Next! Top End Touchup

[XfireZ51]

Now that the front suspension has been rebuilt and re-assembled, I dropped the old oil and some coolant while the car is still on jack stands.
I am going to get the plenum and IH's repainted. While off, I thought I would measure the head ports from GVDs porting. Borrowed a snap guage from Pete and I will be measuring ports at 3 different points, valve bowl entry, secondary throttle plate(where they were), and top. Meantime, I've measured the IH and plenum porting job I did nearly 3 years ago and found it needs to be re-done somewhat. The ports are not as uniform as they should be at 36mm. I almost finished one IH in about 2.5hrs. Ball rolls thru the ports now. One more port to go. Mostly touch up but the ports are looking more uniform. PAssenger side looks like it needs more attention than D/S. Maybe I'll have both IHs done this weekend. Once the porting is done, the plenum and IHs go to the stripper to remove paint and then they get re-painted to visually complement the cam covers.

[Blue Flame Restorations]

Sounds like another good project. Can't wait to see the new paint in person, at Marc's next month.:cheers:

[XfireZ51]

Brett,

I'll try but its gonna be tight. Should be interesting to see how the extra airflow will affect the tune.

[Blue Flame Restorations]

What color(s) are you going with this time???

[XfireZ51]

What color(s) are you going with this time???

Going w silver for top end with red lettering and plenum inset. I'll also use red
ZR-1 splash emblem on air horn.

[Blue Flame Restorations]

Going w silver for top end with red lettering and plenum inset. I'll also use red
ZR-1 splash emblem on air horn.

I'm doing very similar. Stock silver for all with Carter's LT5 coolant pipes and stainless bolts. I like the ZR-1 splash on the air horn.

[rhipsher]

Dom you should paint the top end camo. That would look tough.

[XfireZ51]

Dom you should paint the top end camo. That would look tough.

Maybe a stealth or cloaking paint so nobody can see it

[rhipsher]

Maybe a stealth or cloaking paint so nobody can see it
And when people ask well how does it run with no engine just point to your head and say mental telepathy.

[mike100]

touching up those ports is a lot easier than starting from square one...should actually be enjoyable.

[XfireZ51]

Well the touch up has turned out to be just a bit more. Most of the I/H ports needed help as far as getting a consistent 36mm dia. Now the ball rolls through each port. The pass side needed more work than D/S. The plenum won't need any further tweaking other than smoothing the runner walls. Should be interesting to see what additional airflow does w current tune. Oh and just to show I was pushing it, I have 2 ports with pinholes.
HEY AL!

[ALZR1]

pin holes huh,how thin did you get the surrounding area and when are you coming over?
i hope the pin holes are in the Plenum or the injector housing.

AL.

[XfireZ51]

Al,,

Overall not bad although a larger area on D/S needs help. It's the primary runner and the front bolt hole wall. See you this week. ;)

[Paul Workman]

Well the touch up has turned out to be just a bit more. Most of the I/H ports needed help as far as getting a consistent 36mm dia. Now the ball rolls through each port. The pass side needed more work than D/S. The plenum won't need any further tweaking other than smoothing the runner walls. Should be interesting to see what additional airflow does w current tune. Oh and just to show I was pushing it, I have 2 ports with pinholes.
HEY AL!

I wonder how many hp you'll give up by plugging those pinholes!;) Still hoping you see at least 450 at the wheels before the top end is "finished".

P.

[FU]

No pinholes = not enough porting. Go on and rip them up Dom.

[Paul Workman]

No pinholes = not enough porting. Go on and rip them up Dom.

:-D

Marc says, "If you don't punch through at least once, you aren't trying hard enough!"

P.

[XfireZ51]

I wonder how many hp you'll give up by plugging those pinholes!;) Still hoping you see at least 450 at the wheels before the top end is "finished".

P.

Al creates airfoils from his repairs so he gets more flow. ;)

[LGAFF]

I will say when Al does them you cannot tell someone has been there....

[XfireZ51]

Finished port touch up. Here some pics. I am going to guess there'll be an increase in air flow. I'll probably take these to get stripped
and then to Al for any repairs. The media blasting will help uncover any other weak areas or pin holes.

