1979 Malibu

Update your progress on your various car projects.

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TireSmoker
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Re: 1979 Malibu

Post by TireSmoker »

Things are getting serious! After the aborted install attempt a couple weeks ago, I got the correct input shaft for the trans, and mated it up to the engine. Speece came over again this morning after breakfast and we got the engine trans in the car! No real surprises, took me a couple tries to figure out the crossmember orientation.

-Dave
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Re: 1979 Malibu

Post by TireSmoker »

After getting the engine in, it looked like the engine had a severe down-angle to it. Most of it is just optical illusion with the hoodline, but not all. When compared to the Chevelle (since they are both SBC with same intake), I measure 3* in the Chevelle, which I consider as a Known-Good and 4* in the Malibu. The motor mounts I bought looked tall. I found another set of Moroso's that are shorter, but only by 5/32" of an inch. (Moroso 62515 vs 62510). I'm gonna swap those over and see if it looks/measures any better. I mean, even with a cowl hood, it looks like I'm going to be closer than I thought on clearance by the throttle body.

I'm continuing to pick at things. I've got the battery secured in the trunk, I've scoped out where the cutoff switch will go. I'm waiting on a few more tools and parts, but I have just about everything to start doing all the electrical.

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I've been thinking about the fuel system.. and I did the math!

My engine dyno'd at 440hp. at 7psi, thats 660hp, and 14psi 880hp, not taking other real-world losses into account. I probably won't run 14, but closer to 10. Maybe 750hp? But I'll round up to 800 here.

The internet says that HP x .6 BSFC = fuel consumed in lbs/hr (BSFC = Brake Specific Fuel Consumption) .6 is for Boosted, use .5 for N/A.

800HP x .6 = 480 lbs/hr fuel required.

My fuel pump is rated for 346LPH @ 60psi when running at 13.5V = (346LPH x .2642 gal/L = 91GPH)
91 GPH x 6lb/gal = 546 lbs/hr fuel, so it seems like I have enough fuel pump. I may look at a Hellcat pump if I need more, as it's rated at 525LPH and supplies a real 850hp engine. Surprisingly cheap, IMO, like $200 tops.

For injectors, 480 / 8 = 60 lb injectors. But you only want to run injectors at 85% duty cycle, so 60 /.85 = 71lb injectors. 80lb injectors are commonly available and should work pretty well.
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Basement Paul
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Re: 1979 Malibu

Post by Basement Paul »

Now you have to make sure your fuel line is big enough. There are flow rate charts that will help.

-BP
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Re: 1979 Malibu

Post by TireSmoker »

I'm pretty confident that 3/8" would work, but I'm probably gonna go 1/2" on the supply side anyway. Might need the bigger lines if I go E85 in future.

-Dave
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Re: 1979 Malibu

Post by Basement Paul »

Summit Says:

https://help.summitracing.com/app/answe ... -i-need%3F

What size fuel line do I need?

Recommended Size, Based on Horsepower
Fuel pumps are sized to feed your system with enough fuel to optimize engine performance. However, when using an External Fuel Pump, you can starve it for fuel if the line is too small.

A lot of aftermarket pumps will list the required line sizes. If your pump does not list line sizes, use the table below as a basic guideline.

Recommended Fuel Line Size (from the tank to the pump)
Engine Output Size (inches) Size (AN)
350 hp or less 5/16 in. -5
350-450 hp 3/8 in. -6
450-650 hp 1/2 in. -8
650-1,000 hp 5/8 in. -10

Notes
Make sure the pump is as close to the tank as possible and below the outlet of the tank.
This ensures gravity feeds fuel to the pump. (External pumps push fuel. They don't pull it very well.)
We recommend you install a 100 Micron In-Line Fuel Filter between the tank and the pump.
The fuel line after the pump can be the next smaller size.
When using E85, alcohol, methanol, etc. go up to the next bigger fuel line.

-BP
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Re: 1979 Malibu

Post by TireSmoker »

I think those are more geared towards low-pressure carb setups. Did you increase the fuel line size on your S10?

-Dave
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Re: 1979 Malibu

Post by Basement Paul »

No, but I'm only making 550 at the crank (400 at the wheels). I know Kevin is at least at 3/4" and had to increase it from 1/2" cuz he was running dry. Better to plan for more HP now that do it all again next year IMO. Trevor told me if I go to a blower I'll have to make my lines bigger too.

This is a reasonably complete article saying you're probably pretty safe with your 1/2" unless you go real big:

https://hotrodfuelhose.com/blogs/rad-ho ... ans-to-you

-BP
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Re: 1979 Malibu

Post by TireSmoker »

I've been making progress in bits and pieces on the Malibu while I've also been getting the Chevelle put back together. Once that is done, progress will be a little faster here.

I took a trip up to Paul's on Thursday night and he was able to weld together my seat-adjuster bars, which is a bigger deal than it might sound like. As it comes out of the box, the adjuster bar was for seats with the rails placed much further apart, so I had to narrow it quite a bit by cutting and re-welding. I had Paul weld a nut in there so I could add a knob or something.

