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Showing content with the highest reputation on 04/24/2023 in all areas

  1. GtpKo

    It's begun! - 2nd Gen W-Body 3800 5-speed F23 Swap

    I should mention, this is not a power build. I don't need a stage 3 or 4 clutch quite yet. Not even a stage 2. Sure, on the next swap, for sure I'll go all out stage 3+ or something since I'll need it then but not for this test mule of a car. This dimple on the passenger side firewall area is made for guiding a hole saw to the right location for shift cables. It really appears that the engineers at GM wanted to leave the door open to making a manual option in future model years. Drilled with a 2" bi-metal hole saw, less than a minute. Same on the engine bay side. Sorry for the portrait mode photos at times. Trying to work and remember to pause to take a pic now and then. Here is the wiring harness that needs to be pulled back into the cabin for relocation. However, as I found out later, you may not need to do this if you can just remove the huge rubber plug and enlarge the top portion of this hole. Now this is what I ended up doing - this pic is from the inside of the cabin. You can see where I tried opening up the hole at the bottom for the wiring harness to go through, still seemed to interfere with the clutch pedal a bit. Also, the wiring harness through the bottom seemed to barely have any slack in it when reconnecting. I decided it would be better to enlarge the top of the original wiring harness hole and feed the wires through there instead, going above the clutch pedal mount entirely. You can also see where I ended up drilling holes for the studs on the clutch pedal mount, where the clutch master cylinder bolts to. Now that I remember, there is a pesky inner plate that slides up and down where the brake pedal bracket bolts to the firewall. The holes never stay lined up on their own, I used aluminum tape to hold it in place so I could get the dang thing back in place. Here is the best pic I could get of the wiring harness fitting nicely above the clutch pedal bracket once bolted in. And here is my 2nd attempt at cutting and re-welding the clutch pedal arm to the right angle and height to be even with the brake pedal when both are fully installed and hooked up. Not pretty, but that's what you get when you weld it at the wrong angle the first time. I've decided I will do this whole swap twice. First time works the bugs out. Next time will be on a rust-free car that I will keep for a long time. Here are a couple of pressure plates I have to choose from, first on the left is for a Fiero 2.8, the one on the right is a used one from a Camaro. Both will work but the Camaro one is stronger & bulkier. I'll test fit both and see when I get there. I'm not dropping $400 on a clutch combo until I need it. Anyways... Looking exciting already! Positioning is good for my feet. It's important to make sure you position things where you like while you have the chance.
    3 points
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