81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

I figure I should just jump right in with a swap thread, If you guys are like me you just want to scroll and look a pics lol. I will however include some information.. so watch out. I purchased my K5 in 2009 for 500 bucks, 350/TH350/NP208, it had been sitting in the desert for 5 years, after some TLC, lift, tires, and a SM465/NP205 swap last year, it's been my wheeling and towing rig. I had a properly tuned Q-jet but even then climbing steep hills made for a pucker situation. Solution LS1 or similar LS truck motor, either way it didn't matter to me, I'm looking for driveability, rock crawlability, and towability.

After much parts gathering, I felt I had enough parts to make it happen so it was time to tie up the garage for a few months. Wife.... not happy!:waah:

http://i137.photobucket.com/albums/q.../IMG_5973a.jpg

http://i137.photobucket.com/albums/q.../IMG_5974a.jpg

http://i137.photobucket.com/albums/q...1/IMG_5988.jpg

http://i137.photobucket.com/albums/q...1/IMG_6002.jpg

http://i137.photobucket.com/albums/q...1/IMG_6018.jpg

Some clean up.
http://i137.photobucket.com/albums/q...1/IMG_6027.jpg

http://i137.photobucket.com/albums/q...1/IMG_6036.jpg

http://i137.photobucket.com/albums/q...1/IMG_6035.jpg

Mock up engine ready to go in, Advance adapters brackets, beef 3/8" thick.

http://i137.photobucket.com/albums/q...1/IMG_6067.jpg

http://i137.photobucket.com/albums/q...1/IMG_6069.jpg

Truck oil pan and pulley clear
http://i137.photobucket.com/albums/q...1/IMG_6084.jpg

http://i137.photobucket.com/albums/q...1/IMG_6087.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

99 F-body manifolds fit great.

http://i137.photobucket.com/albums/q...1/IMG_6103.jpg

http://i137.photobucket.com/albums/q...1/IMG_6104.jpg

I will be mounting my 99-00 f-body PCM inside the cab to protect it from water, mud, etc so going through the 99-00 f-body harness was necessary, and lots of unneeded stuff was removed.
http://i137.photobucket.com/albums/q...1/IMG_5936.jpg

I started by labelling all of the wires that go into the Blue and Red plugs, and also got the pin outs from ls1tech.com.
http://i137.photobucket.com/albums/q...1/IMG_5941.jpg

http://i137.photobucket.com/albums/q...1/IMG_5942.jpg

I labelled and removed all sensor plugs from the harness except the Injectors and coils.

http://i137.photobucket.com/albums/q...1/IMG_5947.jpg

http://i137.photobucket.com/albums/q...1/IMG_5957.jpg

http://i137.photobucket.com/albums/q...1/IMG_5955.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Draping the harness over the mock up motor.
http://i137.photobucket.com/albums/q...1/IMG_6144.jpg

1 Sensor / wire at a time.
http://i137.photobucket.com/albums/q...1/IMG_6168.jpg

http://i137.photobucket.com/albums/q...1/IMG_6169.jpg

http://i137.photobucket.com/albums/q...1/IMG_6170.jpg

http://i137.photobucket.com/albums/q...1/IMG_6171.jpg

http://i137.photobucket.com/albums/q...1/IMG_6172.jpg

http://i137.photobucket.com/albums/q...1/IMG_6173.jpg

http://i137.photobucket.com/albums/q...1/IMG_6174.jpg

http://i137.photobucket.com/albums/q...1/IMG_6175.jpg

http://i137.photobucket.com/albums/q...1/IMG_6176.jpg

http://i137.photobucket.com/albums/q...1/IMG_6179.jpg

2008 L92 water pump & Idler, and a Dirty Digo idler relocation bracket so I can run an LS1 intake.
http://i137.photobucket.com/albums/q...1/IMG_6189.jpg

Slight bit of grinding was necessary.
http://i137.photobucket.com/albums/q...1/IMG_6185.jpg

http://i137.photobucket.com/albums/q...1/IMG_6187.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

The wiring, by far the most time consuming and also the most fun.

At first it seems like adding a few circuits would be no big deal, but it wasn't I found myself having to draw myself a schematic of the engine bay to keep on track. Attached is my current wiring diagram.

