While all the bodywork/paint was going on in Georgia, I was rebuilding the 440 and 727, along with some of the major components (heater, steering column, console, seats, etc). For the drivetrain I fabricated a test stand to mount the front suspension with the 440/727 and be used for engine breakin and installation from underneath. Planned to lift front of car with tractor, slide test stand into place, then <carefully> lower body.

Used square tube and casters leftover from a rotisserie project to fabricate a dolly to be eventually converted to an engine breakin test stand. I took some measurements from the Satellite as a reference for height of the dolly. The steering gear was rebuilt by Steer and Gear in Ohio. The front suspension is pretty much stock except for oversized strut arms. I added reinforcement plates to the LCAs.



Test fit:


K member mounted after paint:

looking GREAT!!!

Wow looks like it was well worth the trip across the country to get that body work/paint done. That car looks amazing!!

440-6 Engine. Machine work was done locally at Dougan’s Engine & Machine. I was shooting for 10:1 compression with SRP pistons approx .006" in the hole, about .045" quench. When I did the first mockup after machining, I measured approx .014-.015 piston deck height. Discovered the shop used Chrysler OE rod length (approx 6.768") in their calcs while the SCAT H beam rods I was using are 6.760" long. So the block had to go back for another decking pass. Second pass produced piston deck heights between .006-.007". Machined the intake to compensate.



Used 440 Source alum heads with Comp Cam 10deg valve lock/retainers upgrade. After much deliberation on cam choice, decided on Lunati 60303 cam/lifters. To preserve stock appearance, used OE iron intake/exhaust manifolds, valve covers. MP OE HD rockers, custom length Manton pushrods, and hemi oil pan. Carbs are new, repro 71 versions. Only change I made to carbs for breakin is #65 jets instead of the stock 62s.

Rebuilt both the stock alternator and starter to preserve date coding. Used NOS or new components wherever possible, including 50amp stator in alternator.

Bottom shot of alternator installed:


Below is the drivetrain mounted on the test stand getting ready for break-in:


Engine breakin went well, good oil pressure and temps remained at or below 200degF. Ran at 2500rpm for 30min, with occasional bump to 3000rpm. After breakin, while I was tuning the 6pack, startup and idle gradually deteriorated over time. Investigation revealed oil fouling on plugs and in combustion chambers, suggesting an internal intake leak. Removed heads (pic below), cleaned chambers/piston tops, reinstalled new valley pan using black Permatex between intake paper gaskets and heads (no sealer first time around). This solved the startup/idle issues.



Posted a video of the engine running on the test stand here:

http://www.youtube.com/watch?v=JN5rMmg_bhg

I rebuilt the 727 myself but won’t detail the procedure here. Used 4 pinion planetaries, Alto “red eagle” friction plates, MP deep pan, 4.2 kickdown lever, Trans-go street shift kit. Got a lot of help from Pat Blais Transmissions for parts and Carl Monroe's 727 rebuild book.

Sounds sweet !!! Just right .
What are the specs on the cam ?

Advertised Duration (Int/Exh): 268/276
Duration @ .050 (Int/Exh): 226/234
Gross Valve Lift (Int/Exh): .494/.513
LSA/ICL: 110/106

Great work! B7 is an awesome color, you'll get lots of compliments on it. That car will be stunning when its done, keep up the good work!

Speechless

Thx all for compliments.

Interior. Decided to add factory power windows. Had AMCR drill the holes in the doors and body to accept the harness plugs. Found the pw regulators and a correct harness from a 70 Coronet vert. Drilled out the new attachment points for the regulator/motor assembly in the door panel, not a big deal. The only issue I had was fitting the new regulator/motor in the qtr panel opening, tight fit. Glass and channels are the same, PW or manual. Fabricated some window stops. Have a complete NOS PW switch set.



The steering column is a transplant from a 70 Coronet with console and power steering. Used the suede Baltic Blue interior paint (from Mike Mancini, Instument Specialties) on the steering column and dash. The steering column was completely rebuilt, steering tube was plated. NOS ignition switch, with correct satin finish, NOS turn signal assembly, and NOS harness.



Dash frame beadblasted:

Dash install:

Rear seat (before/after):

Interior nearly done:

Getting engine bay ready:

WOW!!

Amazing!

Looking real good! Can't wait to see it on the road

Thx all. The pix are obviously a little out of order. I'm actually getting close to road trials, just a little more work on the brake system.

Had planned all along to lift the front of the car (with my tractor), then lower the car onto the dolly/suspension/440/727. Fabricated a "lift bar" which attached to the bumper/frame rail fastener holes. I used a forklift attachment to my tractor (Kubota B26) to raise the car via the lift bar. The bar was free to rotate to maintain good contact with the forks.



Here's a practice lift:



Plenty of clearance, once the front caster rig is removed, to roll in the 440/727 dolly.

Here's some installed pix. Had 2 helpers to roll and watch clearance while I operated the tractor. Nobody left to take pix (bad planning). Here it is just after installation (upper BJ still hanging loose, no rad yet). I lowered the car about an inch at a time. Clearance was very tight to the shock towers. Had to move the dolly around a bit to shoehorn it in without scraping the inner fenders and to line up the K member attachment points. About a 2hr operation.

Bumper frames getting ready:


Rear bumper mounted, with NOS bumper stops: