[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Just been around and witnessed the test.

Well, this car has certainly had me scratching my head many times on how to solve a problem. Looks like the emissions is just another one. Sadly looks it’s going to be a bit of a long journey. For those playing at home that reading near the top on the left of 247.313 for CO needs to be under 1, yep, that’s right under 1.0 Humm.

The guy certainly knows his stuff, he has a little 50kW dyno he uses for the tests. I think he is the only guy in the state who is approved to do the testing. He is saying he needs to put it on his main dyno and go through the entire tune. Swap injectors, etc etc.

He is also going to speak to Mike Jenvey in the UK, looks like a fairly long road ahead. The bummer is his main dyno is out of action for the next two weeks. So realistically we are looking around Xmas before its done, if it can at all in its current state.

What a bloody shit.

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Spoke to the mechanic, should have the box in soon.  I am entered in the C4C on the 23rd.  I just can’t/won’t risk driving it unless its passed.  So its going to be a bit touch and go time wise.  Not much time in case of a hiccup.

I have it booked in with a local guy before C4C for a full detail, which will take him a day or so. He’s just up the road from Gawler, comes recommended by Frank so will let you all know how he goes.

So fingers and toes crossed….

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Have some people from France staying with us at the moment.  Last night I took the guy for a quick drive, first time I have had a chance to drive it with the single 2.5″ system.  I can confirm its lost virtually none of the low down torque, lays 11s at a squeeze of the pedal, actually still sounds a bit mental when it spins up.  Also scared the shit out of the Frenchie

Also really pleased to finally get the top radiator hose sorted.  I have been chasing one, finally saw a post on a US site with someone who had done a similar conversion.

It fits a Cadillac Escalade, as well as a 2500 pick up.  The Gates part number is 22358, you just trim the bit you don’t need and are left with the perfect Z section.  Here’s a couple of pics.

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Have some people staying with us for a couple of weeks so hard to get to the car.  But I did manage to drop the exhaust off completely on Saturday, and cleaned up the flanges etc so its all ready for the new exhaust.  Also replaced the exhaust manifold flanges, and changed the bolts over to some nice ARP ones so its easier in future.

Since the exhaust was off seemed a shame to not at least fire it up, sounded farking loud but pretty awesome.  Apologies for the pretty crappy video but I managed to talk my misses into taking it with her iPad.  Might be nice to make up some angled pipes to dump it out the side of the car for drag duty some time

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Well, project quiet down is progressing, starting to annoy me a little bit to be truthful…

So for those playing at home the legal limit is 90 dB.  The issue is dB is not a simple linear measurement.  So a drop in 3dB is half the sound level, so a 6 dB drop is 1/2 x 1/2 = 1/4 the sound level, 9 dB is 1/2 x 1/2 x 1/2  = 1/8, you get the picture.

The level the engineer measured on the test day with the DiPhillio mufflers was 113 dB.  So I need to shed 23 dB, in plain English “A Farken Lot”

So first change was to swap out the rear muffler for a Varex.  That of course meant cutting away the spare wheel well, which I have done.

So this morning I took a reading with the Varex open, it was 108dB

I then shut the Varex and took another measurement, it was 97.5, that’s a pretty impressive reduction, of over 10 dB at the flick of a switch, yes it sounds pretty crappy, and definitely cuts power but heading the right direction, but not enough.

So today I got into fabrication mode and took the Dynatech exhaust comes I bought through Summit.  I then bored a 3″ hole in the 2mm flange plates I got of AAA exhausts and tigged the cones and cleaned them up.  pretty happy with how they turned out.

So I dropped the exhaust off the collector, and fitted these in between the cats and the headers, the cone points upstream.  Started the car up, massively quieter to the human ear, quite incredible really.

Took a reading, so that’s cones fitted, Varex closed 94 dB – not enough Bugger it!!!!

So definitely headed the right way but simply not enough.

So maybe one issue is I am doing the measurement in my back yard so there’s probably sound reflections happening all over the place, so it may drop a little if I did in an open space.

Also maybe its worth getting the car re-tuned as it definitely has effected power, so it may settle it down a bit if it were re-tuned and take some rasp out.

