1969 Chevy Camaro project car g-machine/resto-mod full story [PART-3]

Posted by admin at 14 February 2016, at 20 : 35 PM

[CLICK-> 1969 Chevy Camaro project car full story [PART-2] is here <-CLICK]

Engine, Engine Accessories, Cooling, and Exhaust:

When it came time to choosing the engine setup, I knew it had to meet the following requirements:

1. Big block (easy power and less common).
2. Around 475 to 550HP, 525-600 ft/lbs torque. Nice rumble but still very street-friendly. No more power than that because I’d have no way of transferring it to the pavement with my street radials and I don’t want spend too much time at the gas pump.
3. Carbureted. Maybe fuel injection later down the road (those Hogan units are gorgeous), but keep it simple for now.
4. Forged bottom end, aluminum heads.
5. At first, I was just going to build my own engine as I have built 2 big blocks before and I enjoyed the process. However, after spending weeks pricing out different scenarios, I realized that it would cost me nearly the same to build my own engine as it would to purchase a GM crate motor. By purchasing the assembled crate motor, I wouldn’t have to worry about clearances and I’d get a warranty for basically the same price.

So it came down to the GM ZZ454, the GM ZZ502, and a few others. At that time, it seemed like a lot of people were using the ZZ502, so I didn’t want to be just another Camaro with that engine, so I decided on the ZZ454. People had a lot of good things to say about the engine, I think it met my needs perfectly, and it didn’t seem so common so I went for it.

After receiving the engine, I did the following to it:

1. Replaced the oil pan and oil pump pickup to fit the 69 Camaro.
2. Painted the engine in high-heat blue to match the color of the car (as best as possible).
3. Ordered the GM ‘Chevrolet’ aluminum valve covers and had them eventually painted with matching body color paint.
4. Designed the engine compartment to be as clean as possible by re-routing hoses and hiding electrical wires.
5. Used a lot of stainless fasteners, hose fittings, and billet pulleys and brackets.
6. Purchased NOS Big block 69 Camaro motor mounts and transmission crossmember to ensure a guaranteed fit.

Other than those highlights, here are the details:

Engine and accessories

GM ZZ454 — From Summit Racing, includes shipping to my door, unloading to garage — $6375
ZZ 454/440 Technical Information:
Horsepower 440 @ 5250 RPM
Torque 500 @ 3250 RPM
Max. Recommended RPM 5500 RPM
Compression Ratio 9.6:1
Block 12550307 Cast Iron – Four bolt mains
Crankshaft 14096983 Forged Steel
Connecting Rods 10198922 Forged Steel
Pistons 10215228 Forged Aluminum
Piston Ring 12523921
Camshaft 24502611 Hydraulic roller steel cam; Lift: .510″ I, .540″ E.; Duration @ .050: 211 I, 230 E.
Timing Chain 10114177 Single Roller
Cylinder Heads 12363390 Cast aluminumer 110 cc combustion chambers
Intake Valves 12366986 2.19″
Exhaust Valves 12366988 1.88″
Rocker Arms 12368082 1.7:1
Torsional Damper 10216339 8″
Flexplate 10185034 14″
Valve Lash Net Lash
Fuel 92 Octane
Spark Plugs #4 Rapid Fire Gap .045
Ignition Timing 4? BTDC

Carburetor — Holley 750CFM, 4160, electric choke, vacuum sec, HLY-0-80508S, Summit — $290
Carburetor Tuning parts — HLY-121-135, HLY-122-72, HLY-122-74, HLY-122-82, HLY-20-12, Summit — $65
Fuel Pump — Holley, Summit, 110 GPH, HLY-12-454-11 — $82
Fuel Pump Push Rod — Comp Cams Chromemoly Bronze-tipped fuel pump pushrod, CCA-4607 — $15
Fuel Lines — Summit Dual Fuel feed line with pressure gauge,SUM-G3120 — Aeroquip 3ft Braided fuel line, AER-FCA0603,Summit — Aeroquip Nickel Plated fuel line fittings, 1012,4032,(2)2005, Summit — $104

