1966 GTO L92 / 6L80E / Street Challenge Project

[V8TV]

We've got another new project starting in the V8TV shop - an L92 / 6L80E powered 1966 Pontiac GTO.

This 1966 GTO has seen better days, and this intro video explains the project details from start to finish, including the crazy timeline. It kinda goes like this: Install GM 6.2 liter L92 V8 and 6-speed 6L80E tranmission, install Air Ride Technologies Street Challenge air suspension system, upgrade the wheels, tires, and brakes. Drive on Hot Rod Power Tour. Disassemble entire car, replace quarter panels, repair holes in trunk floor, window ledges, fenders, and doors, paint, reassemble, and take to SEMA 2008. Whew!

As always, we'll be bringing you every step of the build on video.

Intro Video: http://v8tvshow.com/content/view/485/1/

http://v8tvshow.com/images/stories/66_GTO/DSCN0030.png

[muthstryker]

sweet! i think more people should start doing 66-67 gtos not to many of them being "built" up. cant wait to watch this build.

i have a 67 goat myself im working on

[V8TV]

You've got a good project there, too! I love the front tire in this shot of yours:

http://memimage.cardomain.net/member_images/8/web/2300000-2300999/2300009_44_full.jpg

- KO

[V8TV]

We yanked the original engine from the GTO's nose, and later found it to be a date-code correct 1966 389 block. The multiple coats of aerosol paint make it look more like a cosmetic resto than a mechanical rebuild, but we didn't tear it down to see. Now we're focusing on fitting the new 6.2.

http://v8tvshow.com/content/view/491/1/

[BBC69Camaro]

Wow, nice project, definitely keep us updated.

I'd be interested in how you got a 6L80E working in an engine swap. From what I understand they need a custom controller for the trans and not easy to do.

[V8TV]

We're interested to see how it works, too!

I've heard several stories about the trans operation. John Spears at Speartech has had a Silverado with a 6L80E driving around for several months. He reflashed the stock TCM inside the 6L80 and configured it to match his tire size and gear ratio. Claims it drives awesome, so we're working with him on the trans harness and reprogram. We'll let you know how it all shakes out!

[V8TV]

Tonight, we bolted the Street & Performance engine plates and oil pan to the L92 V8 and 6L80E six-speed automatic combination. We were pleasantly suprised to see that it almost fits the car without modification, but we will need to do some more test fitting to be sure.

http://v8tvshow.com/content/view/492/43/

[V8TV]

Wow, this is a huge transmission.

Here's some shots of another test fit from under the car... the top of the trans is 1/4 inch from touching the floor of the car. The trans has to go up at least another 4.5 inches to bring the bottom of the pan to 1" below the frame. Then, the output shaft is up higher than usual, so the trans tunnel and the drive shaft tunnel have to be cut out to make room. Next comes possible issues with the engine / trans angle... the engine may have to go up in the front to allow for the trans to pitch down towards the rear axle, making the engine / hood clearance too tight. Hmmm...

http://www.v8tvshow.com/media2/DSCN0034.png
http://www.v8tvshow.com/media2/DSCN0035.png
http://www.v8tvshow.com/media2/DSCN0036.png
http://www.v8tvshow.com/media2/DSCN0037.png
http://www.v8tvshow.com/media2/DSCN0038.png

[V8TV]

http://www.v8tvshow.com/media2/DSCN0039.png
http://www.v8tvshow.com/media2/DSCN0034.png

[V8TV]

We've test fitted, measured, scratched our heads, tested again, looked at the calendar, scratched our heads again... and we've determined that the 6L80E, while cool, is not going to fit this car in the timeframe required. The trans is just too big, and the amount of surgery needed is going to take a long time, and then it would take just as long to un-do if the trans didn't live up to expectations.

So we talked to Mark Bowler at Bowler Performance Transmissions about his upcoming project... a collaboration with Bowler, Twist Machine, and Gear Vendors to create an 8-speed 4L65E auto that can be paddle-shifted (is Shrifted a word?) up and down through 8 gears. Sounds cool to us, and it actually fits in the car! So the story changes a little, but moves 2 gears ahead!

http://v8tvshow.com/content/view/502/1/

[DG.]