Maybe i have to get a full custom rear big kick ass muffler, at least I have the space for one now.

Or…  I have no bloody idea, more thought required, stuff it.

Took it for a drive, its still plenty powerful, will light it up in a heart beat, but for sure has lost some edge.

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Well, I think I can finally describe my brakes as epic.  Truthfully feel as good in feel and stopping power as my 911.  Had it set up with the Comp Cams electric pump, worked a treat, just was very noisy.  Took a punt and thought since GM put them on one of the VE models, its has to be better.  So lashed out and bought one.  Its much smaller and more compact that the CC one, and much much quieter.  Also seems to pump it all up so much quicker so its hardly on.  Comes with a nice cast alumium bracket so mounting it was easy as.  This is the two compared

And this is it fitted.

Took it for a long drive, just smooth as now.

Down side of the day is looks like the Varex experiment may not be a winner.  Just parked it my back area, and used a noise meter my mate has loaned me.  Does definitely attenuate it, dropped from 102dB to 93.  Which is a lot but not enough.  So not sure what to do from here, bit of head scratching maybe.  It definitely sounds like shit when its closed, but open to me sounds exactly as it did before.  Gumby pic of the meter set up for posterity

And lastly couple of people have commented on how crappy my pedals were, so fitted the HSV set I bought, also some new mats, came up OK I think.

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Just received the photographs from the Street machine photo shoot.  Really happy with them.  these are my pick of the bests

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Well, got it all done, so spare wheel well reduced to make space for the Varex.  Actually I think turned out pretty neat.  So the million dollar question is, is it quiter? answer heaps,.  But I don’t have any rear wheels at the moment as I am getting them re powder coated (thanks Bob Jane for chipping them)  So its stuck in the shed hard against the wall.  Anyhow, hopefully next week end with my mate will take it to a park or something with a db meter he has loaned me and see how much its attenuated it.    For now I have wired it with the switch in a little box so the idea is I will for now just bring it through the rear seats up so can operate it whilst driving it to test it all out. Then once its all sorted will permanently mount the switch in the boot.
Few random pics for posterity….

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Had a bit of fun today, only had a few hours as had a family show for my lads 21st.  Never been a bodywork kinda guy, but figure I have to start leaning for the Kombi.  So made up an infill panel for the spare wheel well and got it welded in.  Should have a full day tomorrow, bit of luck may get to start it with the Varex.

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

And a few of the dynamic stuff

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

So got the pics of my mate form the test day, thought I would throw a few up for interests sake.

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

So a bit of a write up on what happened yesterday, and where I am up to.

So as i say the car is “approved in principal”. At least here in SA the engineering is a two stage process. The first (and hardest & most important) stage is to prove to your engineer the car complies with all the ADR’s, and more importantly is safe and well built. In my case due to the amount of changes to the car and the 454 he wanted to do full dynamic testing. This included brake fade tests, lane change/swerve tests, acceleration, drive-ability and noise level. We did this on an aerodrome run way. Depending on how this goes it may need to be done multiple times until everything is right. He then writes an official engineering report supporting all the various modifications and advises that it should be registered. The second and final stage is to take the car to the RTA and they read the report, assess it themselves and officially approve it.

The first stage is what I completed yesterday. It was a very interesting day. It started off by him sitting down and going through with me every single aspect of the car, and he wanted to know if it was standard or modified. If it was modified I had to in detail tell him what I did, why and how. As I have said before, he knows my engineering back ground so I think I had a bit of an advantage as firstly I was able to tell him in engineering terms what I did, but I also I think there was a trust level there that he was confident in what I had done. For the report I need to put together a package of photos of each part of the car I have modified.

After we finished that we drove out onto the runway which was closed to air traffic for the duration of the tests. First thing I didn’t realize was he does all the driving. I had to stand on the side of the runway just looking. At first that was a bit weird, but it was actually great watching and seeing it cruising past at full noise. He put a data logger inside the car with accelerometers etc, he also had a sensor on the brake pedal so he could measure how much force he had to apply. He then accelerated and braked 15 times one after another. He then measured the brake disc temperature on all four wheels to assess brake fade. That all went perfectly. He then did an emergency full stop, my guess was from at least 110 km/h . The car stopped dead straight with the ABS doing its thing perfectly. He told me he was extremely happy with the brakes.

