There is no easy way out of any project once I start tearing things down. But a 3800 is unique, functional, free. Almost every mod I have to do to run the 3800 is needed for the future N* swap too. The exhaust manifolds is one that would not be, so was hoping to can something off the shelf here.

I was also toying with the idea of reversing a set of stock manifolds and hiding a turbo somewhere.

Something about the prospect of getting to park a GMC K2500 inside the intense meet...

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

At this point you will have to hire somebody to drive one of these things to the Intense meet.

_________________

-Ryan
2004 GTO....LS1, LSA supercharged 525whp, 6MT
96 SSEi...September 2010 COTM........GONE
04 GTP comp G.... December 2015 COTM........GONE
2013 Audi Allroad Quattro

What about small snails on each manifold?

_________________

I do have a pair of garret T25's just sitting here.

But I'm more leaning towards DIY long tubes.

Edit:
Because snails means tuning, which leads to a whole new mess of things to figure out like an OBD-2 conversion, getting correct TCC lockup strategy using only the speed sensor, wideband tuning, and realistically a set of series 1 L67 rods/pistons (and re-balancing), and then it's not just dropping in a motor.

Long tube headers are a few hours of cutting and welding.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

I think that truck would look good parked next to the Blazer at the Intense meet haha.

_________________

-Nick
'95 Grand Prix SE coupe 'Black Betty' gone but not forgotten- my 1st love
'99 Olds Alero GX Coupe the get me by beater- sold
'03 Bonneville SSEi 'Gina' Feb. '16 COTM | 35% tint | smoked tail lights | boat roller mount | carbon fiber accents | Silverline exhaust tips
Ziebart rust protection & undercoating | CompuStar Accustart | LED interior lighting
Intense shift kit | Intense FWI | 3" ZZP downpipe | RDI headers | 3.4 MPS | Autolite 104s | 180 deg t-stat | custom tune | ZZP high flow fuel filter | alum coolant elbows and LIM gaskets | much more to come…hopefully
'15 Buick Regal 2.0 Turbo AWD 259 HP | 10k miles | 2-way remote start | undercoating and window tint to come
'98 GMC Sierra SLE Z71 4x4 | 112k miles | S&B intake | garage ornament | more to come

I've managed to once again forget to take pictures, I haven't done anything to make new progress but I did get some new parts in last week. The radiator support, one newer fender that doesn't have a huge dent in it, and the wheel well liners. Ball joints, shocks, and rear disc brackets are also here.

goal for this weekend is to finish stripping the front end down, and prep for rust repairs.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

Here's the new fuel pump/sending unit setup:


It's the FI C3500 sending unit. It normally uses a low pressure fuel pump. Turns out, the fuel pump originally used on the '86 3.8l SFI engines is an exact drop in, with the 40psi needed to run the 3800/Northstar.

Of course, there are two of these buggers... Still working out the OE method for switching the pumps.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

HAHA This would be awesome at the Intense meet!

_________________

'93 SSE "Guinevere" RIP 1993 - 2019
'01 SSEi "Chloe" Mods: Intense FWI | GenV | WBS Intercooled | 3.2 MPS | 1.9 YT Rockers | SSAC Headers | N* TB | TEP Trans | 3.29 FDR | Torsen LSD
DTM Tuned | Dual AeroForce | Solid Mounts | 255 Walbro Pump | Fuel Logs | GXP STB & Sway Bars | CSS Lowering Springs | GXP Brakes | Disabled DRL
Magnaflow Mufflers | Magnaflow Cat | GXP Seats & Trim | 35 % Tint | Cleared & Tinted Tails | repinS Retrofited Morimoto Mini H1 | 19" GT500 Wheels
'09 G8 GT "Abigail" Mods: Rotofab | LS3 Heads, Intake & Cam | Kooks LT | Solo Exhaust | Tien Springs w/ GXP Struts | Whiteline Swaybars | BMR Subframe Connectors
Achievements: Guinevere - 264k mi | 16.27 @ 84.10mph | March '11 COTM :: Chloe - 223k mi | 13.85 @ 102mph | January '09 COTM :: Abigail - 192k mi | 12.85 @ 112mph

Haven't updated this in a while. I'm getting to the point where I could fill a room with all the parts.
-All new shocks (6 total)
-New front ball joints
-New fuel tanks
-New fuel pumps and sending units
-New NiCo brake line
-Calipers for rear
-Rotors for rear
-Brackets for rear
-Axle seals and differential cover gasket
-VSS pulse generator for PCM
-Adapter plate for corporate metric bolt pattern (engine) to chevy (trans)
-radiator support
-wheel well liners
-1 fender

Things I'm still needing for this portion of the project:
-body mounts (will use the same setup that I used on the LeSabre)
-nylon fuel lines
-adjustable proportioning valve for rear brakes
-wheel studs

Now that the weather is warming up I have more motivation to get some of this stuff done again. Also the driveway is crowded.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

Ended up finding some more parts!
-both battery trays
-OE replica grille
-new fuel tank brackets and straps
-new headlamp covers

That should take care of all the broken exterior plastics on the front end, I already have new side markers, and all of the body parts except the one fender which I plan on fixing the rusted off mount point. Battery trays were kind of a bonus, and now I can reclaim that angle iron from the one I made for another project.

The only down side is the new grille doesn't have the GMC badge on it. But that gives me some opportunity to try and make a more modern GMC badge fit in it's place.

