My 86 Monte SS

[John S]

Ok folks, this is going to be my first attempt at documenting the build on my 4th Gen Monte Carlo SS. In another post where I ranted a bit I did come to the realization that I have never really posted many details about my car here and the last time I did was a few years ago.
So now, I am going to attempt to document my build as best I can. Feel free to comment it up both positive and negative.

First a little History, I bought this car after being discharged from the Navy in 1985, I bought it in San Diego Ca and am the original owner. I kept the car bone stock and it was my DD. It is one of the few things I came away with after my divorce in 1991. Once on my own I decided to start having some fun and making modifications to the car and getting involved in the Street racing scene in Fresno in the early 90's. I was not in any position to do major changes to the car but a shift kit, Cam, Valve Springs and ratio rockers along with an NOS Dual stage cheater system really woke the 305 up. I had a very respectable runner and it was not uncommon for me to go through 2-3 bottles a weekend. I still have the original engine and tranny and the engine ran well until I pulled it out. The tranny on the other hand was definitely getting ready to heave it's guts up
The Car, Early to mid 90’s, the two are with a buddy's the Black Monte, He had a 406 and a 700R4 in the car running low 12's in 1991;



After my kids had grown it was time to leave California and head back to my hometown in NY. I had a good job offer and it would be good to get away from the crazies. When I got back to NY in 2001 the Monte was no longer my DD, I had two other cars that I could depend on and feeling the Monte was in need of some TLC I decided to give it a face lift. I dropped the car off at a shop that belonged to a friend of mine and decided that what we needed was new paint and interior. I really had not decided on too much mechanical work since I did not think it was warranted. The car remained in the shop for almost two years. I was not in a rush and being at Steve's shop kept the car out of my way.
The only pictures I have from this time are when the car when it came out of the paint booth with fresh Corvette bright white.



While the car was being painted I had the interior redone, nothing wild, but I liked it.

to be continued

[John S]

Once I got the car back and dressed it up a bit I started hitting some of the local cruises and shows with it. Here is a shot of it with the 305 still in it.




It was while attending some of the shows and seeing all the great cars I decided that it was time to move in a different direction. It was also about the time I learned about Pro-Touring and decided that is how I would fashion the car. I know I did not hold true to the strictest sense of PT but that's how things work out.
The next step was to determine what I wanted to do with the car and how to get it there. I started researching on the Monte sites as well as here and Lat G and here is what I came up with initially;
Engine was to be a 406 with a 700R4 trans.
Rear Disc brakes
Aftermarket wheels and tires to be determined.
A Posi rear end.
So I started accumulating parts;
I found a Dart little M block while on a business trip in Ohio for a steal;


A set of AFR heads from ebay At this time I also learned that the Dart block could easily be made into a 427, and the heads I had would work with it. So that was the first change in plans.
The next change in plans came in the shape of a used T56 from a 97 Camaro. Folks were starting to put manuals in Montes and I wanted to also. I also got the center console and hand brake from the donor car.
Now I was on a roll and a mission to gather all the parts I would need for the engine.
Original plans called for a Crank trigger and MSD dist. But that was to change after a conversation with Frank @ Prodigy. I was also going to install a manual clutch, That was until I helped a friend install one in his Monte with a TKO 5 SPD. What a PITA. I decided that a hydraulic clutch would be much more user friendly... Little did I know....
I did find that Weir hot Rod products had a bell housing and hyd TO bearing that would work on the LT t56, so I ordered it up as well.

All the parts;




It took about a year but I finally had everything I needed to build an engine. I found a builder in northern NJ, loaded all the parts and took a drive.
Engine Specs;
427 SBC
Eagle forged steel crank, 4”
Eagle H Beam rods, 6”
Weisco Forged Pistons
Cam is a custom Lunati Grind on a .900 base. 0582”/.582” lift 251/262 dur @.050 Solid roller
Crane Gold rockers
Comp Cam lifters

I should note that originally I had ordered a Comp Cams ground on a small base circle. Once installed the engine builder felt that the cam was too big and clearance my end up being an issue. A call to Comp revealed that the cam was ground on a .950" base, their minimum. Lunati was able to grind a similar profile on a .090" base.

[John S]

Finishing the engine;

The short block


The fuel delivery;
I had intended on using a Stealth Ram and the Holley electronics on the engine. Once again during a call to Frank @ Prodigy plans changed. During the call Frank convinced me that the FAST XFI would be a better way to go. And instead of using the MSD dist. And Crank trigger FAST has just released a Dual Sync Dist that will handle all functions and integrate seamlessly with the XFI. SO, the crank trigger and Dist went back to Summit and I had an XFI and dual sync Dist on the way. I ordered the XFI with the universal harness so that I could tailor it to fit how I wanted.



The stealth ram just looked to plain so I had a top plate made and then powder coated the manifold and parts.

All put together…



Next installment I’ll get into the fuel system…

[L & H Kustoms]

Looks good nice project!

[mc84_zz4]

Woo hooo! it's a build thread!
Congrats John, I had not seen some of those before.
I like how you did a lot of your electrical wiring too.

[Tmos87]

Great write up.

