The All About My 1980 Pontiac LeMans Station Wagon Thread...

[xpander343]

how much are you going to have to modify the back seat to get it back in?  Or just gonna go with custom stuff instead?   Looking good. 

[motorhead]

how much are you going to have to modify the back seat to get it back in?

If my measurements and planning works out: none.   That is why the front of the wheel wells retained the stock tubs (albeit with a 1/2" added to the overall depth and width).

And in case you couldn't read the cam card:

Serial # D 2961-13    Spec Card# 24966813
Part #   54-000-11         CAMSHAFT, LS1 CHEVY LS1/GEN III '97-UP
Core     C54-11HH          CAMSHAFT BLANK, LS1 1997 UP 5.7 CORVETTE
Grind #  LS1 13158 /13159  HR113.0
                             DURATION @ .050 INTAKE  227  ROCKER ARM RATIO
VALVE ADJ INTAKE    .000     DURATION @ .050 EXHAUST 230    INTAKE  1.70
VALVE ADJ EXHAUST   .000     LOBE LIFT INTAKE       .3560   EXHAUST 1.70
VALVE LIFT INTAKE   .605     LOBE LIFT EXHAUST      .3580
VALVE LIFT EXHAUST  .608     LOBE SEPARATION         113.0
DURATION            .006     INTAKE C/L              110.0
TAPPET LIFT INTAKE   278     CAM ADVANCE               3
TAPPET LIFT EXHAUST  282     HYDRAULIC               Y
VALVE TIMING        .050     OVERHEAD CAM            N
VALVE OPEN INTAKE      3     JOURNAL DIAMETER        STD      2.165
VALVE OPEN EXHAUST    51     RECOMMENDED VALVE SPRINGS
VALVE CLOSED INTAKE   43     DEPARTMENT              P
VALVE CLOSED EXHAUST   1-     SPC INSTR FOR CUSTOMER
                              SERIAL # ONLY ON CAM

And some interesting cam basics: http://www.carcraft.com/techarticles/ccrp_9812_secrets_of_camshaft_power/viewall.html

[motorhead]

So I managed to get some work done over the last few days.  Dropped out the old 7.5", removed the remainder of the rear suspension and pulled the gas tank.  The gas tank was in surprisingly good shape inside and out, it just needed a good cleaning and some paint on the top to deal with some minor surface rust (the bottom is coated in rubberized undercoating).

The hanger is from a 1994 Astro with MFI/TBI.  It fits very nicely into the wagon's tank which is sort of baffled, it is really just too deep and narrow to matter in my opinion.  As such I didn't make a fuel bucket... but, was considering it.

I slightly modified the hanger to ensure good flow from the Walbro 340 pump and an easy return from the Corvette regulator/filter unit.  The hanger was modified by chopping off the feed nipple to insure that it was a full 3/8" ID from the pump outlet to the regulator/filter.   The return line was opened up above the max fuel line to allow unrestricted fuel drain back.  I have had issues in the past where this becomes a problem in higher performance applications as the low pressure return has to overcome the pressure of a full tank of gas (the original return was/is at the base of the pump). There are also two tabs that have to be cut off the top of the sender to allow it to orient in the right direction.

The sender Ohm'd out at ~92 ohms full, and ~2 ohms empty; which I believe is well within spec.

The lines coming off the sender are the factory fuel lines from a 1991 TPI F-body and are 3/8" and 5/16" ID respectively.. . perfect for this application... and also why I bought the Astro sender shown.  The fittings on the end are these: http://www.summitracing.com/parts/sum-220009b/overview/  and will allow me to run -6 AN feed return lines to the filter/regulator (http://www.speedwaymotors.com/LS1-Fuel-Filter-Fuel-Regulator-Kit,41791.html).

Oh and there is an epic amount of wiring harness attached to the sender to make connecting this to the ECM a breeze.

[daveismissing]

purty-  gas tank looks really nice
Playing Jenga in the garage?

[motorhead]

And then there is the rear suspension.

I've had a set of these sitting around for years: http://www.speedwaymotors.com/Front-Weight-Jack,3386.html and finally got around to putting them out back in something.

The hole for the nut was opened up to 1.75" to allow it to slide up and in, the top of the nut sits flush with the 1/8" thick (4.25" OD) plates/washers that I cut.  The idea here is to ensure that the nut remains in compression so as to not pull out of the old spring perch locator.  The top plate and washer are there to stabilize the nut and support any transferred load.  The washer is also going to provide a clean/flat surface for a second project I am working on to tandem onto this work.

Other than that it is all burned in. 

I am going to have new top hats cut for the Vibe springs which are almost 6.5" in OD at the top.  The old top hats will be modified to serve as new lower spring perches at the axle since they are larger there too.

And the best part? If I don't like it I can just go back to running regular springs... no harm, no foul.

[motorhead]

Last pics.

[motorhead]

purty-  gas tank looks really nice
Playing Jenga in the garage?

Feels more like Tetris as the parts keep rolling in... FML.

[motorhead]

I was thinking about getting a set of these too: http://www.speedwaymotors.com/Wehrs-Machine-WM4910S-Weight-Jack-Steel-Jam-Nuts-1-Inch-Coarse-Set-4,65240.html

[Charlief1]

Be careful when you start adjusting them. The course thread ones adjust fast so you need to only turn them 1/8 turn to do the adjustments in most cases. The jam nut may be a good idea but we never had an issue with them moving even on the worst tracks, and some of them were really bad.

[motorhead]

Be careful when you start adjusting them. The course thread ones adjust fast so you need to only turn them 1/8 turn to do the adjustments in most cases. The jam nut may be a good idea but we never had an issue with them moving even on the worst tracks, and some of them were really bad.

Thanks for the advice.  See my next post for my rationale on where the jam nuts come into play.

[motorhead]

Built a little fuel pressure regulator/filter mount with some mounts for isolator clamps.

[motorhead]

And then it was time to make a harness bar.

The reason for this is most every car built before 1990-something doesn't have provisions for today's modern car seats (ie. tether straps and anchors); and who knows the wagon might even end up being auto-crossed from time to time.

It is integrated into the weight jacks and doubles as a chassis stiffening brace (bolted into the wheel tubs).

[motorhead]

When is a vacation not a vacation?  When you are perpetually working on your project, and it starts to feel more like a job and less like a hobby.

I am actually looking forward to going back to my comfy office chair and sipping coffee for 7 hours a day (the eighth hour is spent at the gym... seriously... I get paid to work out - it is pretty awesome).

There is a desperate need to hit the "reset" button here.

[xpander343]

when it reaches a appoint of hours worked in a day, on said hobby, that if was a job, the govt wouldn't have allowed you to work that many hours in a day, because it would be close to slavery?

[motorhead]

when it reaches a appoint of hours worked in a day, on said hobby, that if was a job, the govt wouldn't have allowed you to work that many hours in a day, because it would be close to slavery?

And they'd tax me for the labour too...

Picked up a tonne of parts today, pics to follow soon.