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Operation Over Haul


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Old 09-01-2009, 07:32 AM   #1
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Operation Over Haul

I have been working on deleting things from the truck, moving some things around, and just generally making the engine bay look cleaner. Here is what I hope to perform in the next few months (I am only able to work on this during the weekend, so im not in a rush):

Cavi Intake Swap
ASP Performance Pullies
Ac Delete
Possible Powder coating a few things (depends on price)
Frenched Rad.
Relocation of the Battery, CPU, Methanol Injection kit, Fuse box
Painted hood and body kit, other engine componets
Rear disk conversion

Below a few pics of the before and what I have completed:

Rear Disc conversion:



Im waiting on new calipers, so project is only about 50% completed:



Engine Overhaul:







AC Delete:

I do have about 90% of the AC gone, the compressor, condenser and the lines are gone:



ASP Pullies:

I have both the alternator pulley and crank pulley off, but before ASP goes on, there will be a clean up of the front.





Progress on other parts:

Cavi intake swap: Im having issues taking off the stock intake, there still something holding it on, but cannot find the bolt

Frenched Radiator: Havent started on it yet

Relocation: Still thinking of ideas of where to put things

Also turbo is off, still needing to get the flex pipe out, but its being stubborn. Will post updated pics when I find my camera of where im at in this overhaul

Last edited by southernrock20 : 09-01-2009 at 07:34 AM.
Old 09-01-2009, 11:29 AM   #2
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Re: Operation Over Haul

here is those pesky exhaust leaks I keep posting about

the one on the downpipe



the gaskets/ on the left is the one from the flex pipe on the right is from the downpipe





Old 09-01-2009, 08:42 PM   #3
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Re: Operation Over Haul

looks like a good overhaul.

getting rid of that big overflow tank and wiper fluid tank will also free up some room as well. with that turbo in looks like your engine bay can really use some more room.

Last edited by beandip : 09-01-2009 at 08:43 PM.
Old 09-01-2009, 08:49 PM   #4
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Re: Operation Over Haul

I am going to add a smaller overflow tank, and I will have to add some sort of other fluid tank for the methanol/ windshield washer fluid. I was thinking of relocating the battery to the bed and just getting some container and but that container in the bed also. but at the same time, kinda dont want to relocate things into the bed. So ideas are welcome
Old 09-01-2009, 08:57 PM   #5
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Re: Operation Over Haul

i would just put the battery in the bed, idk how well that would work if you put a container in the bed for other fluids(Idk what fluids you would want to put in the bed), think about the time it travels to where ever its going, also will the pump be stong enough to pull the liquid that far?
Old 09-02-2009, 12:02 AM   #6
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Re: Operation Over Haul

Quote: Originally Posted by lee-mill
i would just put the battery in the bed, idk how well that would work if you put a container in the bed for other fluids(Idk what fluids you would want to put in the bed), think about the time it travels to where ever its going, also will the pump be stong enough to pull the liquid that far?

I thought about that, I know that pump is pretty strong, and all the fluid would be is windshield washerfluid with at least 33% methanol in it. Here are a few updated pics: I finally got the Intake off, and by the way, whoever designed this thing needs a complete foot up there butt. And do you guys know the safe way to take the fuel rail completely off?



Also am cleaning up the new cavi intake, trying to make it look like a header

Before:



progress: need to use a little bit harder grit to get the scratches out




And also started on the Frenched rad. about 10% complete


Old 09-07-2009, 03:46 PM   #7
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Re: Operation Over Haul

Here is the progress Iv made so far. I have completed the fitment of the radiator, I just need to polish the edges a little bit. I also about finished with the Ac delete, just needing to get a non ac blower and the ac delete box. I also finished sanding down the cavi intake, I just need to clean it up and paint it.











