Chevy LT4 V8 Conversion for my Toyota truck

[JTR70]

7/16/18

Sheet metal modifications: Tunnel at shifter

Cut the tunnel back to accomidate the new shifter location and its larger base. Tried the stock lever that came with this trans and as you can see its a bit too long for this much smaller cab; almost like an old rat rod shifter.

Also gets into the steering wheel as its set up for a much wider full size cab. Custom lever for this application in works.


Gutted that lever for the threaded insert and will build to suit. Rear of the tunnel now opened to accommodate the new 4WD selector location.

The difference between now and what was there originally is minimal and they look like they belong together. So glad I moved that rear selector forward.

My stock Toyota leather boots and console damn near fits though the span of these two levers is just a touch too wide to leave as is but it was close.
Moving onto the firewall next.

Thanks for looking!
Justin

[JTR70]

7/22/18

Begin Fire wall modifications


Mocked up both my heater core and A/C evaporator box to see how much room if any to recess the firewall. My worst case scenario was that I'd have to buy a vintage air system and make my own custom dash, vents etc. Much to my great relief I found ample room between the wall and these housings to make the needed changes. This meant I was going to be able to keep the original dash, heater core, blower motor and ALL the stock ducting and under dash works. I can't begin to relay what a relief this was and just how much ceremony this saved me.


The flap that was cut back to make way for the protruding valve cover still didn't reach the heater housing. I knew almost immediately that I'd be able to keep the original system.


Same amount of clearance to other side with the A/C evaporator box.

planning my basic attack.

Began cutting away the wall in and around the A/C housing.


Then a section in front of the heater core.

Cut the bottom of this bowl feature

with plans to raise it up out of the way and hug the A/C box more closely.

Once I get the new section to hug those housings closer that will give the relief I need for the right engine bank.

Big hole to fill but I'm getting my brain around what needs to happen.

Thanks for looking!
Justin

[JTR70]

7/29/18
Mocking up more of the system to check for clearance with the firewall.


Head and valve cover mock up

If I can get the new wall section to run tight against the housings there will be ample clearance.

Take the original relief section and just turn it quicker.

Raise this lower bowl relief too.

Oxygen tube added. Good clearance on this side but rubs the wall on the left. Will alter the tube to clear.

Also mocked up a hardline that supplies coolant to the back of the heads.

Rear shot of it. Have to make sure all this will clear before I start welding new panels in.

Will clear the left side just fine.

Getting it all to fit together little by little.
Thanks for looking!
Justin

[JTR70]

7/31/18
Exit port issues on the left manifold required me to look into headers a little sooner than expected as those cast iron units don't really lend themselves for modification. I have always wanted the header system by SLP. Much to my disappointment the company is still around but they have long since discontinued parts for this old motor.

After some searching I was able to snag this NOS set. Had to step up a bit but this is the system I wanted.

Slightly larger than old cast iron units

but will definitely flow better.

Along with more performance they really are a work of art.

Initial mock up.

Right side fits about the same as the manifold did.

However one of the tube runners does reach back deeper. Have to compensate for this clearance and for heat. Really glad I bought these before I welded that firewall back up.

Left side of course has the same issues as the manifold.

Exits right over the back of the A-arm. Some mild rerouting will be needed but I can at least modify this tube.

I've complicated things more as other mods needed include the steering shaft but we'll get it all dialed in before its over. It will be worth the extra effort for the added performance not to mention they just look nice on there.

Good clearance with the inner aprons.

Continuing on down this rabbit hole. Thanks for looking!

Justin

[JTR70]

8/7/18
Jigsawing the firewall back together.

Taking the original sections that where removed and slightly angling and fine trimming them to clear the head.

Two sections just swing open more for clearance.

Inside view and time to test fit the heater core.

So far so good..

Good clearance remains between the heater housing all the while clearing the motor.

What is nice about recycling these old sections is that I'll be able to keep a mostly unmolested appearance up top with all the corrugation details. That bottom corner though will have to be free styled. Developing that next.
Thanks for looking!
Justin

[JTR70]

8/24/18

Jig sawing my firewall.

Extremely time consuming and tedious chore of shape experiments to fill these holes. Looking for a continuous profile that will clear the header all the while not encroaching too much into the A/C evaporator housing to keep the modifications to it at a minimum. Decided on bending a section over a piece of tubing and now roughing in a flange.

Promising and feeling on the right path as adjustment for better clearance with the header continued.

Dialing it in and Flange shaped a little closer along the way.

It will give me the clearance I'm looking for. Planning the second bend.

Next bend continues contour of the relief all the while tapering back away from the motor.

It clears but that sucker is going to get HOT. I'll have to look into heat insulation on both sides.

Final section on the upper part of the wall was next. Carries a soft turn transition from the relief to the wall.

Keeping an eye of head clearance as it goes.

A shot of the inside shows the excess that needs trimming next.

Thanks for looking!
Justin