6.2L L94 & 6L80 into my 1992 Blazer

[Nak]

Dropped her off at Get Bent Exhaust in Portland today! Getting a true dual, stainless steel, mandrel bent, crossover pipe behind the transfer case, dual tailpipes out behind the passenger side rear wheels, Dynomax VT mufflers, front and rear O2 sensors. Hoping to have her back on the 11th. Here's the before pics...

 

[YukonXL04]

Wow. Great work man. I would love a 6.2 6spd combo in my 04. Keep it going and keep us updated please

 

[Nak]

Thanks! I'm out of the country this week all the truck is in the exhaust shop so nothing is happening. Next week hopefully will get her running!

 

[yukondoit]

How the hell did I not see this thread!? lol
Your truck is going to one bad mofo! Can't wait and good job on the build and with the pics and updates.

 

[Nak]

Thanks!

Well, things are going to stay stalled for a while... Went to pick up my truck today; unfortunately the exhaust was not what it was supposed to be. The owner will be back tomorrow; hopefully he'll make it right then.

 

[Nak]

And the exhaust is done! You can't see the crossover in the pics, but it's there behind a crossmember. The crossover is band clamped on. I'll have unions installed once I'm sure I'm happy with the exhaust after it's running.

 

[Nak]

I could never do this for a living, I am so damned slow! LOL.

Finished the transmission cooler. Factory hard lines to AN -6 fittings with an Improved Racing 165 degree thermostat and a B&M 30K cooler. Plumbed through the factory in radiator cooler. I wasn't going to use the in radiator cooler, but after a bunch of research I changed my mind. You can see I'll be doing the same with the engine oil cooler. (AN -8) I'll be using the Improved racing low profile 185 degree thermostat for the oil.

 

[Nak]

Getting there bit by bit...

Installed my PML rear diff cover. Mounted the 2001 corvette fuel filter/pressure regulator. Modified my 2 wire alternator into a 4 wire alternator. (Computer controlled to standard voltage regulator.) It's basically a brand new 160 amp alternator, so well worth modifying over buying a new one.

I had to send my harness back to Motech to swap for a new one. The one I had was just too short between the engine and the ECM. Motech was very good about swapping the harness, especially when you consider I bought it months ago. Also, I'm having them modify it with breakouts for fuel level, vapor pressure and Evap purge control. The stock harness has pigtails for the latter two, but I want them to break out near the ECM and run the wires along the frame rail. The stock Motech has them coming out the rear of the trans wiring. That's fine for single exhaust, but it would go right over both my crossover pipe and the driver's side exhaust tailpipe where it crosses to the passenger side. So it'll be a week or two till I get the harness back.

I placed the 2012 surge tank. I'll have to zip tie it down until I get the custom AC hoses done. Still trying to decide what compressor I'll go with.

 

[Nak]

Oil cooler done. I was worried intitially that the thermostat wouldn't clear the front drive shaft, but there was plenty of clearance. Also got the front fuel line run. Up the frame rail and around the brake booster to keep it away from the exhaust. That's the last i'll do until I get my harness back from Motech.

 

[Nak]

I got some questions about the alternator mod. The 2007+ alternators are computer controlled. You can identify them by the two wire connector. I'm sure it's possible to hook them up to computer control, but I've not seen how and why bother? Just get a voltage regulator for a 2004 Silverado and replace the two wire voltage regulator. You'll have to do some cutting with a dremel, but no big deal. I used this guide: http://www.trifive.com/forums/showthread.php?t=116343 My 2012 motor came with a 160 amp alternator with just 5 miles on it. Useless to me with the two wire connector. But 30 minutes of work and it functions just like a normal alternator.

---------- Post added at 11:40 PM ---------- Previous post was at 10:20 PM ----------

Wow. Found this regulator. Fits the late model alternator while only modding the plastic cover? http://www.aspwholesale.com/index.php?_a=product&product_id=1696 http://www.langemachinery.com/Auto Articleshow.asp?ArticleID=22756&xx=QDQX http://store.alternatorparts.com/d3579--.aspx Voltage regulator D3579. Looks like a much better solution.

 

[PavementPounder]

I cannot wait to see a video of this bad boy running! Great job and great thread on the progress!