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0068.jpg

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0069.jpg

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0064.jpg

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0065.jpg

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0063.jpg

[XfireZ51]

BTW, piinhole count is now up to 3.

[Blue Flame Restorations]

Looks good!

[XfireZ51]

Ok. Al has been busy welding up the "pinholes". Should be picking up
"blasted" plenum and injector housings tomorrow and then on to paint.
In the meantime, I borrowed Pete's snap gages to measure the GVD porting on the heads. So here's what I found.
Overall, the porting is pretty uniform. I can see how it was done so as to avoid the "workman complications".
I made 2 measurements, one near the top of the runner, one near the bottom. The average measurements were:

Top: 36.5mm
Bottom: 34.3mm
Mid: 35mm about 2" down the bore

At the very bottom or just before the valve bowl, it appears that not much was removed as I found the porting at a bit over 33mm. Didn't seem to make a difference primary or secondary ports.
Looks like "there's still meat on that bone", but I'll need to leave that for another day. For now, we'll see what a now fully ported top end will do given the larger intake cams and the GVD ported heads.

[Paul Workman]

Ok. Al has been busy welding up the "pinholes". Should be picking up
"blasted" plenum and injector housings tomorrow and then on to paint.
In the meantime, I borrowed Pete's snap gages to measure the GVD porting on the heads. So here's what I found.
Overall, the porting is pretty uniform. I can see how it was done so as to avoid the "workman complications".
I made 2 measurements, one near the top of the runner, one near the bottom. The average measurements were:

Top: 36.5mm
Bottom: 34.3mm
Mid: 35mm about 2" down the bore

At the very bottom or just before the valve bowl, it appears that not much was removed as I found the porting at a bit over 33mm. Didn't seem to make a difference primary or secondary ports.
Looks like "there's still meat on that bone", but I'll need to leave that for another day. For now, we'll see what a now fully ported top end will do given the larger intake cams and the GVD ported heads.

Tojahso! :p

Yep... "Complications"... That's where the flow into the cylinders incudes glycol and Amsoil!:o

Complications lead to knowledge of how to limit flow to just air and fuel without that pesky other stuff.

Dom... I think Uz gonna have to pay for that knowledge - one way or another - to realize what that motor will produce for ya! Those numbers are practically the same as mine, BEFORE I ported the heads. (Knowing where the issues are avoids at least some "complications" w/o compromising the desired flow.)

No ballz no blue chips!! (That thar ball gauge is a 37mm ball down about 20 mm from the top of my head...)

http://i185.photobucket.com/albums/x220/6PPC_bucket/tech%20files/Headporting002Large.jpg

Pete's CNC approach might be one way to get there with the least chance of "complications". But, core shift is a wild card that can result in issues, even with a proven CNC porting...Ask Bob G! (I wonder if Pete's CNC machinist is indexing the machine on the ports of virgin heads before opening the ports up. If so, I can imagine it would be tricky to index the ports of a head that had already been opened up - especially if done previously by hand! I'm not a machinist, but I suppose the head could be indexed from alternative reference points, but the question of uniformity of alternate refernce points comes to mind too.)

Marc and I discussed ways of avoiding "complications" w/o compromising flow. It worked!

Well, if you decide to go mining for the gold that is in that motor, it will be interesting to see how you choose to get there.:-D

P.

[Polo-1]

I hope your are pressure checking for pin holes ;) You will find a lot more with 20psi and water in the jacket....

http://i7.photobucket.com/albums/y292/kpie/DSC08783.jpg

[Paul Workman]

I hope your are pressure checking for pin holes. You will find a lot more with 20psi and water in the jacket....

http://i7.photobucket.com/albums/y292/kpie/DSC08783.jpg

Yep! That includes the IHs too...ask me how I know that.:o

Note weld on inside of IH runner near the coolant pipe interface...

http://i185.photobucket.com/albums/x220/6PPC_bucket/tech%20files/porting10-22-11019Large.jpg

But, with rain, flowers grow. And, Marc pointed out a leeetle problemo in the bowles below the injectors. It's all bettah now; might be worth a couple more ponies...might.:dancing Locobob's method of grinding the radius between the IH and the head while the two are joined...is prolly THEE way to insure the radius is properly preserved making the transition.

http://i185.photobucket.com/albums/x220/6PPC_bucket/tech%20files/porting10-22-11025Large.jpg

P.

