Stephan's SLC Build Log

Stephan E.

Supporter
From the finished oil cooling system back to the fuel system. The swirl tank was relocated from outboard to inboard. In order to make this accessible, the floor next to the fuel tank received a hatch. Now all fuel components can be reached without any problems from the rear and the bottom.
 

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Stephan E.

Supporter
A status update:

The engine bay is 99% done. I made the harness for the accelerator pedal extension and the linkage. Pedal box installed. All fluids are in and the fuel system was primed and adjusted in standalone mode. So far no leaks but I had to rebuild the front brake master cylinder. The one delivered with the kit had a bad seal in it and lost pressure. Found rebuild kit on Ebay. Clutch hydraulics are also filled and bled. I found a suitable crankcase breather, fittings and carbon canister with bracket. Today I ordered my new steering wheel and push button system, more about that when I took delivery. I started routing under dash wiring, closed up the access holes under the dash. Tank cover is installed. Added additional outputs to the rear power cell to drive the door actuators with the key fob. Filler neck is completed. The intake tubes are now all brushed instead of polished. Finished engine wiring and wrapped the exhaust tubes above the V-bands.

Here are some impressions of the finished work
 

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Joel K

Supporter
Stephan, it’s a work of art how it is all coming together. Love the coolers in the diffuser and many other items. Can’t wait to hear that OHC LS7 come to life!
 

Stephan E.

Supporter
I received the custom made gauges. Though that this is period correct and I just love analog stuff. Everything will sit inside carbon fiber. For now I only have four small gauges for the essential hardware but additional ones already pre-wired. If I can find the space to accommodate them there will be a few more. The two large ones are 4.5 in. OD and some creativity is required to fit them.
 

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Stephan E.

Supporter
Stephan, it’s a work of art how it is all coming together. Love the coolers in the diffuser and many other items. Can’t wait to hear that OHC LS7 come to life!
Thank you Joel,

It was a rocky road to build this first of a kind engine integration but every time I look at it makes me forget the pain. Startup is not too far...
 

Stephan E.

Supporter
Some progress on the instrument fitment. Took some massaging to get these large roundies where I wanted them. Mockup with acrylic panel so far so good. The final will be in carbon fiber. Molded the perimeter with hairy glass and Bondo for finishing. Now the instrument opening is inverted from what the factory makes. I have to remodel the steering column shroud since all switches will be removed. More to come...
 

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Stephan E.

Supporter
Here are my continued adventures with my dashboard. I had to modify the steering column, raised it about 3/4" and was able to center it a little better. I have long arms and also noticed that the gauges are covered by the upper part of the steering wheel rim. After the modification I am having an unobstructed view on the instruments and improved ergonomics. I stripped the steering column of all electrical switches, shortened the release lever and modelled a new and much smaller shroud, still being able to adjust the tilt as needed.
 

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Stephan E.

Supporter
I was looking around for a while for some nice dash vents and remembered that previous builders used Audi vents. The aluminum trim and the mechanism are second to none. I am finding those aesthetically pleasing and the trim will nicely accompany the rest of the interior but it takes some effort to fit. The pods are at least 1/4" too small because the OD of the vents is the same as that of the pods. There is some modelling required but when in they looking really clean. Here is the left side for now.
 

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Stephan E.

Supporter
Two month ago I posted success on finishing up my engine bay. Well, that was two month ago. One Sunday morning while happily terminating my dash electrical system and probably drinking too much coffee something hit me. Going back to the beginnings on my build log I was dreaming of using an LS7 with ITBs until the LS7 based Mercury motor became an opportunity with its stock dual throttle body configuration and the ITB idea died. Now over a year later after buying the motor and knowing much more about the engines build quality and its theoretical performance it was time to take the shackles off. I am about to find out what is behind those high airflow values of these cylinder heads. The proprietary wiring and locked ECU was removed including the restrictive intake and the calculations started on a design of a complete new induction system without bottle necks and restraints. The best naturally aspirated design so far is a custom ITB system for these cylinder heads based on tapered 8 x 60mm throttle bodies. A very clean design with the injectors sitting in the heads. Runner length was exactly determined to make max. use of resonating air columns ramming in a lot of fill over standard design manifold hitting that rpm band where the currently installed cams make most power. New intake surface will be almost 100% over the Mercury dual throttle body stock intake. I am still chewing on actuation of the linkage, injector sizes and a matching ECU and harness. Here is the first rendering of the design for calculations and spacing. This is the actual inner surface of the runner length without cylinder heads. The exterior is not considered as of this point. Later it will become a CNC machined billet manifold with flanges for heads and throttle bodies including Carbon velocity stacks. Red are the velocity stacks, purple are the throttle bodies simplified, grey the machined billet manifolds with the transition from longitudinal oval cylinder ports to round 60mm intake ports. Looks like a bottle neck but is just a change in intake runner shape. Yellow is the cylinder head entry.

I can not even imagine how those will sound over 8000 rpm.

Stay tuned...
 

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Stephan E.

Supporter
Hello Joel,

that makes two of us. It is a lot right know but I think the outcome will be one of a kind and I have to add drool protection:cool:. Still wondering what that engine will pull when all done.
 

Markus

SPRF40
Lifetime Supporter
Wow!
When I consider your built quality I can't await to see the finished system! The sound I don't even want to think about......

Are you going to use air filters or plenum? Or pure ITB?
Regards
Markus
 

Johan

GT40s Supporter
That intake lookes awesome. I have always wondered how you measure total air flow in those. Either if it’s MAF or Speed density, do you measure one stack and program the ECU to multiply by 8 ?
Your build is as usual top notch, very proffesional.
 

Stephan E.

Supporter
Wow!
When I consider your built quality I can't await to see the finished system! The sound I don't even want to think about......

Are you going to use air filters or plenum? Or pure ITB?
Regards
Markus
Hi Marcus,

It all depends on how the package will fit and look when the assembly is completed. I'll make the decision about airboxes along the way.

Stephan
 
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