Old 09-07-2009, 06:18 PM   #8
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Re: Operation Over Haul

nice
Old 09-15-2009, 01:14 PM   #9
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Re: Operation Over Haul

I didnt have alot of time to work on it this weekend, but I did manage to do a few things...I do think I have a problem though. I dont think the cavi swap will work. I didnt realize how far the intake dropped down, and well, I have a flex pipe that goes right there, its not comfirmed, but I dont think it will work. Here are some before and after pics of what I did. I didnt get these things powdercoated, Some things came up and I just dont have the money, I just used alot of coats of the VHT high temp paint. I will proabably tear everything down eventually again, And ill try to get it powdercaoted then...


















Old 09-15-2009, 01:19 PM   #10
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Re: Operation Over Haul

looks good, idk how long that paint will hold up tho, also you plan on power washing the engine bay at all?
Old 09-15-2009, 01:57 PM   #11
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Re: Operation Over Haul

If it holds up, cool, it it dont o well, it was only about 15 bucks. I really dont powerwash, more just hose off
Old 09-15-2009, 02:01 PM   #12
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Re: Operation Over Haul

ahh 15 bucks isnt bad
Old 09-18-2009, 10:52 PM   #13
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Re: Operation Over Haul

just curious (i may sound like an idiot haha) but i'm confused about the methanol MIXED with your windshield fluid. Why would you put 33% methanol in it?
Old 09-20-2009, 09:37 PM   #14
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Re: Operation Over Haul

Quote: Originally Posted by gillzs10
just curious (i may sound like an idiot haha) but i'm confused about the methanol MIXED with your windshield fluid. Why would you put 33% methanol in it?

lol, you dont add it, it already has the methanol in it. When you go to wal-mart or auto zone next time, look at the windshield wiper fluid. Find the kind that as a very low freezing point, ex. Rain X has some with a -33 freezing point and on the side it has a label indicating it has 33% methanol in it. Auto zone brand is cheaper. Going that route is cheaper than buying pure at a race shop, I think its like 5 bucks a gallon compared to like a 1.80 for the auto zone brand. And when you run the truck hard, you suck alot of it. I might use pure when I go to the track, but for daily, windshield fluid FTW.

I did a small bit tonight, what I did was try to fab up a way to hide the wires, let me know what you guys think, wheter it will look gay or what not. Its still far from done, but will give you guys an idea of the direction im taking. ALso the cavi intake will not work, so im going to have to go back to the ole stocker.

Before:




cardboard cut out fab:



before



sheetmetal fab work:








Last edited by southernrock20 : 09-20-2009 at 09:41 PM.
Old 10-06-2009, 07:40 AM   #15
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Re: Operation Over Haul

I havent had alot of time the last few weekends to work on this, but today I got with it and accomplished a few things. I finished fabbing that alum. piece to hide the wires. I placed the computer where the non ac fan will be, just for now until I can get one. I plan on mounting the computer on the alum piece. I also will need to repaint most everything. It seems if you just touch the ceramic paint, it just flakes off, on most applications. I just did a quick mock up of what things will look like.

Before:


Almost:


Done:




Old 10-10-2009, 11:53 AM   #16
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Re: Operation Over Haul

are you keeping heat??

and whats up with the sheetmetal mock up? are you shaving the firewall? or just trying to hid wires?

i always love a good tut build. what kit from dts did you get? stage 1?? pics of intercooler mount? lol
Old 10-11-2009, 02:14 AM   #17
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Re: Operation Over Haul

The turbo builds alot of heat in the bay, I dont know how much it dissipates, but it still gets pretty hot under there. The mock up is for 4 reasons, to hide most of the CPU wires. To better organize my relays, in the pic you can see that I have one mounted and the wires in place for another one. I think I have 3 total. To better place the plug wires in a more organized fashion, and the last thing is to make most of my vac lines coming out of a more centered area, opposed to how it use to be (which was vac lines coming from all directions). Once the hood is on, and some better paint, It wont even be noticable. It is the Stage 1 kit, and I will post pics of the intercooler mount in my next update (should be monday)
Old 10-12-2009, 10:46 PM   #18
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Re: Operation Over Haul

I got a few things done, but I had to quit early because I ran out of sandpaper lol. I predict that next weekend I should get alot of things done. My calipers will be here tommorrow, so I should get all or most of that disc conversion done, and if that happens, then I should be able to get my front rotors on as well. And hopefully, I might get as far as putting the core support back in. But well see. And as far as where the Intercooler mounts, its on the frame by 2 brackets.




