50 allowed) Idle 0.00 (2.0 allowed)

There were three or four workers looking under my hood for the visual inspection. They were pointing talking, pointing some more. Man, I thought screwed something up.

 

[79rustyk10]

looks great, I love that color combination.

 

[stevo_baino]

hey do you mind posting some pics of how your ac rad mounts to the rad support? i'm putting ac in my 77 blazer tht didn't have it before (crazy, i know) and i'd just like some reference cuz i've only worked on 80's trucks before and things aren't as easy to switch over as i thought.

 

[AZ79K5Project]

hey do you mind posting some pics of how your ac rad mounts to the rad support? i'm putting ac in my 77 blazer tht didn't have it before (crazy, i know) and i'd just like some reference cuz i've only worked on 80's trucks before and things aren't as easy to switch over as i thought.

I think I have some around. If not I'll take a couple and post up. Give me a day or two.

 

[stevo_baino]

okay thanks a lot

 

[AZ79K5Project]

Here you go.

This one is a little blurry - best I have.
I used a hole saw and drilled out rubber bushings from an old tire to limit the vibration on the condenser. Each mounting point on the condenser has one bushing.


I pulled the radiator out enough to drill out bolt holes through the top radiator support.



The bottom was secured with a bolt and rubber bushing on the condenser side and two self tapping screws through the lower radiator support.


I had room in between the radiator and condenser to put the tranny cooler.

 

[AZ79K5Project]

I’ve been working on this pig for 11 years. It’s changed just a little over the years.

Changed the carb to TBI - best mod I’ve ever done (engine and trans will be next - time to get modern)

New dash gauges
Hydro assist steering
Updated the interior - work in progress
New wiring / power distribution
Kill switch
Redesigned the front number
Built a custom grill - by the way - I suck at welding aluminum.
changed out the crappy aftermarket electric fans with Windstar fans - haven’t looked back
Changed the alt pulley to put the charging curve to better fit low RPM running - I’ll stay below the alt rpm redline by about 2000 RPM’s at max engine RPM - great mod if you have charging issues at idle or low RPM.

1 ton axles with ARB being built - slowly - but in progress.

 

[AZ79K5Project]

15” wheels with 3.5” backspace looks like they’ll fit the Dana 60 with minimal grinding. So, if you are one that is wondering about grinding brake calipers (like I was) - once you look at what you’re doing, grinding is minimal considering the actual thickness of the caliper.

That will save me a bunch of $$ and cheaper tires every time. Bought one wheel from Summit to test -

Now time to buy the wheels.