Builds LS80 Build by Back Bay Customs (1 Viewer)

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Joined
Feb 8, 2017
Threads
38
Messages
346
Location
Portland Maine
Website
www.dogwashetc.com
I purchased my first LC FJ80 about three years ago. I'd been searching Maine Craigslist for about a year for a clean (no rust) 80. I wasn't planning on traveling out of state or having one delivered so I was trying to be patient. Apparently I'm not very patient, I finally found one that the seller had shipped from California about a year prior. It was clean! No rust with the original factory paint still on the frame. However, it was an early model 80 , '91 FJ, unlocked with the much maligned 3FE. Not to mention the interior was completely destroyed from the California UV rays.....yeah it is also the un-tinted version! Sooo it was a mess and I paid more than I should have but the amount of time and blood I would have expended on a rusted out vehicle made it all worth it.

This image pretty much sums up the original interior:
Cracked Pad.jpg

'94 Interior swap:
New Pad.jpg


I bought a '94 FZJ80 about a year after that. This thing was completely rusted out but the interior was pristine! So began the interior swap. And while the interior is out I may as well, do a layer of KnoKnoise, insulation and mass loaded vinyl. I crammed butyl rope into all of the nooks and crannies. Windows got all new OEM gaskets in the front, quarter, and rear glass. Steering shaft seals, shifter seals and many, many other worn out parts were replaced. So with 100% of the interior switched and with the sound deadening efforts my '91 had more of modern feel to it.
Front seat.jpg
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Around that same time a local guy had a 50k mile 5.3 liter L33. The all aluminum vortec with the upgraded internals. L33's came with the 5300HO optioned truck from 2005-2007. He also had a brand new Mark's adapter, Transmission, T-case, pedal and a few other odds and ends. I secured that package and I've been sitting on it for 22 months now. In that time, and since I purchased my 80, I've met quite a few local Cruiser enthusiast's and have made some great acquaintances. One being, @Notch , the chief creator and metallurgist behind Back Bay Customs in Portland, Maine.

Back Bay Customs Tailgate Lid
Rear Hatch.jpg


I actually came to like the 3FE after many hours and monies spent on OEM engine parts and a complete EGR/Smog delete. It still leaked oil and it was powerless on the road...terrible on gas. I get the purest view but if I am going to make this a daily driver and overland machine, I needed more power, better fuel economy, and confidence to be able to take it long distances. The smiles per gallon would be high! It was time for the crew at Back Bay Customs (BBC) to work their magic, to create a thoughtfully built, LS powered, daily driver and adventure vehicle.

So, welcome to my build thread. I decided to add to the V8 swap threads for future reference, to document my 80's transition and for the Ih8mud community. Of course the purist might object .... I'll try to get plenty of pics of BBC's fab work and hopefully some cool video too!
 
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Engine Pull.jpg


52k mile all-aluminum, L33. The L33 is a 5.3L, Gen. 3 small block engine used in GM trucks between 2005 and 2007. Although it is a truck engine, it used cylinder heads closely related to the LS2 and LS6. It came with flat-top pistons for increased compression, and has a unique camshaft. We are going for an industrial machine look with the gray color:
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More progress on the LS80 build! @Notch fabbed some nice meaty motor mounts. The passenger side mount is substantially bigger than the driver side due to the offset motor position. These custom mounts will mate with the original GM rubber bushings which work really well isolating the frame from engine vibrations.


Motor Mount 1.jpg
Motor Mount 2.jpg


For perspective, close up of the mount in hand:
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"I crammed butyl rope into all of the nooks and crannies. "

Could you explain this a bit further? Soundproofing is on my list for the winter.
 
Hello fellow Mainer! I think i used to own the truck rusted out with mint interior! Was it white by chance with a homemade rack?
 
"I crammed butyl rope into all of the nooks and crannies. "

Could you explain this a bit further? Soundproofing is on my list for the winter.
Yeah sure thing @NateMob! Butyl "rope" is similar to other anti-resonance material such as Dynamat. It typically comes in self adhesive rubber (butyl) rectangles that you stick to sheet metal to keep it from vibrating and making noise/vibrations. The "rope" is the same thing but it comes in a long coil. The butyl rope is used to stick into crevices or where two body panels come together. Resonant deadening is usually done at the factory on new vehicles but it dries out and becomes brittle over time and it is prudent to re-apply sound deadening after a few decades.

Second Skin Butyl Sealant Tape – Sound ... - Amazon.comhttps://www.amazon.com › Second-Skin-Multipurpose-Butyl-Rope
 
Love those engine mounts ! 6.0 with manual trans I've broken a few FJZ rubbers over the years. Seems to be better now I have the missing metal covers back on again but those ones look indestructable ! I've got a back bay tailgate lid too all the way out in Australia.
 
Love those engine mounts ! 6.0 with manual trans I've broken a few FJZ rubbers over the years. Seems to be better now I have the missing metal covers back on again but those ones look indestructable ! I've got a back bay tailgate lid too all the way out in Australia.

@ALX4X4 Australia! That is awesome! Back Bay Customs does nice work. Their tail gate lids are solid.
Open lid.jpg
Lid.jpg
 
BBC has been incorporating some innovative design features into my build. I have read many LS builds in the forums and a common issue that folks run into is the oil pan clearing the tie rod and the transmission pan clearing the drive shaft. I could be wrong or mistaken but I believe many people install body/suspension lifts to help overcome these problems. I believe these fitment issues also dictate engine placement. My L33, is the high output truck engine which has the deeper oil pan. Instead of using the f-body Camaro pan, @Notch has decided to retain the original truck pan which has extra oil capacity over the Camaro pan.

The pan was cut to allow clearance of the tie rod. Holes were drilled through the original pan to create a baffle effect when oil is sloshing around during off-road excursions and the custom pan was welded on. Nice touch!
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Great thread! Will be watching exitedly!
I’m contemplating an LS swap down the road and have called a few shops. Any idea what the expected cost out the door is going to be? I’ve been quoted everything from 30 - 75k.
 
Great thread! Will be watching exitedly!
I’m contemplating an LS swap down the road and have called a few shops. Any idea what the expected cost out the door is going to be? I’ve been quoted everything from 30 - 75k.
All depends on what you want. I dont think there's an exact way to price it out. It depends on what they run into for problems and what can be re-used. Are you wanting a used motor or new crate motor? New or used trans, fabbed components or off-the-shelf components, etc., etc., etc. Too many factors, keep shopping.
 
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I have to say in my opinion, after running the stock 5.3 for a bit, it has me wanting either a 6.0 or a step up on the camshaft over the stock 5.3 camshaft. Also just a heads up, the walbro fuel pumps can be noisy. I had 2 different walbro pumps on my 4runner, both were pretty noisy.
I've read that in other threads but hopefully the sound-deadening and mass loaded vinyl I put down will help!
 

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