Sounds great.. No sense in rushing an option you're not sure about to begin with.

[BBC69Camaro]

...create an 8-speed 4L65E auto that can be paddle-shifted (is Shrifted a word?) up and down through 8 gears...

I wondered about this myself. Would it be a seemless 8 gears, or would you have some kind of toggle switch that you would have to hit to turn on and off the Gear Vendors in between gears on the 4L65E? If it could be a seemless 8 gears on the paddle shifters then that would be pretty awesome. Definitely interested in how you get that working.

Looks like a great project!

[V8TV]

We received our new 4L65E transmission from Bowler Performance Transmissions the other day, and now the progress on the GTO continues...

http://v8tvshow.com/content/view/542/43/

[V8TV]

To those looking to swap in a new Variable Valve Timing engine into your hot rod project, keep an eye on hood clearance, because the VVT hardware adds some length to the block, making accessories a little tricky. Here's what we did to make them work on the GTO.

http://v8tvshow.com/content/view/560/43/

[V8TV]

We zipped the body off the frame, had the frame media blasted, and boxed it up in preparation for the Air Ride Street Challenge suspension system. Pretty soon the bottom half starts going back together!

http://www.v8tvshow.com/forum/index.php/topic,216.msg1199.html#msg1199

[V8TV]

The GTO's chassis got a bath in the new Eastwood Ceramic Chassis Black. We like the satin finish, and hope it has the chemical and chip-resistance for a driver. It's a 2-part catalyzed chemical that cures up hard. Spraying is pretty simple, although it seemed to like to run just a little if you "pound" it on.

Video: http://v8tvshow.com/content/view/566/1/

http://www.v8tvshow.com/images/stories/videos/66GTO/66FrameS.jpg

[BBC69Camaro]

The GTO's chassis got a bath in the new Eastwood Ceramic Chassis Black. We like the satin finish, and hope it has the chemical and chip-resistance for a driver. It's a 2-part catalyzed chemical that cures up hard. Spraying is pretty simple, although it seemed to like to run just a little if you "pound" it on.

Just wondering, how do you think the paint from Eastwood compares to say powder coating durability wise? Do you prefer one vs the other?


Thanks!

[V8TV]

Hey BBC -

Paint isn't going to be as tough as powder, but it is more "do-able" for the average guy. It costs less to paint a chassis yourself (usually) than to have one sent out for powder. Smaller items can be powder coated in-house... we use our little Eastwood kit all the time and the results are killer. Big stuff, though, is a little harder.

As for this Ceramic paint, when the parts are properly prepped, seems to be holding up really nicely. We've only had it applied for a couple weeks, but it seems to be surviving in the shop environment - typical bumps and stuff - without any chips or damage. We'll see how the chassis looks after some miles are on it to really make a good assessment. Does that help?

[BBC69Camaro]

Oh yeah definitely.

Another question, have you ever tried the Por-15 line?

I have been doing a lot of painting on my project so I am always looking for new types of paint that work well that won't break the bank :thumbsup:

[V8TV]

The low-buck route for chassis and stuff is still Rustoleum satin. It can take a week or so to fully cure, but it looks pretty good and stands up to abuse.

The only experience I have with POR-15 is removing it... it was all over the GTO frame in the front when it arrived here. It was a mess. Porous, drippy, and poorly applied. The media blaster wasn't very happy with removing it. I'd like to try some sometime.

[BBC69Camaro]

I have been pretty impressed so far with Por-15, first used it on my engine block. So far brake clean, paint thinner and hammering didn't phase it in the slightest. The prep is killer (which is a drawback depending on the item); the surface has to be perfectly clean or don't bother with it.

I tried their Chassis black on my firewall because of the results I saw on my block (for pics see link in sig). Tried it on a few other parts as well, all came out pretty good.