Distributor – GM HEI — GM Part # 93440806 — $193
Spark Plug Wires — Taylor Spiro-pro 8mm,male HEI/female socket,73053 — $64
Spark Plug Wire separators — Taylor, TAY-42700 — $15
Spark Plug Wire Billet looms — Billet Specialties polished billet aluminum wire looms, BSP-69523 — $85
Distributor hold down clamp — Summit 400505, billet aluminum with hardware — $21
Grounding Strap Kit(3) — Classic Industries, CA69GS81 — $20
Wire heat protection wrap — Summit, RUS-629110, 1/2″ x 120″ — Summit, RUS-629060, 1/6″ x 36″ — Summit, RUS-629080, 1/3″ x 36″ — Summit, RUS-629150, 3/4″ x 120″ — $79

Pulleys, Brackets — March Serpentine Billet System, BBC, long water pump, Summit MCH-23050 — $510
Power Steering Pump — Summit, Chrome, Saginaw Keyway, Summit SUM340103 — $161
Power Steering Pump hoses — Classic Industries, 71 Nova PS pressure hose, 70254 — $33

Alternator — Powermaster, 100Amp, polished, 1 or 3 wire, Summit PWM-27294 — $130
Belts — Serpentine for Alternator and Power Steering — $28
Starter – Mini Hi-Torque — Powermaster PWM-9000, Summit — $167

Valve Covers — GMPP Aluminum valve covers, Part # 12371244, Ebay — $230
Valve Cover gaskets — Fel Pro, Summit, FPP-1635 — $42
Vacuum caps — Various sizes, Summit, HLY-26-105 — $8
PCV Valve — Summit Billet Aluminum, Summit, SUM-440308 — $19
Breather — March Billet Aluminum, Summit, MCH-9795 — $35
Valve Cover Grommets — Moroso Baffled Grommets, Summit, MOR-68775 — $5
Intake Manifold Vacuum fitting set — Summit, Stainless steel, 90 degree, 3 pieces, PRS-1042, PRS-1052, PRS-1044 — $53
Heater Hose fitting, intake manifold — Summit, Stainless steel, 90 degree, 1/2 NPT, 5/8 hose, PRS-1037 — $26
Heater Hose fitting, water pump — Summit, Stainless steel, 90 degree, 1/2 NPT, 3/4 hose, PRS-1050 — $33
Heater Hose — Local auto parts store, 5/8 and 3/4, about 6′ length of each — $30
Water neck — Summit SUM G3801, chrome, 15 degree — $8
Thermostat — Jet Performance, Stainless Steel, 180 degree, high flow, Summit, JET-10171 — $14
Air Cleaner Assembly — Holley Powershot Air Cleaner Assembly(blue material), 3″, Summit HLY-120-146 — $62
Air Filter Top — Proform, PRO-141-307, Summit — $48
Additional Air Filter — Holley Powershot Air Filter, 3″, Summit, HLY-220-5 — $40
Air Cleaner Nut — Proform “GM” nut — $11
Oil Pan Kit — GM 4-quart kit, Part # 12495360 — $182
Oil pan drain plug gasket — Classic Industries, G8757 — $2
ARP Engine Bolt Kit — Summit ARP-535-9601, Polished Stainless Steel, Hex point — Includes motor mounts, intake, headers, valve covers, oil pan, timing cover — water pump, thermostat housing, fuel pump, distributor, alternator brackets — $110

GM BB 69 Motor Mounts — Ebay – GM NOS big block motor mounts, 3990918 (new # 3962748) — $187
Big Block Engine Frame Brackets — Ebay – GM NOS big block frame mounts, 3980941 L, 3980942 R — $77
Motor Mount Bolts — ARP, Classic Industries AR43315, Stainless, Summit — $14
Bright Blue Engine Paint – 3 cans — Summit, VHT-SP732 (2) — $24

