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Old 10-12-2009, 09:41 PM   #1 (permalink)
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The Polar Bear - 5.3 ZJ on coil overs

In the beginning there was a white ZJ (the Polar Bear), an idiot with a broken hand and a 5.3 from an ’03 Silverado.





It had a 5.9, pulled that shit. I wanted a more powerful and efficient motor, for those interested, the 5.9L is for Sale.



First things first, strengthen up the unibody, inside and out.



Next started fabing the motor mounts.


Passenger side:
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Old 10-12-2009, 09:43 PM   #2 (permalink)
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Driver’s side:

And finally on its own:


Now on to the coil overs.




Next added a 4th bolt for a waggy steering box.


Cut a hole in the fender for a second battery.

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Old 10-12-2009, 09:55 PM   #3 (permalink)
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Fabbing the air bump brackets. Mocked them up in SolidWorks first.



Working on the track bar.
Frame side bracket:

Axle side bracket:




Track bar at ride height:

At full bump:

Clears the diff by .75”


Primered the engine compartment.



And that's where I'm at now. I painted it yesterday, this week I'm going to wet sand it and next weekend I'll clear coat it and start the final assembly.
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Old 10-13-2009, 04:52 AM   #4 (permalink)
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I guess no one knows what to say. I say kick-ass! That's thinking outside the box. Takes some will power to deal with bracing a uni body for abuse.
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Old 10-13-2009, 05:21 AM   #5 (permalink)
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Looks good
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Old 10-13-2009, 08:38 AM   #6 (permalink)
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Looks great! Plans and spec on the motor? And what trans and transfercase?

I spy two Gen III whats the other one?
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Old 10-13-2009, 08:54 AM   #7 (permalink)
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Thanks guys. That picture of the motor is from when I picked it up at the wrecking yard, so that other motor isn't mine. For now the internals are stock. I had the ECU programmed by Wait 4 Me Performance with a mild tune. I'm going to weld a custom set of long tube headers after I get it to pass smog (I live in California). And Im just going to use a short intake tube with a K&N filter for the intake.

The transmission is a 4L60E and the transfer case is an NP242 adapted using an adapter from Advance Adapters (they are conveniently 45 minutes north of me).
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Old 10-13-2009, 12:39 PM   #8 (permalink)
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What happened to your hand and do you plan on a cage?
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Old 10-13-2009, 01:50 PM   #9 (permalink)
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Lookin good, man. That 5.9 is HUGE

Keep up the progress
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Old 10-13-2009, 03:32 PM   #10 (permalink)
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What happened to your hand and do you plan on a cage?
The hand was my own dumb ass fault, I punched a palm tree after a friend pulled some f'd up shit. And then I didn't get it checked for a month and by then it had fused back together at a bad angle so they had to operate to reset it.

A cage will definitely happen but right now I just need to get it driving again so I have a car for the winter.
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Old 10-13-2009, 04:50 PM   #11 (permalink)
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Originally Posted by downtowncb View Post
Thanks guys. That picture of the motor is from when I picked it up at the wrecking yard, so that other motor isn't mine. For now the internals are stock. I had the ECU programmed by Wait 4 Me Performance with a mild tune. I'm going to weld a custom set of long tube headers after I get it to pass smog (I live in California). And Im just going to use a short intake tube with a K&N filter for the intake.

The transmission is a 4L60E and the transfer case is an NP242 adapted using an adapter from Advance Adapters (they are conveniently 45 minutes north of me).
Why not save money and get a GM NP241 drivers drop?? They are common and will bolt right on the 4l60 with a stock adapter and it will have VSS in it.
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Old 10-13-2009, 05:44 PM   #12 (permalink)
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Or if you want to keep the NP242, pull the input from a similar year NP241C and swap it into the NP242. No adapters necessary. Still have to deal with the VSS though...

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Old 10-13-2009, 06:28 PM   #13 (permalink)
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Thanks guys. I have two VSSs to deal with. I'm using the one in the 242 to feed the Jeep ECU so my stock gauges work and the one between the 4L60E and 242 that Advance Adapters provides will serve the Chevy ECU for shift points and what not. Also I already had the 242 and Advance Adapters is only 45 minutes away. I just drove up to their shop and after chatting with one of the guys for two hours, getting a full tour of the shop and getting to check out and crawl under their four door rubicon, they gave me a really good deal on their kit.