[John S]

Ok, next up SUSPENSION;
I've been through several versions of suspension on the Monte. The first upgrade I made to the front end was the addition of the SC&C front frame cross brace. What a huge improvement just this item make and if anyone with a G body does not do anything else to the front suspension I highly recommend this unit. The heart of the front suspension though, has become the Spohn tubular lower A Arms & SPC adjustable upper arms. I went with the adjustable uppers because I wanted to be able to make alignment changes myself and so far have been happy with them The lowers have the Del-a-lum bushings installed.
The first go around was with QA-1 single adjustable shocks with Moog springs.I used this initially with the 305 still in the car. With the new engine weight changed enough that I wanted to go with Coil overs. I currently have Alston adjustable shocks mounted with 8x2.5" 600lb springs. This setup gave me the ride height I wanted and a good firm ride. I am considering going to a double adjustable now since I have heard that Alston has really improved the shocks. New Urethane sway bar bushings were installed as well. I still have the OEM sway bar in for the time being, more on that later.

The rear suspension started with the stock rear end and boxed control arms, then added QA1 adjustable shocks, new bushings and dual rate springs. With the addition of the Moser rear end I installed Spohn lower control arms and Edelbrock adjustable uppers. Once more the stock sway bar is still in place, but that will change very soon as well.
I've been talking to Mark at SC&C once again, it looks like a Watts link may be in order once I can line up a few other details. Hopefully I'll get installed by June.
Here are some pictures of the setup;

[RobertGP]

Lookin sweet!

[Motown 454]

Sweet project! You used some nice parts in you motor. Are you going to try it on a dyno? It should make some nice numbers. You'll have a nice ride when your done.

[BulldawgMusclecars]

Very nice! Always loved the Monte SS bodystyle. There is a really nice one for sale down the street from my shop right now.

[John S]

Sweet project! You used some nice parts in you motor. Are you going to try it on a dyno? It should make some nice numbers. You'll have a nice ride when your done.

Thanks, and stay tuned. I've had the car together for several years now and have made some changes to the engine. It has been tuned and dyno'd and I'll be posting a video in one of the upcoming posts.

[THE TECH]

Really nice setup!

[The Stickman]

Nice build. Very clean.

[John S]

Setting up the fuel system to feed the 427 took a little thought. I needed to keep the stock tank but felt installing a sump was in order since the standard fuel ports and lines would not supply enough fuel volume for the injected engine. I decided to go with all Aeromotive hardware which would include an A1000 pump, Aeromotive pump controller, Referenced regulator, pre and post filters a Y block and check valve. All this not to mention all the braided lines and fittings.
I wanted to mount the pump as close to the tank as possible so out came the sawzall and the stock spare tire well was removed from the trunk floor. This opened up all kinds of room around the rear frame rail.
I mounted the pump to a piece of 1/4" aluminum plate using cushioned isolation mounts. Using the rubber mounts make the pump almost noiseless and you can barely hear it run during startup and not at all while the engine is running. To supply the volume of fuel needed a -10 hose was run from the sump, through the check valve and into the Pre-Filter. I installed the check valve since the pump sits higher than the 1/s mark on the tank and it would prevent fuel from draining back out of the pump.
1/2" aluminum tubing was run from the post filter down the frame rail along with a 3/8" aluminum return line. The return line was run to the original supply line on the tanks sending unit. I modified the tubing so that the fuel would return high up in the tank and not disturb the flow down around the sump.
The 1/2" tubing ends just before the firewall and feeds into a -8 braided hose into the Y block, then -8 from the Y block to the fuel rails.
SO far this system has run good and I have not experienced any fuel overheating problems. This may be due mostly to the fact that I have driven the car for more than about an hour constant and the pump controller.

The Sump and fuel pump filter installation.




The modified sending unit for the fuel return


Supply and return lines down the frame rail


Feeding the fuel rails, this has changed a bit since removing the Stealth ram


Next, the new intake

[John S]

The Monte had been running for almost two years when I decided to change the intake and TB. The first Dyno and system tune netted 434Hp and 450 Lbft at the ear wheels but the engine was not getting enough to feed the top end. Although a fabricated intake would be the best way to go it is not within my budget at this time so instead I opted for a Victor E manifold and the F.A.S.T. throttle body. New fuel rails were also in order with larger internal volume.
At the same time of installing the new intake new set of headers and a Pypes exhaust were put on. The original headers were 1-5/8" primary and a Pypes 2.5" exhaust. The new headers are Hedman Hustler race headers at 1-3/4" and a Pypes 3" exhaust dumping at the mufflers. I've since installed tailpipes on the car and it sounds much more manageable now.

The new TB


The new intake in the oven being de-gassed and pre heating before powder coating it with Satin Black.


Putting it all back together...


Since I had the front accessories off and I was powder coating parts anyway I decided to dress things up a bit. Not everyone cares for the look but I'm happy with it... for now.


I ended up having to make my own throttle cable and return spring brackets since this high $$ TB does not come with any.


A view of the regulator


And the finished product, at least how it looks now.


Next was dyno and tuning, the engine gained about 20 HP and 30lb ft and will rev clean up to 6500 without a hiccup. It might go more but we have not pushed it there yet.

The dyno run, sorry for the poor quality, it was the best I had to work with.

[CruizinKev]

schweet!!!!

[chumscustoms]

sweet build i am getting ready tostart on a ss as well and these threads are great info
keep it going

[jackfrost]

cool project. I wouldn't mind hearing more about the manual trans install. what'd you use for pedals?

[John S]

Pedals are stock G body pedals. I only had to modify the clutch pedal to mount the MC arm in a suitable position for pedal pressure.

[John S]

I picked up a few things from UMI while at the GM Nationals last weekend. When I got home I placed an order from Spohn and here is the result;

Frame braces from UMI and Pro Touring swaybar from Spohn.

I also got a drive shaft loop and billet tie rod adjusters from UMI, those go in next.