Before I started I made a trip to the pic-a-part to get a few needed items, buss bars from early 90's full size chevy trucks, and a 175A buss fuse and mount off an early 2k S10.
http://i137.photobucket.com/albums/q...1/IMG_6264.jpg

The goods, and man wiring stuff is expensive....!
http://i137.photobucket.com/albums/q...1/IMG_6265.jpg

http://i137.photobucket.com/albums/q...1/IMG_6266.jpg

http://i137.photobucket.com/albums/q...1/IMG_6268.jpg

Water proof relay and fuse panel box.
http://i137.photobucket.com/albums/q...1/IMG_6278.jpg

http://i137.photobucket.com/albums/q...1/IMG_6311.jpg

http://i137.photobucket.com/albums/q...1/IMG_6331.jpg

http://i137.photobucket.com/albums/q...1/IMG_6325.jpg

Wiring still needs to be loomed.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

At this point the wiring is completed in the engine bay, all that is left is to loom it up an run the wiring to the gas tank for the pump and tank pressure sensor, as I'm planning to use the evap purge to control my tank venting, I'm still not sure if I'm going to run an f-body evap canister yet but well I will see when I get there. I have modified the stock tank to accept an in tank pump from a 03 3500 truck, it fits perfect. Here it is mocked up with a 99 F-body pump assy. The tank ring kit was from vette works, boil / clean the tank, cut the old ring out to size tack on 4 corners and seal it.

http://i137.photobucket.com/albums/q...1/IMG_6047.jpg

http://i137.photobucket.com/albums/q...1/IMG_6048.jpg

http://i137.photobucket.com/albums/q...1/IMG_6049.jpg

http://i137.photobucket.com/albums/q...1/IMG_6050.jpg

http://i137.photobucket.com/albums/q...1/IMG_6051.jpg

http://i137.photobucket.com/albums/q...1/IMG_6052.jpg

Finally on to the motor, which is what was has been holding up my swap process, When I started the I had a complete minus heads 00 LS1 from an F-body, but after pulling it apart and inspecting the block it was no good, and turned into my mock up block.
http://i137.photobucket.com/albums/q...1/IMG_5925.jpg

So I was monitoring craigslist for a motor and found a complete 4.8, it had a spun bearing, and a chewed up cam, but the block was solid.
http://i137.photobucket.com/albums/q...1/IMG_6053.jpg

http://i137.photobucket.com/albums/q...1/IMG_6058.jpg

http://i137.photobucket.com/albums/q...1/IMG_6059.jpg

http://i137.photobucket.com/albums/q...1/IMG_6063.jpg

Interestingly enough, both of these motors had fram filters on them when I got them.....

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

I have been wanting to swap in the same combo into my 78, but I am wanting the lq9 engine. Was curious on what was needed for it to bolt to the sm465.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Engine details.

• 5.3/4.8 block
• LS1 Crank
• LS1 143 pressed rods
• 4.8 Flat topped floating pistons (bored to fit LS1 pressed rods)
• 862 Heads with LS6 Valve springs.
• Stock 02 5.3 cam(Drivability, Towing & Crawling)
• LS1 Intake / Injectors / Throttle body

From everything I have read and per the compression calculator, I should see about 10.4 compression. I might go with a larger cam in the future but for now with manifolds I'm sticking with a smaller proven cam. I want headers but haven't figured out what route I will go yet and / or which longtubes will fit. Same with the truck intake, I would like to run one but for now I have a complete ls1 with injectors rail etc.

The block got new cam bearings and some cleaning.
http://i137.photobucket.com/albums/q...1/IMG_6208.jpg

10/10 LS1 crank sitting on some clevites.
http://i137.photobucket.com/albums/q...1/IMG_6255.jpg

Ring gaps checked and pistons ready to go in.
http://i137.photobucket.com/albums/q...1/IMG_6368.jpg

Rod journals checked... alll good.
http://i137.photobucket.com/albums/q...1/IMG_6373.jpg

http://i137.photobucket.com/albums/q...1/IMG_6375.jpg

http://i137.photobucket.com/albums/q...1/IMG_6380.jpg

Cam, oil pump, windage tray and pick up tube installed.
http://i137.photobucket.com/albums/q...1/IMG_6394.jpg

Bottom end wrapped up!
http://i137.photobucket.com/albums/q...1/IMG_6396.jpg

Top end work now

Coat of Chevrolet Orange.
http://i137.photobucket.com/albums/q...1/IMG_6340.jpg

Valve lapping.
http://i137.photobucket.com/albums/q...1/IMG_6383.jpg

Exhaust valve before
http://i137.photobucket.com/albums/q...1/IMG_6386.jpg

After
http://i137.photobucket.com/albums/q...1/IMG_6387.jpg

Intake
http://i137.photobucket.com/albums/q...1/IMG_6384.jpg

http://i137.photobucket.com/albums/q...1/IMG_6385.jpg

New valve seals/seats and LS6 springs.
http://i137.photobucket.com/albums/q...1/IMG_6389.jpg

http://i137.photobucket.com/albums/q...1/IMG_6390.jpg

Where it's at now.
http://i137.photobucket.com/albums/q...1/IMG_6401.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Welcome to the LSx club. Looks like its coming along nicely!