Needless to say, it's already installed, the new input shaft is in the 242 and I can't take it back.
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Old 10-13-2009, 10:14 PM   #14 (permalink)
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I'm interested on how your going to make it pass smog... great build.
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Old 10-13-2009, 10:42 PM   #15 (permalink)
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I'm interested on how your going to make it pass smog... great build.
Very carefully haha. Actually the '03 motor I had only has catalytic converters and EVAP for emissions, both of which I have or am going to include. After all of the research I've done I think I've satisfied all of the requirements. And if it does fail, I'll transfer it to my address in Nevada.
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Old 10-14-2009, 07:29 AM   #16 (permalink)
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Very carefully haha. Actually the '03 motor I had only has catalytic converters and EVAP for emissions, both of which I have or am going to include. After all of the research I've done I think I've satisfied all of the requirements. And if it does fail, I'll transfer it to my address in Nevada.
Cats and hook up the EVAP system. GM quit using the EGR that year. As the GM controls the fueling better to reduce the emissions.

I don't think you'll have a problem. As long as the EVAP system doesn't leak. Did the ZJ have an EVAP canister? All you have to do is hook the canister purge valve to it.
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Old 10-17-2009, 09:03 PM   #17 (permalink)
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Coated the transmission with an industrial epoxy thats tough as shit. It's a lot grayer than it looks in the photo. I'm doing the transfer case tomorrow.



We've got a few projects going My Jeeps, my roommate's baja bug, and other roommate is painting his motorcycle. Our neighbors LOVE us.

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Old 10-18-2009, 06:07 AM   #18 (permalink)
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Very nice work all the way around! What epoxy did you use on the trans if you don't mind me asking. I have mine apart and after it comes back I was thinking about coating it with something.

Also I love the Papa Johns delivery sign on the top of the Bug!!!

Keep up the great work!
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Old 10-18-2009, 07:34 PM   #19 (permalink)
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Thanks! This is the epoxy I used, I bought it at an industrial coating shop.



I finally finished painting and doing the clear coat! and for the first time since June was able to start putting stuff back on it.


Also, the bug drove today for the first time in 4 years!
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Old 10-19-2009, 07:57 AM   #20 (permalink)
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I like the detailing, cleaning, and painting the engine bay! Top notch!

Oh yeah FUCK the neighbors!!!
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GM Gen III/IV V8 swap info

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Old 10-19-2009, 10:14 AM   #21 (permalink)
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Lookin good man, what are you using to cut all of you brackets etc?
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Old 10-19-2009, 10:55 AM   #22 (permalink)
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Lookin good man, what are you using to cut all of you brackets etc?
With a grinder! haha I did a little write up on how I did these on Mall Crawlin, I'll copy it over here for reference.

Since I've got a little time before class, here is how I have gone about making all of my brackets with nothing but a grinder, spray paint and sheets of sticker paper. I use SolidWorks for my modeling because I get it for free through Cal Poly but if I didn't have that luxury I would use Alibre

1. I start by measuring the dimensions that I need from the frame. For example on the track bar bracket, I measured the distances between all of the bolting holes and how far they were from the bottom on the frame. I used this information to dimension them in SolidWorks.





2. Next I used the extrude function in SolidWorks to turn them into 3D, since I used 1/4" steel to make the track bar bracket, I made the model 1/4" too.



3. After turning all of the 2D plates into 3D parts, I combined them all in an assembly. Here I can see how it is all going to fit together and where I need to make changes.



4. I then take the plates and turn them into drawings. All of these drawings are printed out and stuck to cardboard. I take the cardboard model and use it to make adjustments to the parts to ensure the bracket will come out as I need it.



5. Once I'm satisfied with the drwaings, I print them out 1:1 on large sheets of sticker paper. These I cut out and stick to the metal that has been cleaned with brake cleaner or lacquer thinner. Below is a photo from my construction of motor mounts.



6. I then spray around the edges with spray paint in case the sticker comes off I still have a line to follow.



7. Once all of the brackets are cut out using the grinder, I take the pairs that are supposed to match and clamp them to the drill press and drill the hole. I then use the hole and a matching size bolt to clamp the two pieces together and put them in the vice. Then I use a flap disc on the grinder to give the two pieces the same profile.



8. And I am left with professional looking pieces that I can use to construct my brackets.



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Old 10-19-2009, 04:39 PM   #23 (permalink)
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This is an amazing build. I'm really impressed by your ingenuity, especially given the basic hand tools you have access to. At first I thought you were another professional machinist with access to CAD driven cutting tools. Well done.
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Old 10-19-2009, 05:41 PM   #24 (permalink)
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Thank you very much!
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Old 10-19-2009, 06:11 PM   #25 (permalink)
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Yeah saw the "boxer's break" and had to comment. Nice hardware pins in the metacarpals, Titanium?

Keep the build going, Nice fabrication and cad. Killer
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