For kicks one day, I tried taking the stuff off a small part. After a night in the hot tank, the paint even partially lived, believe it or not! After its bath and a good steam cleaning still some paint still stuck around, finally had to soda blast it to get it all off, impressed me.

I do like the idea of painting stuff once and not worrying about it for a long time. Not a paint I would use for everything but it does have its uses.

[V8TV]

Interesting. How did you apply it? What's the dry time like?

Thanks for the info!

[BBC69Camaro]

How did you apply it?
Brushed it on (to spray it on I needed a respirator that I don't have) I actually found that the cheap sponge brushes from OSH hardware worked quite well once you got the hang of it, the paint will dry without brush marks as long as it is applied with even strokes w/o going over it a second time before it is dry.


What's the dry time like?

One of the pains of using this paint, I have found it can vary from as little as 30 minutes to 8 hours. I believe it needs 3 days to fully cure. The paint is a 3 step process (zinc coating, Por-15 undercoating and then top coat). Por-15 has no UV resistance and will fade if not top-coated. Por-15 pulls water from the air to dry hence the variation in dry time.

Been experimenting with using Por-15 as the undercoat but then using a rattlecan primer and rattle can topcoat (haven't quite got that perfected yet). Hoping to maybe paint my rear-end that way to save some time.

[V8TV]

Quick shot of the "temporary" paint scheme... it's going to get a silver stripe at the color break, and then it stays un-cleared for the Power Tour and the CC Nats. Then it comes back here to have the quarters and floors ripped out and a "real" paint job!

http://www.v8tvshow.com/images/stories/66_GTO/DSCN0569s.jpg

[Hdesign]

Hey Kevin, I haven't forgotten about you on the paint with this. I've been completely slammed for months.

[V8TV]

I know, Ben.. and this scheme is just a quickie to test the driveline. We'll stay in touch on the final for SEMA.

[V8TV]

After seeing the Air Ride Technologies 1966 Chevelle thrash the autocross at the Run Through The Hills III event, we were sold on the outstanding handling AND smooth ride of the Air Ride Street Challenge suspension system. This time, we build the front 1/2 of this system on our '66 GTO. We're still pushing to get this car on the road for the Hot Rod Power Tour in less than a month.

http://v8tvshow.com/content/view/579/43/

[V8TV]

We're kind of jumping ahead and posting nightly video updates as we push to get the GTO ready for the Power Tour. We'll be posting more of the detailed installs later, but for now, we'll post these quick updates, as we've got about 18 days to make this a driver!

Video: http://v8tvshow.com/content/view/580/43/

http://www.v8tvshow.com/images/stories/videos/66GTO/66GTO18Days2.png

[V8TV]

New 2005 GTO seats went in today...

http://v8tvshow.com/content/view/582/43/

[V8TV]

We finished the back 1/2 of the GTO's Magnaflow exhaust kit off by running it through the bumper in place of the original reverse lights... came out pretty trick. We'll get to the reverse lights later!

http://v8tvshow.com/content/view/583/43/

[V8TV]

The good news is that the GTO finally came to life! The Mast Motorsports controlled L92 sounds really sweet. We're thrashing to get some brake issues fixed and waiting for tires, but we should be driving it today. Lots more video coming!

[V8TV]

The GTO is finally as finished as it's gonna get for Power Tour... here's a couple snap shots. Lots more video to come on the build and driving it... hard!

http://www.v8tvshow.com/images/stories/66_GTO/GTOGallery/DSCN0983s.JPG
http://www.v8tvshow.com/images/stories/66_GTO/GTOGallery/DSCN0996s.JPG
http://www.v8tvshow.com/images/stories/66_GTO/GTOGallery/DSCN0967s.JPG

[V8TV]

http://www.v8tvshow.com/images/stories/66_GTO/GTOGallery/DSCN0968s.JPG
http://www.v8tvshow.com/images/stories/66_GTO/GTOGallery/DSCN0957s.JPG
http://www.v8tvshow.com/images/stories/66_GTO/GTOGallery/DSCN0943s.JPG

[V8TV]

Here's a quick shot of the MAST CAN gauges...
http://driven-1.com/images/slidehow-dashgages.jpg

[Hdesign]

Looks great Kevin!!!:thumbsup:

[J2SpeedandCustom]

Looks great Kevin can't wait to see it. The gauges are SWEET!!!!

