VZ Calais Alloytec to LS Conversion

[Mitchell Pope]

Hey fellas,
Throwing a thread together about my progress on LS swapping my VZ Calais. Long term hoping to run a LS3, short term running LS1. Follow me on Instagram @gmhvz_build

Originally I had the 190kw Alloytec, the vehicle ran well for a couple years until I cracked the radiator and the vehicle overheated.
I pressure tested the system, found the thermostat housing was leaking. I removed the Plenum and manifold where I found it had burnt a number of valves.

I lost a lot of interest in the car at this point. The car was parked up for a couple of weeks until I decided to pull the engine and gearbox. Since then the car sat for over a year.

Recently I found a wrecked VZ calais with LS1. The vehicle starts, runs and drives. The Calais cost $3000, more than i was hoping but it is the perfect donor. The vehicle was in Melbourne, Im located North of Adelaide. The trip was 19 hours return. The vehicle had been stripped but still started and drove. This is the new donor vehicle.
The plans are to complete strip this vehicle and convert it over to the Original Calais.

The dash was stripped and then removed. The wiring harness was removed from the dash frame. Currently my next challenge is to remove the whole loom from the interior. The fuse box has to be manipulated through the small opening on the firewall.

I removed all the wiring from the engine bay, the loom connected to the engine loom though the positive battery terminal. The rest of the dash loom ran to the head lights, front horns and bonnet release switch though the radiator support. The moulded trim around the strut tower was removed, the fuses and relays were removed from the fuse box.

This loom and fuse box was fed though the firewall opening and the entire loom removed from the vehicle.

Up next, Engine and gear box to come out.
I cut the upper and lower radiator support panel out. I didn't need to but it just gives me some more room. This way i can remove the engine and Trans together without having the crane hit the roof.

 

[Mattde]

I'm really looking forward to seeing how this build progresses! There's bound to be a few headaches along the way but it will be a rewarding build that's for sure!

 

[Mitchell Pope]

Decided to change my plans, was going to remove the engine and trans from the K-frame, then remove k-frame later on.
Once I had the engine and trans unbolted from the car i found it was fiddly and awkward to try and manoeuvre them out. I decided to bolt the engine back to the K-frame and then drop the whole assembly. I removed the 13mm on the bottom of the steering shaft, the two brake lines going to the front calliper, strut top nuts and both wheel speed sensors.I made sure no fuel, coolant hoses or wiring was left between the engine/trans and the body. I removed the 4 K-frame bolts while the engine was supported on the engine crane. This was much quicker than my previous plan. I now need to lift the vehicle high enough to slide the engine and trans out from underneath.

I managed to lift the front of the vehicle just high enough to slide the engine and front struts out from underneath. I Removed the engine mount bolts and separated the engine/Trans and K-frame. Next step is to remove the Trans inspection plate and remove the torque convertor bolts, remove the exhaust manifolds then mount the engine on the stand.

With the engine out and on the stand, Its time to remove the rear cradle. Couple Subframe bolts, handbrake cables, brake hoses and diff mount out of the way. Its ready to fall out.

Not a lot left now. Take the fuel tank out the worm out what hard lines I need (if any).
Fingers crossed the Car will be gone in the next week or so and the Original calais come come back and be stripped down.

Ive been playing around online at http://commoconfigurator.net/ to try and get an idea on what I want the Calais to look like long term. Ive put a Collage together of a variety of colours. Would be good to hear some feedback on your preferences.

Progress!!
Everything has been stripped off the car. A lot of the parts I wont need but Ive stripped to keep as spares. The doors have been removed to make it lighter.

Everything has been sorted into Ex-Holden stillages and onto pallets.

Ive rolled the Calais shell outside and have managed to cut the car in half to make it more manageable. Once the car was split, family helped me lift the half shell onto a trailer.

 

[gungazza]

lot of work but looks like you got it worked out ,want to do mine lol

 

[JoshlikesCalais]

well done! Jeez a 19 hour round trip lol I thought driving to Mt Gambier to buy a car was bad enough

 

[Mitchell Pope]

While the shed is clear, I plan on working on the K-frams, engine and Trans before bringing the original Calais back.
Ive started on the rear sub frame. Remove the sway bar, brakes, Diff, control arms, bushes and bearings. New nolathane bushes will be fitted, new wheel bearings and hopefully, 3.9s and TruTrac diff centre fitted. While everything is apart, bits and pieces are being sent out to be sandblasted and powder coated.

Once the control arms were removed from the subframe I had the challenge of removing the hubs and bearings. The rear cap on the drive shaft was removed with a 3 jaw puller.

Once the rear cap was off I faced the challenge of removing the drive shaft. The subframe has been stored outside for the last couple weeks and has seen a lot of rain, this has caused a lot of rust on the splined shaft. I tried using a puller to push the shaft out, wouldn't budge it. I tried using a brass hammer, again no luck. I bit the bullet and smacked them out with a large hammer. This damaged the thread as I was expecting. Im now hunting around for some new rear wheel hubs. Once they were out though, the bearing was all good to be removed. I used a small hydraulic press I bought on eBay for about $70.

The subframe bushes were pried out using 2 pry bars.
Now that everything is disassembled its ready to go out to be blasted and coated.

 

[DaCoffee]

hi, hows the progress happening on this as im about to do the same thing and will post pics up as i go along too and this will be my first time changing a more modern car over to a V8 as i have done a few of the old 6 cyl engines over but not something like this.
im just getting all the parts from a wrecker for a great price with everything to change from the alloytec (rattle tech)

 

[DaCoffee]

I got the engine crane today to start getting all my tools to do the job but still working out what I need to do the same job and if anyone has a list would be great and the reason why it was used would be good cos only have 2 weeks solid to get mine done. Ex got everything so starting my tools again

 

[DaCoffee]

So I asked a guy about conversion alloytec to LS and got this info to share, I will keep posting more in here as I learn along the way.

Youd want a standard one which I also have.

Vz are probably the trickiest of the lot.
You'll need.
Pcm-engine ecu.
Engine loom.
Bcm-body control module.
TAc- throttle actuator module
V8 accelerator pedal. Different to v6.
Vz engine with bolt ons electric throttle body and vz maf etc.
Possibly instrument cluster too
Any ls1 trans will do
I've heard some say the body loom but dont see why cant run separate wiring harness from pedal to the tac though.

I have vz ss ecu. Engine loom. And battery power starter loom. Bcm with key fog, pim and tac all from the same vz ss car.

If u use a 4l60e transmission that wasnt from a vz. I also have the inhibitor switch that suits the vz loom.

 

[Aus78Formula]

I wonder how many LS cars you could buy for the price of the conversion once done! You must love that particular car.