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'66 El Camino: Engine Swap, Pt. 2 The engine upgrade on the '66 El Camino continues with a beefed up cooling system, short RAM intake and performance exhaust. From "Resto Rides" episode DRRD-103

(Continued from page 1)

Now that the front clip has been reinstalled it's time to move on to updating the exhaust system. Andrew and Christie look at how to mate the LT-1 manifolds up with the El Camino exhaust. Andrew also works to make the car's air-conditioning system match up with the new engine. He also updates the cooling system.

In this phase of the project, the exhaust system is mapped out so it can be fabricated at our local muffler shop. The A/C condenser is installed along with a high flow aluminum radiator, hoses and a high-torque electrical fan to keep everything cool.

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New Exhaust System

One of the great things about using a pull-out-ready engine is that you can use the factory manifolds and flanges.

• The LT-1's downpipes don't fit with the El Camino's exhaust, so Christie uses flex pipe to measure for a custom pipe that will be fabricated to fit the new system. Fabricating new downpipes requires some heavy-duty tools; so using a professional muffler shop will save time and money.

• Under the car, Andrew and Christie decide to cut the mid-pipes short to make room for the custom sections.

• With the factory flanges stuck in the ends of the flex pipes, Andrew and Christie work them into position.

• To keep the measured bent pipe from straightening out during transport to the muffler shop, thereby losing your measurement, put a piece of masking tape along the bend. If the flex pipe bends out of measurement, the tape will crease and you'll know to return it to a flat position without creases to once again obtain your correct measurement.
  
  
• Use the masking tape to set the angle of the bends. Mark the location for the oxygen sensor where the cross member is, plus the final length of the pipe so the shop knows where to mount the catalytic converters.

	Installing the a/c evaporator canister
	Connecting the a/c lines

Air-Conditioning System

The previous owner of the El Camino installed a new air-conditioning system. Unfortunately, the compressor on the new engine isn't compatible with the system. Andrew has to switch the compressor out with a new one that will work with the system.

• Andrew removes the grill by drilling out the rivets. He installs a modern condenser to cool the freon. Andrew backs out the hood-latch bolts, and the AC condenser slides between the latch and the radiator support. When it's in place he replaces the latch bolts.

• Next, Andrew installs the dryer, which filters moisture out of the freon circuit and keeps the AC system rust-free.

• To complete the system, Andrew hooks up all the lines and fittings.

• At the muffler shop, Christie's friend Bryan begins work on the new downpipes. First, he uses the flex pipe templates to make the proper mandrel bends, which create angles without creasing or collapsing the pipe.

• Then Bryan cuts the bent pipe down to accommodate the catalytic converter and braided flex pipe.

• When Andrew and Christie installed the custom gas tank in the El Camino, they had to cut out the old tailpipes. Now they have to put the tailpipes back together. Since either side of the cut pipe are the same size, Bryan has to swedge — or expand — the cut ends of the tailpipes so their larger ends will slide over the original pipes and clamp together. Once all of that is done, the pipes are good to go.

	Installing the radiator
	Connecting the transmission cooler line

Cooling System Upgrade

The new engine has a closed-loop system, so it needs an upgraded radiator with overflow tank fittings. Along with the new radiator, Andrew also installs an electric fan that will plug into the harness. You have to have an independent fan running on the radiator to keep it cool. Once it's installed the fan will be controlled by the engine control unit.

• Instead of mounting a used LT-1 radiator, Andrew and Christie install a custom radiator that has a built-in transmission cooler. The existing transmission cooler lines need to be cut apart and adapted to fit with the new car. Andrew bends a new pair of transmission cooler lines to bridge the gap between the cut lines and the new radiator.

• Andrew tightens up the lines and fittings and moves on to adapting the radiator hoses.

• Because the new radiator wasn't made to connect to the LT-1 engine, it will take some work to fit the radiator hoses. Andrew cuts and trims the hoses to get a decent fit. Later, he'll go to the auto parts store and do some trial-and-error hose fittings until he can find the best permanent solution.

• Once the hoses are on, Andrew plugs the electric fan into the harness. The custom cooling system is almost complete. The remaining portion of the upgrade will be done after installation of the short RAM air intake.

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