TOTAL — $9687

Cooling System and Hoses

Radiator — Ebay, Aluminum Radiator for BB, with heavy duty tranny cooler — $366
Fan — GM 18 1/4″ seven blade, Classic Industries G8354 — $84
Fan Clutch — Thermal, 3″ depth, big block application, Kragen parts store — $33
Radiator Cap — Summit, Billet Specialties, BSP 75120 — $20
Temporary radiator cap (break-in) — Local auto parts store (lever style for easy pressure release during breakin) — $7
Fan Shroud — GM NOS, Big Block 69 Camaro, Ebay — $95
Catch Can — 18 oz, Summit SUM-300101, polished aluminum — $46
Upper Radiator Hose — Classic Industries, MH106 — $10
Lower Radiator Hose — Flexible, from local auto parts store — $18
Shipping (Summit) (Multiple) — $44

TOTAL — $723

Headers and Exhaust

Headers — Hedman 66001, ceramic coated, Summit, 2″ primaries, 3″ collector — $485

Exhaust system — Flowmaster American Thunder, 2.5″ Header-back, aluminized, Summit — FLO-17129(67-68) doesn’t have long & ugly stainless exhaust tips like ’69 — Comes with DeltaFlow 40 series mufflers — $292

Different mufflers, larger/quieter — Flowmaster 50 Series, Stainless Summit FLO-842551 — Didn’t fit well so I sold on Ebay for $160 — $212 – $160

Header Reducers — Hedman HED-21112, Ball and Socket Flange, 3 in. Inlet, 2.5 in. Outlet, Aluminized — $25

Muffler Heat Shields — Flowmaster Muffler Heat shields, reduce cabin temperature drastically — $55

Shipping — Summit — $21

TOTAL — $930

Electrical and Audio:

Since I have done a number of custom audio system installs in my short lifetime, this part of the project was one of my favorites. Designing the custom trunk panel and amplifier mount setup, subwoofer enclosure, and overall audio system was fun stuff. Designing and installing the various components of the security, electrical, and ignition system was also fun (well, it’s better than bodywork). The American Autowire kit certainly made things easier. A heat gun and professional shrink wrap butt joints were used for all of the wiring where necessary, and the audio system uses professional components and wiring.

The battery was mounted in the trunk for better weight distribution and to permit easier hookup to the audio amplifiers. It also helps to free up some space in the engine compartment and make it more ‘clean’ looking.

Here’s the parts breakdown on the electrical and audio system. The security system details have been left out of course.

Electrical

American Autowire Complete Car Kit – 1969 Camaro — $439
Battery Relocation Kit — $40

Battery to Starter Wire – Taylor 0/1 Gauge, 20ft, premium — Taylor 21540 — $120
Optima Battery – Red-top, 800 CCA — ULT-9002-002 — $135
Billet Aluminum Battery Hold-down assembly — HDBOPT — $105

TOTAL — $839

Trunk, Audio, & Security

CD Receiver – Pioneer, new — DEH-P6800MP — $196
Rear Speakers – Infinity Reference 6X9″, new — 9612i — $71
Front Speakers – Infinity Reference 4″ , new — 4012i — $57
Subwoofer – Infinity Kappa 10″, new — 102.7 — $107
Amplifier 1 – Alpine 4x70W, new — MRP-F450 — $192
Amplifier 2 – Alpine 1x220W, new — MRP-M450 — $129
Wiring – 80ft speaker cable, 17′ 8-guage power, 2 16′ RCA — $75
Misc – Fuse Cases, Battery Junction, Speaker connect — $42
Misc – Battery terminal for 0/1 Gauge + (2) 8 Gauge — $43
Materials – Wood for subwoofer box and trunk panels — $81
Materials – Wood glue, caulk, screws, brackets, port tube — $15
Materials – Spray Adhesive — $11
Materials – Quick disconnect clips, fuse holder — $30
Materials – Spray Adhesive — $13
Materials – Black Spray paint, stainless fasteners — $10
Materials – Fabric for Speaker Box — $23
Materials – Vinyl/Leather + Foam for Trunk Panels — $44
Materials – L brackets and scews for panels and sub box — $22
Materials – Carpet/material for trunk floor — $30
Antenna – Underdash — $27

TOTAL (excluding security system components) — $1218

[CLICK-> 1969 Chevy Camaro project car full story [PART-4] is here <-CLICK]

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