[XfireZ51]

Paul,

As I wrote, I am willing to concede the fact that the head porting is not up to today's specs. We knew that when we initially installed the heads altho we only measured it using Pete's ballz. Now I have a better idea of "by how much". And I'm not at a point either financially or time wise to dig into addressing the issue. The top end has been cleaned up and it wasn't a matter of "hogging out" the IHs but removing some of the high points and basically smoothing out the rough patches on the runner walls. The plenum had no problem with swallowing a 36mm ball. I'd say 36.5mm is probably more like it. Its still not a Locobob level job, but it should help. How much is a guess right now. I know what my next motor project will be when I get around to it, but the car is already pretty fun to drive and maybe now with the front end re-done, and top end re-ported it'll be even "funner". We'll see. If anything, I want to install the 3.73s next.

[mike100]

...We'll see. If anything, I want to install the 3.73s next.

Yeah, me too. I ran into a guy on the street who used to have a 94 ZR and he said that 3.73's were his favorite modification. Word has it that a lot of the testing on prototypes had 3.73's and that was the intended ratio for the LT5 before measures to beat the gas guzzler tax figured in.

Between that and headers, I think I'd be happy just to get to that point...I have a couple of other cars to feed also :p

[Paul Workman]

We'll see. If anything, I want to install the 3.73s next.

R U gonna race it at BG? Might be interesting to see what the new trap times are going to be, even if you do a "softer" launch than you might otherwise. That way you'll have a bench mark to see what the gain will be with the taller ratio.

P.

[Blue Flame Restorations]

R U gonna race it at BG? Might be interesting to see what the new trap times are going to be, even if you do a "softer" launch than you might otherwise. That way you'll have a bench mark to see what the gain will be with the taller ratio.

P.


You boys be safe at BG. I don't need anymore ZR1's.

[XfireZ51]

Yeah, me too. I ran into a guy on the street who used to have a 94 ZR and he said that 3.73's were his favorite modification. Word has it that a lot of the testing on prototypes had 3.73's and that was the intended ratio for the LT5 before measures to beat the gas guzzler tax figured in.

Between that and headers, I think I'd be happy just to get to that point...I have a couple of other cars to feed also :p

Mike,

Don't forget I have a taller 19" Z06 tires/rims on mine so the 3.73 will help bringing the "effective" rear axle ratio back to a 3.45 using 17" wheels.

Brett,

Aren't you coming to BG?

[XfireZ51]

Got the "blasted" Top End pieces from Al today. I'll post pics tomorrow.
Super welding job! Next up paint.

[sammy]

dominic , how do you prep your surface to get things ready for paint ????

[XfireZ51]

Here's the top end after AL's welding and blasting.

[XfireZ51]

Top End pieces at paint shop. Going aluminum w red inset and lettering on plenum.

[XfireZ51]

While the top end is at paint, I decided to clean up valley and prep head mating surface for injector housing gaskets. Well wouldn't you know something decides to roll under the starter. Which has me pulling ignition housing/coils and starter. I notice some of the starter connections showing wear and insulation looking brittle and cracking. I have a spare motor I rebuilt and replaced parts including solenoid and contacts. Also pulled coils off ignition housing and reseated everything using dielectric grease. I feel like I was able to pre-empt a starter issue in the future.
In the land of LT-5, its always something!

[XfireZ51]

Found some round stock foam that fits the head ports or IH's very nicely.
Allows you to plug up ports and leave mating surfaces free for cleaning.
Worked great.

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0083.jpg

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0082.jpg

[Blue Flame Restorations]

Great idea, Dom! What color is your plenum going to be?