After that he did a heap of driving, turning, accelerating etc, I assume he was checking for drive-ability, and knocks clunks or bangs. Last thing was a lane change swerve test. There are three sets of cones, he drives up and swerves across through the second set, then immediately back to the set in the first lane. He starts at 60 km/h, then moves up until he thinks he has hit the limit. He has a helmet on, and its pretty spectacular to watch. With mine the last one he did was at 110, he came up to me and said well you cant do better than that.

Last thing was the noise test, which it failed. I sort of knew it would. I have a Varex muffler I bought off VS_Manta, I spoke to Doug about using it, and he liked the idea. So I am going to fit that. Its something I want anyway, to have the ability to quieten it down if I get pulled over, or near home or whatever.

So all in all, a great day.

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Woo bloody hoo! The Senator just sailed through the engineering tests at Goolwa aerodrome with flying colours. The engineer at the end no bs said, quote “Gary, that is superbly built car”  Went down with a mate, he took a heap of pics, was a very very interesting day.  Just enjoying a celebratory drink with the misses.  Tomorrow if I get a chance i will do a bit more of a description of the day.  The car performed flawlessly.  Only problem is its a tad too loud, which I sort of thought might be the case, but i have a plan with that.  Peaking!!!

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Well one custom designed pair of air filters fitted up :)  These were made for me to my sizes by UniFilter.  These are what I plan to use in the interim for road use.  It also provides a better spot for the IAT sensor and a clean side bleed point for the crankcase vent.  Took a bit of working through to make it all work.

I had to design up some 10mm spacer blocks to bring the backing plate out enough to clear the intake runners. I just don’t seem to be able to take a nice shot of the bay, it doesn’t look anywhere near as busy in real life, but what the heck I guess.  I actually quite like them, obviously not as horn as the bare trumpets, but more practical for the street.

I have also gone back and refitted the Tuff Mounts.  Unfortunately its drizzling with rain here, no way I am taking it out in that, I think its forecast tomorrow as well but maybe there will be a dry spell and I can take it for a fang

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Just tinkering really, maybe I move the radiator back and then this goes over the top and draws air form in front.

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Well gotta say right feel like I am living the dream with the car.  Seriously would not change one thing on it, just a total blast working on like today, then taking out for a quick shake down spin afterwards, bloody heaven!!

So finished off the brake vacuum pump, I think that’s one job totally nailed.  I ended up having a bit of a brain wave, no doubt some brake guru will say its the way to go and been done before but I hadn’t read about it before.  What I have done is left the vacuum from the motor tee’d into the vacuum pump line as before.  What I had to do was fit a second non return valve to it through.  That way the main vacuum is provided buy the engine like before, and so all the electric pump is doing is topping it up.  Its way better than using the pump alone, it hardly comes on, is also fail safe.  I also fitted a neat switch hidden down on the right hand side so I can override it if I want to.  The brake s now are just perfect, really really happy.  Also bought some different cable sheath and neatened it all up so it looks as factory as possible.  I am pretty happy with the wiring, to me it looks neat anyways.

Also installment #2 of “learn to do everything myself so I don’t have get raped by people charging me obscene amounts of money” went well.  I have bought an air flow gauge, and been speaking with Mike Jenvey in the UK about how to synchronize the throttle bodies.  So today I spent an hour or so, doing what he suggested, its not particularly difficult, but there is a definate process involved.  Now I think they are spot on.  The car now idles at less than 800 rpm happily.  So I think that’s one job I have at least started to get a handle on doing myself.  At some stage I have to plug in my laptop the OBD port and at least start to look at what the hell all that means

Lastly I have been prattling on a bit about the throttle response of the ITB’s.  So I have attempted to take a video.  Bear in mind this is on a private road, by myself, with one hand firmly on the steering wheel but the other trying to hold the phone as well.  The fuel pumps are not that noisy to the human ear, its must be some weird ass phone microphone thing going on.  Video one was a trial, I didn’t go anywhere near flat, the second one I let it rip a bit more, I will let it speak for itself lol.  (volume up)

