Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

I set the engine back in the chassis to see how things fit and it looked pretty good. I couldn't wait to see if the Hydroboost mount bracket I found on Ebay, the P/S pump I ordered from Rock Auto and the hydroboost hoses I ordered from the local GM dealer were all going to play nice so I mocked it up with success.
Attachment 1609875
The newer o-ring style power steering hoses from the pump wont fit into the older steering gear box but I read somewhere that I could swap out the gear box with a 86 K20 which will accept the newer lines. It will also tighten the steering from 4.5 turns lock to lock to 3.5 turns. I picked up the new gearbox the other day and will post install pics soon. Suffice to say it all fit great, only added piece I needed was a new rag joint for the new gearbox since it used a smaller input shaft diameter.

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

The original core support was rusted through in a couple of spots near the battery tray so I ordered a new one a couple months ago. Now that the engine is back in I got the chance to mock it up with the radiator and electric fans that Dad had purchased. Found a few conflicts and I made some mounts to adapt the shroud to the radiator. I also had to drill out the spot welded lower radiator saddles and recycle them to the new core support. Looks like the new core support was set up for a 3 core radiator where this truck has a 4 core.

I made some reliefs on the lower corners of the shroud where the bottom radiator saddles where hitting it and changed location of the fan circuits so they existed the shroud closer to where I plan to mount the relays.
Attachment 1610474Attachment 1610475

Radiator and fans painted and installed. Now I'm into wiring.
Attachment 1610477

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Speaking of wiring, here's a tip that might be useful to some members. If space permits, sometimes it makes life easier to joint the two wires you are soldering with a piece of wire wrapped around the overlap, like this:
Attachment 1610480

Then solder:
Attachment 1610481

Then heat shrink:
Attachment 1610482

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Made good progress on wiring this week. Still much more to go inside the truck but the driver side engine bay is taking shape:
Attachment 1610483

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Great progress! Thanks for taking the time to post and just as importantly photo documenting the hurdles as you overcome them.

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Great idea on holding the wires together I'll have to use that trick!

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Any more updates?

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

A lot has happened since our last post on this truck project. The good news is that the 72 K20 Custom Camper is done. The 2004 8.1L was completely rebuilt and a mid-range Competition Cam installed. I had it dyno-ed in Seattle. 450HP at the rear wheels and over 600 ft/lbs.

Just a quick review. I started the swap in 2014 after acquiring the engine, transmission, ECU and a variety of other parts from a 2004 Suburban. I determined the basic architecture of the new setup - mounts, crossmembers, firewall mods, etc. However, I quickly figured out that I was over my head when I tackled the wiring (New harnesses throughout, new Vintage Air A/C, moved gas tank.) So I shipped it to my son. He is a detail wizard. Thanks to him, the finished product looks, runs and drives like GM did it. In particular, the steering box made a huge difference. It has won a couple of trophies in the Seattle area and now resides here in Wasilla, Alaska where it is lurking in my garage, waiting for clean dry streets.

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Campbel - I'm glad you asked about progress. I've been meaning to update the project thread for a long time, but work just keeps getting in the way it seems. Like Dad said, the cool part is that's its finished and being enjoyed. Makes me pretty happy to see Dad take it to shows and generally having a good time in it. Engine runs real strong and the 8.1 quickly identified a need for a posi in the rear axle (an HO52 no-spin or an axle swap might be in the truck's future). Doesn't take much to light up those tires and driving it around the engine makes it feel like the truck weighs about as much as a Volkswagen.

Here are some more photos of the project in final stages.

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Wow, beautiful truck nice complete build. Good things take time, well worth the wait.

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Really makes me want to get my 8.1 swap going after seeing this one. I can only imagine how an 8.1 will drive in my shortbed 4x4. Also what radiator is that in post #42?

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

The radiator is the original that came in the original truck. Remember, it is a 3/4 T Custom Camper, so it I likely the most radiator that GM offered in its light trucks back then. It has now seen a few miles with the 8.1L and has no trouble keeping it cool. Admittedly, we haven't done any heavy hauling or towing, but I think it is plenty for the job.

Re: 8.1L and 4L85e swap into a 1972 Custom Camper 4WD
 

Oh ok that's what I was planning on using on mine. Now I just have to find a fan that will fit in a factory shroud.