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Running a SM465 with a Gen3 is basically the same, there is only a few differences. 1st is flywheel I will be using a NFW1050 $55 bucks at o'reilly is it deeper and makes up the .4 offset and will mount to a standard 11-7/8 clutch. 2nd an LS7 pilot bearing P/N 12557583 to properly support the input shaft because of the .4 difference in spacing between the block and crank. 3rd 5qty M10x1.5x40 bolts to hold the bell housing to the block. Additionally I have a full write up of the SM465 swap attached to the old 350 on my blog http://morecoffee.me/index.php?view=bulletin&blog=74 It pretty much covers it all.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Thanks!

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

How did you get the VSS signal off of the SM465? Have an SM420 I might like to use, imagine the solution would be much the same...

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

The plan now is to not do anything with it, just let my tuner do his thing. I would however like to have cruise ctrl in the future so I will be dealing with it at some point. For the speedo I'm going to use an autometer GPS speedometer.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Nice build! I'm stealing some of your wiring ideas, if you don't mind. The buss bar and lugs are on my junkyard shopping list.

Funny, this:Reminds me a lot of this: :lol:
http://i80.photobucket.com/albums/j1...8/8e5e324f.jpg
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Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Thanks and you can't beat the buss bars for a buck a piece!

Hmmmm.... Now you got me thinkin' I should be able to hit 88 MPH pretty quick with this new motor........

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

More progress today, picked up my head bolts and continued on.
http://i137.photobucket.com/albums/q...1/IMG_6403.jpg

http://i137.photobucket.com/albums/q...1/IMG_6411.jpg

http://i137.photobucket.com/albums/q...1/IMG_6410.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Looking good! :chevy: Nice to see someone painting the heads-- most leave them raw aluminum, but I like the 'sleeper' old school painted look for something a little different. Besides, pretty much everything these days has Al heads, so no need to show em off like a gen 1...
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Edit: by the way, the flux capacitor crack wasn't a knock on your work- I love those movies!

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Thanks, I like the aluminium look but had time on on my hands, and no money in my pocket so I figured what the hell... different is cool!

No offence taken, I love those movies too....... All I kept thinking about when I saw the flux capacitor was... How am I going to generate that kind of power!:lol:

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Everything is now loomed.
http://i137.photobucket.com/albums/q...1/IMG_6419.jpg

In her spot at last!
http://i137.photobucket.com/albums/q...1/IMG_6423.jpg

LS7 pilot bearing installed, the old ls1 pilot bearing did not come out without a fight!
http://i137.photobucket.com/albums/q...1/IMG_6431.jpg

Sachs NFW1050 flywheel. Notice the thickness.
http://i137.photobucket.com/albums/q...1/IMG_6435.jpg
http://i137.photobucket.com/albums/q...1/IMG_6436.jpg

Original clutch and bell housing on. Bell housing bolts 10 x 1.5 x 40. Running a howe hydraulic throw out bearing connected to a Tilton 7/8 master cylinder.
http://i137.photobucket.com/albums/q...1/IMG_6437.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Great progress! You are really flying with this thing. Also, props to another Vegas member! :metal:

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Where is this on the S10?.. I was in the yard this weekend and grabbed a buss bar off the full size, but didint see the fuse block on any of the s10s...

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Great build..that motor is looking sweet..

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Thanks, I had to take a week off work to get the motor built and in, now things are going to start going slow again. This whole money thing keeps holding me up too!

The one I found was under the battery tray.

Thank you.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Put these suckers back in today, This was the original cross member that came with the th350 / NP208 combo, it bolted to the SM465 / NP205 adapter with the same bushings. It moved forward on the frame roughly 2 inches.
http://i137.photobucket.com/albums/q...1/IMG_6450.jpg

Mocked up and tacked the exhaust, I got a 10' stick of 2-1/2 OD from an exhaust shop up the street for 30 bucks, then a few thrush welded mufflers from Oreillys. For the mandrel bends I cut up an old F-body y-pipe, worked out well.

Driver
http://i137.photobucket.com/albums/q...1/IMG_6453.jpg

Passenger
http://i137.photobucket.com/albums/q...1/IMG_6451.jpg

http://i137.photobucket.com/albums/q...1/IMG_6469.jpg

http://i137.photobucket.com/albums/q...1/IMG_6462.jpg

http://i137.photobucket.com/albums/q...1/IMG_6454.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Welded up and ready to go back in.
http://i137.photobucket.com/albums/q...1/IMG_6472.jpg

http://i137.photobucket.com/albums/q...1/IMG_6483.jpg

02 bungs in
http://i137.photobucket.com/albums/q...1/IMG_6484.jpg

I want to just dump them and call it good, but I know better. So after she is on the road I'll probably finish the piping, I want them to come out behind the rear tires on the side if the truck.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

I'm confused....two bungs but on one side...and w/o a cat between them?

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

The rear bung is going to be for my wide band.

