jasons LSx/2004r FC Build Thread

[zbrown]

Nice clean fc!

[digitalsolo]

Fuel rail and injectors installed:



Driver side header cut apart and welded back together, it's got the 3" to 2.5" reducer and v-band on it now as well.   I will repaint this with some high temp paint also, just to seal everything up.



Passenger side needs a touch more clearance in the floor pan area and then I will put the reducer and v-band on it as well.   Then I'm ready to build the rest of the exhaust system.   

[digitalsolo]

Okay, not as much progress today since I was tearing apart my FC, but I got a little done:

Pulled dash, relocated the heater hose holes and modified the heater core to fit the new location and installed them with sealed (very tight fitting) grommets.   Filled the old heater hose holes, filled the other A/C hole, and put a grommet around the main harness hole.

I also found a spare FC wiper harness in my parts pile, so that's installed.   Still need to build a close out panel for the factory harness hole and get the wiper harness run though it.  Oh, also swapped to the F-Body throttle cable.



Tomorrow I'm going to hit the yard to look for a few parts and hopefully get started on the engine bay wiring harness tuck.   Assuming I can find a MAP sensor I'll be able to final install the intake manifold.  If time allows I'll snag the engine bay side heater hoses and put them in, try to get the passenger header finished up and repaint both of them so they look a little nicer while I'm at it.

Oh, almost forgot, I drilled the block for the upper alternator mount hole.   Waiting for the tap to get here currently, so I haven't had a chance to tap it and install the alternator yet.

[turbo-civic-si]

its not fair when the LS engine bolts into a MAZDA better than a Chevy. 

[digitalsolo]

LOL, it's funny because it's true. 

Made some progress today.  Got a MAP sensor and some injector connector locking clips and final installed the intake manifold.   Finished the modifications of the passenger side header and painted them both with some VHT 2000* Flame Proof paint.   Also pulled the engine harness loose in the bay to prep for the wire tuck.   Hopefully I'll get the harness tuck mostly sorted out this week and then I can get the fuel system, engine harness and some of the exhaust sorted this weekend.   We shall see.

[digitalsolo]

Little more progress.   Radiator is in on modified Granny's mounts.   I tilted the radiator back and lowered it 4mm to allow a Taurus fan to fit.   Also installed the transmission cooler (it's a big hoss Hayden Tru-Cool unit).  Swapped the crank pulley for an F-body unit.  Finally, the wiring harness is pulled into the interior to start the wire tuck process.   

Tomorrow I'm going to try and complete the wire tuck, and, if it goes well, start integrating the LS1 harness and install the headers.    I need to figure out the radiator hose situation.

[digitalsolo]

Wire tuck completed:

Relocated relay harness/Volvo fan relay:



Completely wired engine/bay:

[spacevomit]

 

[jasons]

Impressive.
Straight out first class work Blake.
-Jason

[digitalsolo]

Thanks guys, I'm trying to work fast, but geeze, those harness tucks are a LOT of work.   I worked on that today from 10 AM to 5:30 PM, and I had an hour into pulling the harness into the interior yesterday.    I am -really- happy I created the harness tuck guide last time I did this though, probably saved me 3-4 hours this time around. 

Tomorrow I'm going to try and finish the fuel system and get the LS1 harness integrated into the FC harness, which should let me put the dash back in as well.    Sunday, I'll get the driveshaft measured, install the fan, final install the headers, get power back in the chassis and try and get radiator hoses on it.

Things left to do (off hand list)

Wire LS1 ECU
Wire fuel pump
Install dash
Radiator hoses
Install/wire cooling fan
Wire oil pressure sender
Install/wire water temp sender
Install shifter
Get driveshaft built/installed
Build exhaust system
Install pinion snubber
Install camber bar
Install brakes
Install bushings on endlinks
Install endlinks
Fabricate air induction system
Modify gauge cluster for electric speedo
Wire voltage/tranny temp gauges
Bleed brakes
Finish tranny cooler hoses
Wire transmission kickdown/lockup
Bleed cooling system
Swap throttle body cam
Build throttle cable bracket
Fill fluids
Check tranny fluid pressure
Bolt check
Test drive
Deliver car
Misc. crap I'm forgetting.

[MDoe8]

Love the wire tuck, well done!

[digitalsolo]

Thanks!

It's worth noting that as part of the wire tuck I removed all the connectors that aren't in use, but everything chassis side that is still there (namely headlights, horns, wipers, windshield sprayers, front/side markers, etc. is still hooked up and should function like stock.   

[digitalsolo]

Finished up the cooling system (minus a couple water pump bolts), serpentine belt drive, tranny cooler, headers, clutch master blockoff plate and a few more odds and ends yesterday/today.   Going to try and finish up the wiring today, and order up the driveshaft flange so that I can get that part complete.

PCM should be back from VATS removal next week, and I'll finish the fuel system tomorrow.    Ordering plug wires, which should be all that's left for it to fire up.   Still waiting on some brake parts to finish that up.

Some pictures:







You can see I still need to fabricate a couple of block off plate for the factory wiring pass through.   Need to do one on the passenger side as well, and the speedo cable hole.

All in all I think it's looking pretty good. 

[jasons]

That is beautiful...I need a Kleenex. 

I love the way those headers turned out. Everything looks very nice.

-Jason

[digitalsolo]

Made a little more progress today.   Found some intake couplers in the garage and mocked it up.   I need to pick up a bandsaw blade to tweak it a bit, but it looks like it should fit well.   Also final mounted the radiator fan, and made some progress on the interior wiring.   I have to do some yard work tomorrow, so probably not much progress then, but Wednesday I will try to get the power to the starter/alternator sorted, and hopefully finish up the dash wiring changes.

After that, I just need to finish the block off plates and I can put the dash back in and test power in the chassis.   The PCM should be back any day, then I just need to install the last of the fuel system, throw some coolant/oil/tranny fluid in it and it should be ready to start.

Getting new front brake calipers since the pins in these were seized HARD.   I have the rest of the brake parts, so this Friday I will get the brake system finished, suspension finished, and, if everything else gets here, see if it can start heating some coolant up, and shortly after, take it around the block.   We'll see.