Builds Brandi: 75 40 + 5.3 + fj60 H42 + splitcase .... build and lots of questions (2 Viewers)

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Great thread was lots of measurements/info/discussion!

On post 15 there is a photo of 2003 C5 Corvette exhaust manifolds. I believe the style others have suggested are the 1999-2000 C5 manifolds, which are different than the 2001-2004 manifolds. I have an LS1 in my FJ40 and those are what was used.

That said, I have removed the manifolds and cut them apart somewhat. I cut the collector flange off and will re weld that where the curved portion of the tubing starts. I will also likely weld it an an angle, but I need to reinstall the manifolds to determine the optimal angle and then tack it.

On an LS swap into a Tucker Sno-Cat, we used some Pontiac LS manifolds and had to mill the flange that bolts to the cylinder head a bit to angle the bottom of the manifold inward for frame clearance. That worked well.
 
For your senders. On the temp sender, just shoot a note with your order the year of your 40/gauge cluster and we can exchange for the appropriate sending unit


 
Looking ahead, need some guidance on parts...

Oil sender:
- what do I need to hook up the oil sender on the LS for the stock Toyota gauge?
I have the stock Toyota sender plugged into the oil cooler delete. It seems to work well.
Temp sender(s):
- what do I need to hook up the temp sender for the stock Toyota gauge? While I assume I also need to keep the ECT sensor for the LS ECU?
Yes the ecu will require the oem sending unit. Mine was in the driver side head. In order to use my stick guages, I adapted the Toyota sending unit into the passenger head. This kinda works, I use it as a vague indication of temp. For an accurate read I use the app on my phone.
Exhaust:
- the manifolds I have use a 2.5" outlet, even if I upgrade to a 6.0 lq4, I can't imagine I would need more than a two and a half inch main pipe and muffler for the main run.
So does 2.5 off the manifolds into a Y with a single 2.5 pipe out the back makes sense? It certainly does if I'm buying the DIY exhaust pipe tubing kit.
I couldn’t find a way to route the passenger exhaust straight back- to much interference with the driveshaft and transfer case. I toured under/in front of the oil pan and back on drivers side.
Fuel pump:
- I am getting a replacement OEM tank as mine had some rust holes. I want to run an in tank pump.
I've read various threads with various solutions of cutting up a GM pump, welding in the flange, getting a complete aftermarket drop-in unit, etc.
Current thoughts from those who have gone down this road, specifically part numbers would be great. Thank you
I really like the Yukon fuel pump in the tank. I didn’t have to weld anything, just make a flange that went in the tank. Not to loud and has been very reliable.
 
@archie73
Thanks
What year/brand/style Yukon pump?
I was just researching them online, some have a plastic top some have metal tops, etc. the depth was okay or was it adjustable?
I followed someone else’s advice on this and used a 2003 Tahoe/yukon pump. It initially looks to tall, but the body is spring loaded. It will adjust to the stock height. It has a plastic top with flange. I made a set of rings (1 inside, 1 on top) to clamp the flange to the tank.
 
Some updates, motor, trans and xfr are in.

The champion LS radiator arrived and I wound up moving the radiator support down two and a half inches and towards the passenger side two and a half inches.
I modified the bottom driver side to give it as much clearance to my Saginaw steering as possible.
This allowed the lower hose to clear the stock LS mechanical fan and It also almost perfectly lined up with the stock shroud. I just have to increase the opening for the larger fan and extend the shroud to cover half the fan.

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Also to note, I didn't get the summit exhaust manifolds posted earlier in this thread because I thought they look nearly identical to the Camaro manifolds I already had, so I got the Corvette manifolds mentioned to try something more different.

The 97-04 Corvette manifolds do not work at all with the Advanced Adapters engine mounts.

See pix.

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I ran into that problem when I installed a 454 into my 40 decades ago. The blk hugger headers dumped on the frame mount. I moved the frame mount forward and extended and reinforced the blocks mounting plate towards the rear. The rear motor mount bolt became the front motor bolt.
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Lots happened since the last updates

- 2010 Camaro manifolds modified to clear clutch slave on passenger side and driver's side was angled inward and rearward. I love that you can easily cut and weld and modified these manifolds.
- Stainless diy exhaust tubing kits arrived. 2.5 in before the Y pipe into a 3-in out the back. This is the next project.
- rustoleum regal red rattlecans laid on the inside of the tub, I started just to do a color check and then just decided to keep going LOL.
It is way too glossy for me I'm researching how to put a matte clear over it.
- ordered and installed a custom clutch slave hose
- modified the stock 2f fan shroud to work with the stock LS mechanical fan. Had to open up the diameter a couple of inches and extend it towards the engine a little bit to cover half the fan
- easily found a couple of radiator hoses that worked with the LS fj40 radiator at O'Reilly's, both are simple 90° bend hoses. I got a 90° thermostat housing (and new thermostat) and pointed it downward to make the lower hose easier.

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Can you post the part numbers for the upper and lower radiator hoses you ended up using (to help others in the future)? I ended up going to my local parts store and matched up hoses as best I could with a piece of bent welding rod, but I never wrote down the part numbers. I searched all over here and came up with some mixed answers but never found one post that had both. Ended up having to cut/splice my lower with a piece of exhaust pipe to make it all work, so I’d love to see how you ended up doing yours as well.
 
Good call, I meant to do that and post all the pertinent information, but life got in the way.

upper rad hose gates 22827
lower rad hose gates 22692
Generic Amazon housing, but Mr Gasket makes one from summit that includes the thermostat

This only works because I moved my champion LS swap radiator down 2" and over to the passenger side 2" to center it all on the stock shroud and stock LS mechanical fan. And I added a 90° adjustable thermostat housing to the water pump that I pointed straight down.
Obviously the stock hoses are longer and were trimmed to fit. I just picked those pieces based on their diameters and having a section somewhere that had the bend that I needed.

I have to look up what thermostat I wound up using as it was a PITA with the early 5.3 WP, it normally uses an integrated housing/thermostat, and ones that were commonly recommended didn't work, and I didn't want to change the WP to the newer style.

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Good call, I meant to do that and post all the pertinent information, but life got in the way.

upper rad hose gates 22827
lower rad hose gates 22692

This only works because I moved my radiator down 2" and over to the passenger side 2" to center it all on the stock shroud and stock LS mechanical fan. And I added a 90° adjustable thermostat housing to the water pump that I pointed straight down.

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Nicely done. I might steal this
 
Good call, I meant to do that and post all the pertinent information, but life got in the way.

upper rad hose gates 22827
lower rad hose gates 22692
Generic Amazon housing, but Mr Gasket makes one from summit that includes the thermostat

This only works because I moved my champion LS swap radiator down 2" and over to the passenger side 2" to center it all on the stock shroud and stock LS mechanical fan. And I added a 90° adjustable thermostat housing to the water pump that I pointed straight down.
Obviously the stock hoses are longer and were trimmed to fit. I just picked those pieces based on their diameters and having a section somewhere that had the bend that I needed.

I have to look up what thermostat I wound up using as it was a PITA with the early 5.3 WP, it normally uses an integrated housing/thermostat, and ones that were commonly recommended didn't work, and I didn't want to change the WP to the newer style.

View attachment 3908114

View attachment 3908115

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Quoting again.

I did the exact same during my mock up thanks to this post. Moving the radiator helped so much for clearance on the hose.

Ordering a thermostat housing next.

Which one did you order? It looks like it will work perfectly.




——— Edit : just slowed down and read you had the Amazon one.

Thanks again for the info.
 

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