After some tweaking, this is how the exhaust will sit.
http://i137.photobucket.com/albums/q...1/IMG_6496.jpg

http://i137.photobucket.com/albums/q...1/IMG_6486.jpg

Some cheap autozone hangers for now.
http://i137.photobucket.com/albums/q...1/IMG_6487.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Made some more progress today, decided to work on the fuel pump and wiring.

What I'm using to pull this off.
http://i137.photobucket.com/albums/q...1/IMG_6497.jpg

http://i137.photobucket.com/albums/q...1/IMG_6503.jpg

This is the vetteworks pump ring, I would suggest not using the aircraft bolts supplied with the kit, because the first time you have to change your pump this might happen, only all of them broke! Looks like I'll be removing the ring and installing some different studs....:metal: Fun!
http://i137.photobucket.com/albums/q...1/IMG_6510.jpg

Module assy is plenty tall enough for the stock tank.
http://i137.photobucket.com/albums/q...1/IMG_6509.jpg

http://i137.photobucket.com/albums/q...1/IMG_6507.jpg

http://i137.photobucket.com/albums/q...1/IMG_6516.jpg

Feels like the further I get to the finish line, the longer everything takes!

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Some good progress yesterday, all fuel lines fabbed and installed, oil pressure sending unit in and fuel tank installed. Hooked up my battery and gave it a go, but the starter I had was junk. After a new starter she spun up and produced good oil pressure. I then put fuel in the tank and let it prime, checked for leaks none, then I tried to start her, but no go, I checked everything and it appears I'm barely getting fuel to the rail, when I open the schrader valve just a dribble comes out. Time to troubleshoot and then wrap up the radiator/radiator support.

Tapped an old ls1 oil pressure gauge for 1/8 fitting.
http://i137.photobucket.com/albums/q...1/IMG_6538.jpg

Sender Installed.
http://i137.photobucket.com/albums/q...1/IMG_6539.jpg

Fuel tank ring reinstalled, along with a 90 for the fuel vent, both of them welded in then sealed with gm engine sealer.
http://i137.photobucket.com/albums/q...1/IMG_6536.jpg

Return loop.
http://i137.photobucket.com/albums/q...1/IMG_6545.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

She's alive!

I figured out my fuelling problem, the fuel pump module does not have a regulator build in, so I'm going to have to change up my fuel loop to include a corvette filter, easy stuff so I made due with some electronics cleaner :)

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Got the fuel issues resolved, added a Corvette filter to set up, had my tuner swing by and do some magic, and she is now running on her own.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Finished up a few things and took her for a small road test a few minutes ago. I'm going to let her cool down, check her over and go for a longer road test.

Corvette fuel filter / regulator
http://i137.photobucket.com/albums/q...1/IMG_6554.jpg

Fuel line wrapped with exhaust blanket by the muffler.
http://i137.photobucket.com/albums/q...1/IMG_6559.jpg

Engine bay pass
http://i137.photobucket.com/albums/q...1/IMG_6567.jpg

Engine bay dr
http://i137.photobucket.com/albums/q...1/IMG_6568.jpg

She finally soaked up some sun today!
http://i137.photobucket.com/albums/q.../IMG_6570a.jpg

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

This is beyond awesome man, Great job! Maybe I'll get the courage to do this some day. Keep at it!

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Thanks and I love you avatar!

I got her out wheelin yesterday for the first time, a nice trail with many obstacles, she ran great, made the swap so worth it! Figured I would post a few vids.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Makes me want a 4x4 to go rock crawling!

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

I like the underhood fuse box, where did you pick that up?

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Nice work! Glad you finally got her running- makes me wanna get mine going. Are you going back with fender flares?
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Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

I had the housing laying around, it used to house an old RV jack control board. I gutted it and added the stuff I wanted.

No the fender flares are out.

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

I was getting tired of taking my laptop with me to monitor my temp, especially when wheelin. So I picked up a 3/8 sender, put my file in the vise, the sender in my drill and took it down until it was the appropriate size for my M12 x 1.5 die. The final product came out good and worked like a charm.

http://i137.photobucket.com/albums/q...1/IMG_6625.jpg

http://i137.photobucket.com/albums/q...1/IMG_6626.jpg

http://i137.photobucket.com/albums/q...1/IMG_6627.jpg

Almost forgot to post up some new wheelin videos from this weekend, 2nd time out since I go her back on the road. It's so much better wheelin with the fuel injection and gobs of power at my disposal. I still need lots of practice not stalling while crawling up obstacles, it's a fine line between not enough throttle to turning into a rock bouncer!

Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

Cool toy! That looks like fun. Almost makes me want a 4wd...
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Re: 81 K5 "Arctic Blaze" H.O. 5.3 / SM465 swap
 

It's always nice to get some love http://www.lsxtv.com/videos/car-feat...-5-3l-upgrade/