Despite making a cardboard template of the mounting holes, somehow a couple the actual holes ended up in the wrong place. I can only get 3 of the 4 seat mount bolts to line up.. grr.. but progress. The seat goes back and forth.
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I've also collected pretty much everything I need to complete all the wiring. I bought a heavy duty crimper + ends for doing 1/0 gauge battery cable so I can do the trunk mount and safety switch. I have all the connectors and MS/MS3X harnesses to build the engine harness. I also bought these to install in the gauge panel. The one on the left has a LED voltmeter display between the ports. That will let me get rid of the Summit voltmeter in the panel and maybe put in something like a trans-temp gauge instead.
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I ordered 25' of 1/2" nickel-copper (Nicopp) tubing for doing the bulk of the fuel lines. I ordered a 525LPH hour pump from a Hellcat and a set of 80lb injectors. I need to test the fuel pressure regulator to make sure it rises with pressure.

As soon as I can move it into the lift bay (Chevelle occupied), things will start moving a little quicker.

-Dave
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Let there be light!

Post by TireSmoker »

So I finally got the Chevelle put back together, so Maliboost has been moved into the lift bay.

I got the battery wired up with the remote safety switch. The main ground is temporary, as I don't have enough black 1/0 cable to get where I want. I have headlights, taillights, license plate light, and 4-way flashers. But no turn signals. Not sure about brake lights.

-Dave
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Re: 1979 Malibu

Post by TireSmoker »

Another sub-project completed -- driver's seat conversion to seat tracks is completed. There might need to be a minor seat belt adjustment, but I did get fully strapped in for the first time! I'm feeling a lot better about where I'm at with this car than I was at the beginning of the weekend.
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Re: 1979 Malibu

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TireSmoker wrote: Mon Apr 04, 2022 12:11 am After getting the engine in, it looked like the engine had a severe down-angle to it. Most of it is just optical illusion with the hoodline, but not all. When compared to the Chevelle (since they are both SBC with same intake), I measure 3* in the Chevelle, which I consider as a Known-Good and 4* in the Malibu. The motor mounts I bought looked tall. I found another set of Moroso's that are shorter, but only by 5/32" of an inch. (Moroso 62515 vs 62510). I'm gonna swap those over and see if it looks/measures any better. I mean, even with a cowl hood, it looks like I'm going to be closer than I thought on clearance by the throttle body.
so just for documentation, the motor mount swap was a bust. After swapping the shorter mounts onto the engine, I couldn't get them to line up with the frame mounts. I'm not sure if I would need a matching set on the frame side-- probably. I put the taller 62515 mounts back on and will go forward like this until the angle becomes an issue. I set the hood in place and checked throttle body clearance from underneath -- looks good.

-Dave
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Re: 1979 Malibu

Post by TireSmoker »

Major hurdle accomplished tonight -- the main fuel line from the back of the car up to the engine bay is (roughed) in! I love Nicopp -- its so easy to bend, even in 1/2", and I was determined to use as much of it as I could. This is ~$3/ft versus ~$9/ft for PTFE stainless braided. I'm making sure everything will be E85 compatible. I started from the rear suspension and worked forward, just sort of bending it as I went. I'm not sure where I'm going to terminate these in the engine bay -- on the wheelwell or down on the frame. From there, I'll have to use braided stainless over to/from the engine. The return line I'm going to do in 3/8".

Also, thanks to Paul for the assist on the hole saw, I can now start working on all the EFI wiring. I ran both the MS3 & MS3X DB37 plugs into the hole, located the ECU where it's going to be. Then it was divide and conquer.
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Re: 1979 Malibu

Post by TireSmoker »

I received and installed a grommet for the big hole I cut in the firewall. Final wiring can now begin. I also installed a 3/8" NiCopp line for my return. Holy cow, it's sooo much easier to deal with than the 1/2" stuff I used for the feed. I have some tube-to-AN adapters I will install, and the short sections from the tank <--> lines and engine <--> lines will be done with braided stainless.

I modified the gauge panel. I removed the Summit oil pressure and volt meter. I replaced the oil pressure with an Autometer Unit that matches the temp and vacuum gauges. It leaves me an open 2 5/8 hole, which I'll prob use for trans temp. I also added a couple USB ports, and the one on the left will display voltage in the middle, so I didnt lose that functionality. Thanks to Paul for all the hole saws!

I made a quick cardboard template for the Megasquirt electrical panel in the passenger footwell.

Kurt should be here today to weld up some fuel cell mounts. If that goes as hoped, It will be completely mounted today and I can work on the connections to the hard lines.

-Dave
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Re: 1979 Malibu

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Another major item accomplished today -- Kurt came over and welded some mounts onto my fuel cell. It is now fully mounted in the car! It's level from side to side, and angled back just a little bit to keep fuel at the back, where the pump will be. I'm really happy with how this turned out.
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Re: 1979 Malibu

Post by TireSmoker »

Made up my power distribution/relay panel tonight. It's configured so that the injector + coil relays won't power on until the fuel pump relay turns on. Can't accidentally have injectors or coils powered with the engine off that way. I just need to physically mount it in the passenger footwell now.
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