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Tuesday, May 15, 2018

Trailblazer SS manifold swap with LM7 5.3 truck.

GM let their engineers run and they came up with a better performing intake manifold than even the stock early truck style. I did swap this using parts of the original 2000 LM7 setup. The bare manifold is GM part # 12580420 which I got from Amazon.
TBSS on the right Early truck on the left
       The orginal fuel crossover won't fit over the TBSS manifold. I made some braze on connectors from steel hydraulic fittings. Threads turned off and bored to .500" 3/8" JIC ends interchange with -6 AN fittings
Here is the steel crossover section I cut out.
Crossover connection made with Earl's speed-seal teflon line. I made an Aluminium retainer to hold a 3 bar map sensor in.
I'm using DEKA 80lb injectors which are longer than and the original fuel rails from the truck manifold. Truck rails will work with trimming and spacers. They  need different holes drilled
Oring for the crossover is size 112. It needed changed as it had taken a set and was no longer flexible. I used a Viton Oring
Added a fuel pressure sender in place of the regulator
Installed and running. I used the truck manifold fasteners after removing the rubber washers.
 Running good enough the install and refine the tune...plenty of fuel at the moment
This is what the default Megasquirt Goldbox transmission control screen looks like.

Saturday, February 10, 2018

Fuel surge tank with internal pump


tank from Ebay 5x5x12 with six #8ORB bungs and fittings, it is just less than .100" thick aluminum. Installed a Walbro 450LPH pump inside.
top cut off
5x5x.5 aluminum with 4.00 hole to weld in top
5x5x.75 aluminium for pump and fittings mount
Used a Champion J99 industrial spark plug for a electrical pass thru.
 Bulkhead fitting with o ring for the pump discharge

          lid seals with o ring

 Changed to a different electrical pass thru when the first attempt of using a burner electrode failed. This one is 1/4 steel all thread with a washer brazed on. Delrin bushings and an O ring seal.

Powermaster booster pump repair

Replace vanes, rotor and cam ring. This pump would run but made no pressure
pump parts come out the end after ring is removed
         Drilled a hole to get at an end of the wire ring
        wear plates, cam ring, and outlet only fit one way as they are keyed or pinned
       Vanes had worn enough that one got out and no pumping happened.
          going back together

Sometimes the wire snap ring can be reused, We used a snap ring on this one with some machine work

Saturday, January 6, 2018

Trigger wheel for LS going in Dakota. Tach drive

            Eight space trigger for Dakota tach signal going on the harmonic balancer
 This eight space trigger wheel is used by Dodge on their 5.9's. GM did not do this.
                Plug weld on to the balancer
            There was about .160" clearance from the seal to the balancer. Made the    wheel about .1" thick  for clearance.
                 Puller still fits if needed
          Starting to make the sensor mount, attached to accessory mount.
      Trimmed the Dakota sensor and bolted to new mount. Dakota ECM should be happy with an original sensor.
Wheel and sensor clear all the LS stuff

Sunday, December 10, 2017

Timing mark for LS engine

LS engines have no timing mark. The balancer is not keyed either. We made a pointer and filed a mark on the flywheel to indicate TDC on cylinder 1. Used a piston stop to get two references and filed the mark at the halfway point. Want to verify the engine computer has an accurate input for crankshaft position.

    Timing tab is cut out of a license plate. Aluminium will bend out of the way    without damage to the flexplate if it contacts
         Made the tab with a slot so it could be stored pulled back from the flexplate
        Painted the file mark white.

Traction bars for Dodge Dakota

Patterned after Caltrac, Assassin and Slide a link bars. Didn't use Heim style bar ends because I didn't want the rattle.