Dampner installed using home made tool. The broken exhaust manifold bolt: I have soaked it in penetrating oil for 2 weeks, welded 6 nuts to it (one at a time), and still no luck. last Friday afternoon I started to drill it out and broke a drill bit off inside of it. grrr.... I'll get it.

Earlier this weekend, $2100 in Holley Terminator X Max LS showed up. I ordered it on Memorial day so it was $400 off. I am keeping DBW and also ordered a CAN to USB adapter for tuning (part number 558-443). The EFI part number is 550-927. That is for a 24 tooth reluctor wheel, Multec 2 injectors, DBW harness, the handheld display, and 4L80E control (whch also includes the trans harness). Since kit is for a Gen III LS I know I am going to also need a Gen III to Gen IV knock sensor harness (pretty easy to find for about $20) and I think I am going to need to extend the Cam sensor plug. It does come with an injector harness but I have to re-use the coil pack harnesses. Mine are in good shape so I am covered there.

 

If it makes you feel any better, trying to remove LT1 exhaust manifold bolt in the car. Broke off an extractor in it and had weeks worth of penetrating oil. After 15 or more nuts I finally got one to stick.

 

HAHAHAHA! Yep! Misery loves company!

 

What welding process are you using? I prefer flux core welding for anything that really gets stressed, plus it's better for dirty, rusty and gunky steel. It's also a hotter process than mig, so it gets better fusion and the heat tends to break the threads better.

Last year I went to my brother's house to do something and he had like 3 broken manifold bolts on the LQ4 he was swapping into his OBS. I took my little chintzy Century inverter flux core because my 240V is too big. I remember one gave me trouble. It took me like 4-5 tries. Oh, and he only had a tiny tin can with rusty nuts, LoL.

Sometimes welding a washer first helps. If you can get uncoated nuts and washers, that's the better option. If you could rotate the engine so you are welding downward, even better. Maybe try heating the area around it with a propane torn as sort of a "pre-heating". That way more heat goes into the fusion instead of dissipating and getting sunk into the surrounding area.

 

I think I was doing mig but I may have been using flux.

Apparently the best way to do it is stick.

Also I was welding washers and I actually like doing it that way

 

I was using flux core. At this point, it's pretty well drilled out so I think I just need to try to get that broken drill bit out, then EZout the rest. If that does not work, I'll drill a little more and tap it. I'll take all these hints though; I am SURE this will happen again!

We had a flood in my house this winter and we are just now getting the house put back together. Pretty much allllll my effort is focused on that at this point. That's also why you can see all the boxes in the background of all my pictures. Those are the things that go in my house and rebuilding stuff.

 

No pics but I am close to starting my install. I have been buying parts to prep for install.
A​​​​s far as my 8.1 goes I have bought (I did not buy all these from Summit, but am using their links):
Carter STS1 Carter Replacement Fuel Pump Strainers | Summit Racing For may pickup strainer. It's 100 Micron rated. I have a 10 Micron post pump filter on my shelf waiting to go on as well.
Walbro GSL392BX Walbro High-Pressure Inline Fuel Pumps | Summit Racing Should flow plenty of Fuel for this appplication even if I continue to mod it. I prefer inline fuel pumps since they are so much easier to troubleshoot and replace. This part I did order from Summit. I know there are a lot of fake pumps out there but I am hoping by ordering from Summit I have a better chance of getting a real one. My fuel rail has a factory pressure regulator so I plan to run that. This should complete my fuel system other than the actual lines. I will run hard lines and Nylon lines. I used Nylon on my last Jeep install and loved it.
Chevrolet Performance 10379038 Chevrolet Performance Throttle Pedal Assemblies | Summit Racing Since it was recommended by Holley for the Terminator X Max LS DBW and is a factory part.
Summit Racing SUM-910124 Summit Racing™ Split Lock Bolt Kits | Summit Racing I bought cheapie headers so I need better, locking bolts
Summit Racing SUM-G9011 Summit Racing™ Headers | Summit Racing I REALLY hope these headers generally fit. Once I have the engine in for the final time and I know these don't need any more "mods" they will get sent out for ceramic coating. I plan to run REMFLEX gaskets on them. I also need to add the O2 bung before the ceramic coating.

We plan to move back into our house tomorrow (after 8.5 months in an Airbnb) so I should be able to start wrenching in the next week or two. I won't have it running by the end of the summer like I wanted but hopefully by Thanksgiving.

 

Back in the game. Got my truck all prepped top recieve its new power plant. I have done more work to the truck itself but will focus on the engine and trans here.

When I went to marry the trans and engine, the LS bellhousing bolts were about 1/8" too long.

I probably could have just added a washers but I thought it would be better to cut them. I made this jig and cut about 1/4" off, beveled the tip, and locktite'ed them in.

That worked! So hoisted this beast into it's future home to figure out placement. here it is mocked in place.

After this pic was taken, I pulled it back out, welded the mounts in place and have painted the firewall and chassis.
I trial fit the @Summitracing BBC headers SUM-G9011 and they fit like a glove! I will weld the O2 sensor bung on and ship them out for Ceramic coating this week. I hope to have the motor back in the truck for good later this week so I can start wiring and plumbing it. More details in on my IFSJA.com thread here:
1971 J4000 Chuck McTruck

 

Cool! It's coming along nicely :-)

 

@rang-a-stang,

Awesome project you've got going, and that 8.1 is a perfect beast for a build like this! Great to hear our SUM-G9011 headers fit the swap smoothly. Keep us posted here on PerformanceTrucks—we're pumped to see it come together and can't wait to hear it roar on its first road trip. Good luck with the rest of the build