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Yippidy bloody doo da, so bloody happy.  Have been chasing the source of the drive line harshness for what seems like ages.  Been under the car so many times, just couldn’t work it out.  Anyhow, today spent a great day and pulled the exhaust collectors off as I wanted to make a positive retainer for the passenger side.  Whilst I was there thought I would try a rubber trans mount.  Removed the Tuff Mount, thought that feels weird, pulled it out BINGO.  Stupid me had used bolts that were too long.  With a regular trans mount it doesn’t matter, as the bolts are up in fresh air in the middle of the mount, but with the Tuff Mount they cant be any deeper than the flange. Otherwise they drive against the other side and lock it up.  You can see on the mount where the bolts have been fouling.  Took it for a squirt, smooth as a gravy sandwich baby lol.

So main job was to get the collectors right, as I think I have had an air leak before the cat and O2 sensor.  You can see here where the collector has worked back.

So I made up a mild steel tab, and welded it to the headers.

Then made up a mating part on the collector, this picture with the paint makes the welds look ratshit, trust me it looks way worse then it is, actually I was really happy with it.

So that essentially locks the passengers side like they come from pacemaker as one piece.  I also cleaned all the joins thoroughly, fitted all new exhaust gaskets and also bought some M10x1.25 fine pitch flanged bolts and nuts for it, the ones that come from Di Phillipo were pretty average, coarse pitch bla bla.

Only headache was my header to cylinder head gaskets are unique to the LS7 heads.  And the gaskets I had I half wrecked pulling them out.  On the passenger side I ended up very carefully cleaning them back to the backing plate and used high temp gasket sealant.  Looks like it worked perfectly, I think tomorrow I will do the drivers as I didnt do that side like that and I can hear a slight hiss.  Will order some more gaskets from the US during the week.  Might even buy a top end overall set just so I have them hear if they are ever needed.

Then also bought a lovely tailored car cover for it, they were doing a bit of a deal on the Qld HSV fb page which I am on, fits perfectly, beautifully made, should keep it in A1 condition.

Took it for a spin (literally) before putting it away, running sweet as, just loev the power delivery, tomorrow going to hopefully do the brake vacuum pump, and fix the drivers header gasket.  Loving it

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Had a bit of fun working on it today.  Decided I better start going through everything from a roadworthy sense.  I haven’t been happy with the front lights, there’s been something a little bit dodgy/intermittent. Turns out the reason the headlights were so poor is they actually weren’t hooked up correctly.   Anyhow, decided it was easier to remove the bumper, get it up on the hoist and do it properly.  Bought some nice high intensity globes and fitted them.  Also gives me a chance to show how I mounted the washer bottle and brake vacuum tank.  Also discovered I forgot to refit the horn, nfa where that is in the shed so looks like a trip to UPI tomorrow to grab one, everything else works perfect for rego.  I think tomorrow I may have a stab at setting the front headlight height etc, no idea how easy/hard that will be.  few pics;

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Yea drove it again today and then went over it again on the hoist I think your right.  I am sure they are great for what they are designed for ie racing, but there has to be some sort of give somewhere.  I will swap them at some stage just to try.

Gave it a a good wash today, I guess you could say he got it pretty straight

[VRSenator065Participant Adelaide SAVR Senator LSx454 1960 Kombi (project) 1921 Nash Hot Rod (future project) View build HERE Member since: February 17, 2015 Posts: 5 777]

Well have to say yesterday I lived a bit of a dream ha ha.  Spent the day with a pro photographer doing a photo shoot for a feature in Street Machine.  I reckon for me anyways, that’s about as good as it gets for a car I more or less screwed together in my shed at home.  Just was absolutely awesome, felt a bit like a celebrity.  Took a couple of happy snaps while it was on, I am not allowed to see or show any of the pics until after its published, and that may not be for a couple of months yet. I thought to be approached by SC was bloody awesome on its own, but to get in SM just brilliant

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