One of the things I'm working out now is how to replace the shifter linkage with a modern cable. This would allow me to use the 4L60e shifter shaft that let's me use a neutral safety switch. Looks like all I'd need to do for that is put a bracket on the end of the column. I've got the old cable from the SSEi console shifter so I'm going to see if that will fit. The other advantage to a shift cable is that the linkage was pretty worn out so I'll regain use of all 7 detents and never have to worry about it again.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

It's about time I got a real update going here. Spent some time this weekend continuing the tear down process, and finding out that it's a good thing that I did. The drivers side universal joint on the front axle had spit out all the needle bearings on all 4 pivots. It was basically flopping around in there, not sure how it never broke. This might mean that I have to get a new axle shaft though, I won't know until I get them apart to see if any damage was done to the yokes.

This is one of many reasons why I hate drum brakes. The drums never fail to fuse themselves to the hub:


Found out why this drum would always hang up whenever it was parked for any duration, much of the hardware was rusted off:


Once I got the drums off, which took a whole tank of MAP gas and a 12lbs sledge hammer, I moved on to something that would be less of a full-body workout. Front end disassembly! The front upper ball joint was holding on by hopes and dreams. Which also meant that even with an impact it would just spin in the housing. So I used the cutoff wheel to split the nut, and a prybar to jamb the ball joint into the knuckle so it couldn't spin while I hit it with the impact. Result:


And the front end is mostly disassembled:


And a size reference picture, that's an H-body drum:


And all the ball joints are off!


Next up, the differential. I need to remove the rear axle shafts for the rear disc conversion, I have a 14B semi-float rear, so I have to remove some stuff in there to get the axles out. Additionally I've had some concerns about backlash. So once I got the cover off that's the first thing I checked. So here's the kicker: There is no (excessive) backlash between the pinion and ring gear. In fact I would never have believed that there was 300k+ miles on this thing.. Very smooth, almost perfect condition. What I am finding however is that the differential (between the spider and side gears) is where there is some play. Further investigation is required, but overall I'm not as concerned that this is going to turn into a can of worms as I was before.


There are a lot of seals and stuff that are just destroyed. The front brakes, which only have at most 6000 miles on them, are completely shot already thanks to the lack of functioning rear brakes. So that's two more rotors, loaded calipers, 32 new lug studs, front axle/hub seals, pitman to steering arm links, steering damper, front wheel universal joints, new motor mounts and trans mounts, sway bar bushings, and I'm sure there will be more.

Task for the next few days is to continue removing brake and fuel lines, then cleaning all the grease and rust from the front end.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

This looks like so much fun, it makes me think that I might want a truck instead of a motorcycle next.

_________________
Tyler

2002 Galaxy Silver SSEi "Silver Shadow" 181, xxx miles- DD, tinted taillights, 10000k HID low beams, GXP strut brace, carbon fiber overlays, GXP door bezels and vents and Aeroforce Interceptor Gauge, cleared corners, drilled and slotted rotors, painted calipers, Intense Stage 1 Performance package, smoked door reflectors.
2001 Galaxy Silver SE 119, xxx miles- RIP
2007 White G6 Economy 96, xxx miles- Wife's car, carbon fiber inserts, tinted windows.

As much as I love doing this stuff, I'm learning to hesitate to tell other people it's fun, though that doesn't make it any less fun for me.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

Makes me pine fore my 88, which has the terrible half antilock system that was an option . Brakes were terrible the whole time I owned her, and I had them rebuilt after they blew out on me as I was about to jump on the freeway! Otherwise simple and luxurious, I had a Sierra SLX.

_________________
Roads... Where we're going, we don't need roads

Got the front end stripped down to the frame today. Ready for cleaning!

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

The mad welder in action.......
http://youtu.be/KKvSu-rPecc

_________________

-Ryan
2004 GTO....LS1, LSA supercharged 525whp, 6MT
96 SSEi...September 2010 COTM........GONE
04 GTP comp G.... December 2015 COTM........GONE
2013 Audi Allroad Quattro

It's all cleaned up! Next step is some bedliner on the parts exposed to the wheel wells

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

Made a little progress, I had to chase down a few things though and that didn't help me get anything done.

Got the ends of the rear axle cleaned up and the rear disk brackets installed:


And also stripped everything from the rear frame to get it ready for the POR15 treatment:




There's some heavy stuff i need to chip off first, but the frame is all surface rust. Plan is to replace the rear springs and shackles in the near future, too far gone to bother with them. Brackets look okay, but may need the rivets drilled out and replaced with bolts. Exhaust hangers are beyond repair.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

Going full restoration now? I love these projects

_________________
Ryan

2003 Bonneville SSEi - The Black Mirror SOLD!
2002 Bonneville SE - The Mutt Complete 2004 SLE interior, drivetrain, and body harness swap, ECC swap, HUD swap, black GXP wheels, GXP headlights and tinted tails - SOLD
2003 BMW 540i M Sport, 2001 BMW X5 4.4i, 2010 GMC Acadia, 2017 Grand Design Imagine 3150BH
1982 Cutlass Supreme - The fun one

I had a lot of fun today with scrapers, wire brushes, sanding disks for the angle grinder, a 4 inch wide paint brush and the POR15. Messy, messy, messy. But I'm interested in seeing how well it holds up. I had 1 quart, managed to put down 2 coats and still had leftovers. I wasn't able to get everything coated on the frame though, the bed will have to come off for that and I don't have any intent to do that this round.

I'm interested in seeing how well this holds up, and if I have to re-do any areas. Also, making progress on the rear disk brake setup:




Having fun with the sway bar:

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67