 

[Nak]

Thanks! Yeah, I'm getting anxious myself! Once I get the harness back all that's left is new fuel tank wiring, new fuel tank, fuel lines from tank to fuel filter mount the ECM and install the intake. I'm out of town till Wednesday, I really hope I have a harness waiting for me then!

 

[Nak]

The harness should ship 2nd day air on Monday... Waiting is killing me!

 

[NTYHOE]

Just registered so I could subscribe to this thread.
Planning on doing the same swap to my 99 in a couple of years.
Great job so far!

 

[Nak]

Thanks! I'm getting very antsy to get this thing running!

The harness finally came fro Motech! Unfortunately, I'm now gone on a work trip for a week, then I have to do the wiring on our remodel. The earliest I'll be able to work on the truck will be the 14th, but I might have to go on another trip by then. So, possibly the 20th or so before I can get back to it. Frustrating, because I should be able to get her running with about two days of work...

 

[Steveman2000]

Just like NTYHOE I just registered to keep track of this amazing write-up. I've got a 95 2dr that I want to do this exact same thing to. Sadly it'll be a few years though.. (college is expensive) Hope you get everything sorted out soon!

 

[Nak]

Thanks! Hopefully she'll be running pretty soon...

The framers are done with the second stage of our remodel, so I was able to clean up the garage over the last two days and get the Blazer back inside. I'll be working on both the remodel and the swap concurrently. (I had really hoped to be done with the truck before the remodel started up again!) Anyways, not that much to do on the truck so hopefully I can get her going this week if I don't get called in for a work trip.

Today I'm routing the rear diff vent to the engine bay and running the fuel tank wiring. (I don't like how the stock vent is so low.) Also, I should get the harness in place. After that's done I'll need to get the fuel tank mounted and filled. Filling it will tank some time because I'm going to fill it a gallon at a time while recording the fuel sender readings with HPtuners. That's so I can calibrate the fuel level to be pretty much exact. Then the intake goes on and the fans get wired. A few small details after that and she should start!

 

[Steveman2000]

Hey Nak so I know its been less than 2 weeks but I'm curious how the build is going, and if you would tell me about that hidden winch you've got, as i'm considering getting a hidden winch as well.

 

[Nak]

Hey Nak so I know its been less than 2 weeks but I'm curious how the build is going, and if you would tell me about that hidden winch you've got, as i'm considering getting a hidden winch as well.

Sure. It's a Ramsey REP 8000 winch and a Ramsey hidden mount. The mount sits level with the fairing under the bumper. You have to cut the fairing, but that's not a big deal. Its' nice because it gets the pull down low. The winch is fairlead is visible, but not very noticeable. I've often thought of making a cover of some sort that would hide it completely as well as keep debris out of it. Shouldn't be too hard. Iv'e also tack welded the mount to the frame. You have to grind off the welds before you can remove the winch. (Theft protection.)

I'm making minimal progress. First I had to work on the remodel, then I got called out of town, then I was home for a day and got called out of town again. Very frustrating, as a couple of full days should see this running. I've gotten some small things done. One O2 harness lengthened, the other shortened. All the vent lines are in place. Fuel tank wiring is done. Still to go: Mount and calibrate the fuel tank. Hook up the fans. Hook up the windshield washers. Install the O2 sensors. Mount the ECM. Install the intake manifold. Fill the coolant. Make a few changes on the tune. (Disable DOD until 1000 miles.) Run the Battery grounds and Alternator connections. AC connections. I think that's it...

 

[Nak]

Fuel tank & system is done. The 2012 plug for the fuel tank vapor pressure sensor had to be trimmed to fit the 1998 fuel sender/pump module. Should still be weatherproof. Hoping to start her up tomorrow evening!

I've been studying the tuning process and found a very good reason--performance--to keep the evap system operational. The ECM uses the Evap system to determine percentage of ethanol in the fuel. It then adjusts the tune for the fuel. Only a Flex Fuel engine will do this, but this is a pretty cool thing. Without the Evap operational, you'd have to tune the engine to take advantage of the high octane rating of E85. With the Evap operational, fill her up with E85 and instant extra horsepower! E85 = Cheap race gas. Also, in the near future we're likely to see different levels of Ethanol in our fuel. It'll be nice to have a correct tune regardless of the % ethanol.