I painted the alum where the MSD box mounts, it makes things look alot better, and also connected the fuse box back in



Progress on rad. support





I decided to cut a few holes in the fab work I did, and will add these SS bushings to run the wires and Vac. lines through. they should stand out against a gloss black finish. I also drilled a few holes to mount the plug wires on that fab piece. I hope it turns out good:









I also placed where the Methanol Injection pump will mount:

Old 10-13-2009, 08:44 PM   #19
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Re: Operation Over Haul

not feeling the yellow loom, looks to ricey, but its your ride. Turbo is cool though.
Old 10-14-2009, 08:05 AM   #20
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Re: Operation Over Haul

Quote: Originally Posted by tt85_GM
not feeling the yellow loom, looks to ricey, but its your ride. Turbo is cool though.
Im planning on more yellow entwined with the truck, maybe it will look less out of place the more the truck comes along, but thanks!
Old 10-21-2009, 03:15 PM   #21
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Re: Operation Over Haul

Quote: Originally Posted by tt85_GM
not feeling the yellow loom, looks to ricey, but its your ride. Turbo is cool though.



color'd loom FTL. Also to be honest, not digging the sheet metal, it just looks thrown together to me. Just my opinion.

Look into this stuff, I love it.

http://cableorganizer.com/wire-management/
Old 10-21-2009, 11:25 PM   #22
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Re: Operation Over Haul

do you have any pics of the turbo manifold?
Old 10-26-2009, 05:26 PM   #23
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Re: Operation Over Haul

The brakes look good, but my eyes could not focus on any of the engine pics. Too much stuff going on cluttering up that engine bay. While you are working on it yank off that yellow loom and toss it out. Also not a fan of the sheet metal. Adding a lot of clutter under that hood.
Quote: Originally Posted by southernrock20
Im planning on more yellow entwined with the truck, maybe it will look less out of place the more the truck comes along, but thanks!
No it will still look awful. You are accenting things that should never have attention drawn to them.

Last edited by TA^Guy : 10-26-2009 at 05:35 PM.
Old 11-09-2009, 05:18 AM   #24
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Re: Operation Over Haul

Ok guys, I havent forgotten about this. I have had alot of things going on. A game came out a few weeks ago (Borderlands) so I had to dedicate some time to it (good game by the way) and also have had alot of problems with the truck. It was nothing major, just stupid stuff. But instead of making this a ranting post, I decided to just let you guys know of the progress.

All the major projects are completed in the sense that the fab work and test fitting has been completed. All that needs to be done now is just put everything back together, bleed the brakes, and fill all the fluids up. I need to ask a favor from you guys though. I am having troubles with 2 things:

>putting the injectors back into the intake (i dont want to break them)
> getting the alternator back on ( I cant figure ou how to put that bracket back on for some reason)

I am going to try and have this truck back together next weekend. Running, probably not lol, but everything on, yes.
Old 11-09-2009, 11:28 PM   #25
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Re: Operation Over Haul

Check out the 2.2 section, I seen a how to on injector swap earlier today.
Old 11-20-2009, 10:04 PM   #26
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Re: Operation Over Haul

Its been a little to long for an update, but work has completely reversed my schedule, so its been very hard to work on the truck, but I have finished the rear disc conversion, along with just finishing the front rotor swap to the slotted. No major progress on the bay though. But I am off for the next week, so hopefully alot will get done.

The old rear brakes:



The pre final rear brakes:



The final, completed look:





The old front rotors:




The new semi finished rotors, paint is still drying on calipers and I need a C-clamp to get them on the new rotors lol:



Thanks for all your guys help.



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