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Convincor LS Swap Project Thread

Well, the headers are here. I got them bolted on last night and murphy's law kicked in. Of course the tails don't line up with the existing holes. So, tonight I am going to have to take either a grinder or a hole saw to the transom. Needless to say. I'm sick to my stomach thinking about doing it, but it needs to be done. Hopefully I have her running on the hose again by this weekend WITHOUT reversion!!!

Wish me luck, I'm gonna need it tonight!!!
 
RNGRDVE said:
Use a hole saw and save what you cut out for filler to glass into the old holes.
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I did make a plug to use in the existing hole with a new pilot hole for a hole saw, but my only reason for taking a grinder with me as well is that I don't have to remove that much material. Maybe only a 1/2" or so. And I can machine some new trim flanges to cover anything I cut/grind. I just hate the fact that I have to take eiher to my boat!!!!
 
corey331 said:
I did make a plug to use in the existing hole with a new pilot hole for a hole saw, but my only reason for taking a grinder with me as well is that I don't have to remove that much material. Maybe only a 1/2" or so. And I can machine some new trim flanges to cover anything I cut/grind. I just hate the fact that I have to take eiher to my boat!!!!
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Good luck on the modification. I'm really looking forward to seeing the results of all your hard work with this project.
 
Getting closer Corey. The best part is very near ! Also it's extremely hard to guide a holesaw without having material to drill a center point. Been there done that !! Good luck and see you on the lake !
 
Problem Child said:
Getting closer Corey. The best part is very near ! Also it's extremely hard to guide a holesaw without having material to drill a center point. Been there done that !! Good luck and see you on the lake !
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I machined a plug today that fits in the stock exhaust hole. Then I drilled a pilot hole in it that's offset the direction I need for the hole saw drill bit to use as a guide. It should work good, but not sure I will go that route yet or not. Going to take a good hard look at it and maybe get a second and third set of eyes on it before I do any kind of cutting!!
 
I was scared just drilling the intercooler dump hole and holes in the dash for added gauges. I can't even image how much of a nervous wreck I would be cutting holes for the tail pipes. :eyecrazy::eyecrazy::eyecrazy:
 
Well, after staring at it for about 2 hours.....measuring, and remeasuring...then measuring again, I got the first hole cut. It lines up pretty good now. I'm going to have to hit it with the grinder just a little bit to make it line up perfect, but it looks like the new trim rings lightning sent me will cover everything up nicely. I'm going to cut the second hole tonight, which will be much easier knowing that the first one worked. Then I'm going to machine some trim rings for the inside of the transom to give it a more finished look.
 
Hack said:
We need some PICS!!!!!
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I'll snap some for ya. I'm doing some more transom work after this is done. The previous owner changed tabs and while they plugged the old holes, they didn't finish them to my standards. So I'm going to be fixing that as well. All just in time to redo all kinds of stuff on the transom next year with the addition of an IMCO extension box, hydraulic steering, k planes and a billet swim platform. I would be doing a lot of that stuff this year, but it's time to stop working on it and start using it!!!!
 
corey331 said:
I would be doing a lot of that stuff this year, but it's time to stop working on it and start using it!!!!
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I hear you on this as I'm in the same situation. Ran out of time before the nice weather hit. Now I try to do and much as I can between boating on the weekends which sucks. Work just seems to get in the way of progress. lol
 
Well, got the exhaust all fitted in. Took some more grinding than I had planned, but it fits and the trim rings cover the new holes. It's not going to be perfect, but it'll do until next winter when I can redo the transom. I got the transom all sanded down tonight in preparation for the gel repair. Also got my inner trim rings machined today. The CNC was being used, so I did them old school on the Bridgeport. They still turned out pretty good. Hoping to have all the gel repaired by Thursday. Once that's all done I'll final assemble my headers and fire it up on the hose again. Barring any issues I find then, I might dunk it this weekend at my little local lake just to putt around and make sure I don't have any issues with the cooling system. Then I'll probably tow it back down to Cumberland next week sometime. Keeping my fingers crossed that everything goes well!!
 
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