[V8TV]

Thanks Ben and J2 - the gauges are really killer. And powered by the ECM, so no senders are needed. Trick stuff. The LCD in the middle lets you cycle through MPH, RPM, MAP, AIT, Oil Press, Temp, Man Temp, Hours, TPS, and many more by hitting the black button. Very cool.

[Rubes]

I'm headed out to Ames on Wednesday morning...we'll look for ya there Kevin.

[V8TV]

We won't be there, Rubes, but the car will. I just got word from the car's owner, Stefan, that the GTO ran 13.40s at 108 with massive wheelspin on the Power Tour during its first drag strip pass. Heck, it only has 300 miles on it total! With some traction and tuning, I think the mid-high 12s are not far off. The L92 with VVT is nice!

[V8TV]

Catching up on some of the install videos on the GTO... here's the Air Ride MuscleBar sway bars and PosiLinks articulating end links on the GTO's front suspension. The links are cool, they keep the bar rigid but also prevent binding. These are 2 key elements making an air-equipped car handle well, but they will also work on traditionally sprung cars.

Video: http://v8tvshow.com/content/view/585/118/

http://www.v8tvshow.com/images/stories/videos/66GTO/66GTO9_AirRideFrontInstall2still.png

[Grambo90]

very clean ride.... i REALLY want those gauges, where can i find them because google is telling me nothing.

[Rubes]

very clean ride.... i REALLY want those gauges, where can i find them because google is telling me nothing.
http://www.mastmotorsports.com/page.php?Category=Technology&Section=M-90%20ECM&id=85
unfortunately, the way I understand it is that you have to use their ECM to drive those gauges.

[V8TV]

Here's the rear Air Ride Street Challenge suspension system and Currie 9+ rear axle housing going in... it's only the axle housing because a major shipping company (to remain nameless) "lost" 33 spline axle... Other than that, no major hiccups with the install. We chose to weld in the upper air spring brackets to make it a little cleaner.

http://v8tvshow.com/content/view/590/1/

[BBC69Camaro]

Cool update, I like the touch of tack welding that washer in the spring perch.

[V8TV]

We've going through all the build pics and posting photo galleries of the GTO build... there are over 550 photos total, which will be in 13 or so separate galleries. The first 5 sets are online, and the new ones will be publishing all week. If you didn't see the videos and are interested in this car, check them out at the link below.

http://v8tvshow.com/content/blogcategory/74/118/

[V8TV]

It's been a while, but here's another update on the GTO - the 2 tone paint process.

http://v8tvshow.com/content/view/657/118/

[V8TV]

Here's a look at the Mast Motorsports M90 ECM and their killer CAN network gauge package. We installed their M90 in our L92 GTO along with their harness and throttle pedal, then made a dash insert for the gauges. Very nice stuff.

Video:

http://www.v8tvshow.com/forum/index.php/topic,216.msg7516.html#msg7516

http://v8tvshow.com/images/stories/66_GTO/GTOGallery/66GTO6.07.08_s_068.jpg

[Driven1]

Hello!

I figured I'd get on board, register and let everyone know how this car is performing.

I took it out on it's maiden voyage on the Hot Rod Power Tour last year and it made the trip just about flawless. The one thing that was an annoyance was one of the plugs in the O2 sensor hole of the header worked it's way loose, but didn't fall out so I had a weird rattle.

The car has gotten me upto 25.3 MPG and was averaging 22MPG on the tour.

It's fun to drive and I have plans to get this project continuing on to help with the mission of DRIVEN1 (http://www.driven-1.com)

Thanks and look for more updates!

[V8TV]

Just posted a huge photo gallery on the GTO, something like 540 pics or so covering the build from start to finish. Or at least until we get it back to do some more mods!

http://www.v8tvshow.com/images/stories/66_GTO/66GTOBigGallery/index.htm