[XfireZ51]

Plenum, IHs, Coolant tubes etc. have been painted. Just need to have lettering done. Paint is an aluminum silver w red lettering to match cam covers. I was able to install IHs and fuel rails yesterday. Do coolant tubes today before Easter dinner. Should have plenum back on this week and finally take it out for a ride.
I am interested in feeling diff w poly bushings in front end. Also like to see if re-porting top end did anything for SOTP feel. Should have it there for Marc's BBQ.
BTW, my client BNC Auto Body in Schaumburg did the top end and the cam covers if anyone needs a source for paint. Cris does a super job. I'll post pics later in the week.
Meantime, I also have H4 headlamps coming to replace the sealed beams. Should do the fogs also.
3.73 gears are up next.

[Paul Workman]

Plenum, IHs, Coolant tubes etc. have been painted. Just need to have lettering done. Paint is an aluminum silver w red lettering to match cam covers. I was able to install IHs and fuel rails yesterday. Do coolant tubes today before Easter dinner. Should have plenum back on this week and finally take it out for a ride.
I am interested in feeling diff w poly bushings in front end. Also like to see if re-porting top end did anything for SOTP feel. Should have it there for Marc's BBQ.
BTW, my client BNC Auto Body in Schaumburg did the top end and the cam covers if anyone needs a source for paint. Cris does a super job. I'll post pics later in the week.
Meantime, I also have H4 headlamps coming to replace the sealed beams. Should do the fogs also.
3.73 gears are up next.

Good news!

Say...Who, What, Where to get the H4 headlamps?? That is something I've been wanting to do for a while. OH... How $$$???

Hope to see ya in a couple weeks if not before!

P.

[XfireZ51]

Paul,

Here's what I got. =Jeff= has same. Conversion kit.

200mm H6054 H4 EURO HEADLIGHTS WITH CITY LIGHTS

Find them fleabay.

[XfireZ51]

Includes some very nice bling from carter! Excellent work.
Paint work done by Cris Hinojosa at BNC Auto Body in Schaumburg.
Startup should be this weekend.


http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0125.jpg

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0126.jpg

[ZZZZZR1]

Red white and blue!!!!


Very nice Dom!!!!


:salute:

David

[Scrrem]

Very Nice!!:thumbsup:
Rich

[XfireZ51]

Red white and blue!!!!


Very nice Dom!!!!


:salute:

David

Dave,

That's actually aluminum silver. It looks a bit white because of the light. The blue Samcos are leftover from #474. Wasn't sure about them but I think they are just enough to break up and accent the red/silver. Not sure yet.
I actually just "brushed" the crossover coolant tube and then put a couple of coats of clear on it.

[FU]

Looooooooking good Dom.

[carter200]

Includes some very nice bling from carter! Excellent work.
Paint work done by Cris Hinojosa at BNC Auto Body in Schaumburg.
Startup should be this weekend.


http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0125.jpg

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0126.jpg

Dom,
Looking sweet and when you are ready to do those coolant pipes you know where to send them. ;)

[XfireZ51]

Dom,
Looking sweet and when you are ready to do those coolant pipes you know where to send them. ;)

You got it Carter!

[ScottZ95ZR1]

That looks fantastic Dom. I really like the contrast with the center of the plenum and cam covers being a different color. Looks great :cheers:

[Blue Flame Restorations]

BIG thumbs up!!!!!!!!!!!!!!!!! :cheers:

[mike100]

I like the mirror image negative contrasting redstripe/silver stripe effect.

[sammy]

that is the best looking paint scheme i have ever seen .great job dominic

[Ccmano]

Nice work! I may do my next one that way...

H
:cheers:

[XfireZ51]

Nice work! I may do my next one that way...

H
:cheers:

Hans,

Always great to hear from you. U r missed here at the FBI.
Yeah, THAT MAT I'd unplugged but there's another one in the radiator shroud taking up the slack. ;)

[Ccmano]

Good to hear from u too. Wish you guys were closer. Anybody coming out for the west gathering in October in Vegas?
H

[4-cam]

Looks Great, I really like the contrast

[tomtom72]

:thumbsup: Now that's what I call a well coordinated paint scheme! Absolutely great looking!

:cheers:
Tom

[Paul Workman]

that is the best looking paint scheme i have ever seen .great job dominic

Yessir! I agree! (=Jeff= move over ;) ) I just might have to use it as my "deskdop" photo!:thumbsup::thumbsup:

P

[-=Jeff=-]

Yessir! I agree! (=Jeff= move over ;) ) I just might have to use it as my "deskdop" photo!:thumbsup::thumbsup:

P

LOL...


I just need to get some better angle engine shots like Dom..:-D

[XfireZ51]

Finally got the motor started last night. Started w a bark. Actually ran pretty well
but I had set TPS volts looking to then adjust IAC steps at idle. However,
I discovered a vacuum leak coming from the top of the throttle body/plenum interface. It's right by that tiny pin hole in the center behind the throttle body/ coolant passage plate. Pulled it apart last night and I suspect the gasket I used may be too thin to seal properly. When I removed the gasket, there was no "impression" made in the gasket. So it appears that the coolant passage allowed air into the TB area. Leak wasn't "terrible" but motor wouldn't idle below 1000rpm. Hoping to grab a new gasket later today and hopefully that will fix things.

As for the motor paint scheme, thanks for all the great comments. What's incredible about the LT-5 is that it's like a canvas for us to show our own interpretation of what really is an automotive and mechanical piece of art.
;)

[Bob G]

now He will keep his hood shut

[XfireZ51]

now He will keep his hood shut

Hey Bob! Welcome back to the frozen tundra.

[FU]

No more fruit loop's colored engine.

[Ccmano]

I believe we will call it the "Sorresso Stripe" Every FBI member must have one!
H
:saluting:

[Paul Workman]

I believe we will call it the "Sorresso Stripe" Every FBI member must have one!
H
:saluting:

Hans,

I'm surprised Dom chose a RED stripe...I figured it would have been BLUE!;)

I DO like the way it turned out so much that I'm using it as my "desktop"; just don't tell anybody!;)

Wish you could make it to Marc's BBQ next Sunday! Your FBI brothers miss ya, buddy!

P.

[1990 quasar blue]

Hans,

I'm surprised Dom chose a RED stripe...I figured it would have been BLUE!P.

That made me laugh out loud.
Seriously though, great job as always Dom. Your attention to detail in everything I've seen is terrific.

[XfireZ51]

[/COLOR]138267]Hans,

I'm surprised Dom chose a RED stripe...I figured it would have been BLUE!;)

I DO like the way it turned out so much that I'm using it as my "desktop"; just don't tell anybody!;)

Wish you could make it to Marc's BBQ next Sunday! Your FBI brothers miss ya, buddy!

P.

Paul,

I'm keeping the BLUE Samco hoses so I will be
"FAIR and BALANCED".
Right now I am chasing one or more vacuum
leaks. Had a sticking throttle which I think I addressed.

[Blue Flame Restorations]

Dom, it really looks good. I also like the red stripe on the plenum.:dancing

[-=Jeff=-]

I had the red stripe first ;)

http://vettextc.net/ZR-1/10-19-2009/DSC_0131.jpg

[Paul Workman]

I had the red stripe first ;)

http://vettextc.net/ZR-1/10-19-2009/DSC_0131.jpg

Well...now...there ya go again w/ the gorgeous motors!!! I had that picture on my desktop for a while at work. Awesome, =Jeff=!

P.

[XfireZ51]

Ok, it will be officially called the Bartlett Stripe or BS for short. :cheers:



I had the red stripe first ;)




http://vettextc.net/ZR-1/10-19-2009/DSC_0131.jpg

[XfireZ51]

I had the red stripe first ;)

http://vettextc.net/ZR-1/10-19-2009/DSC_0131.jpg

Well not really RED more like candy apple but close enough. But mankind advances incrementally upon the steps of individuals until finally there is a breakthrough.
And so we have the combination of contrasting, yet complementing stripetude that is this:

http://i187.photobucket.com/albums/x198/Z51Xfire/IMG_0126.jpg