5.3L LS swap and overall restoration – Reference photos with descriptions
…arranged newest to oldest…
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plug wires installed...

plug wires installed...

oem Gbody power steering hose on left (flared). newer hose on right (o-ring).

oem Gbody power steering hose on left (flared). newer hose on right (o-ring).

oem Gbody power steering hose on left (flared). newer hose on right (o-ring).

scored a better battery tray at the yard...

scored a better battery tray at the yard...

Fuel lines...

Fuel lines connected...

Fuel lines connected...

first version of TV / throttle cable bracket fabricated...

first version of TV / throttle cable bracket fabricated...

first version of TV / throttle cable bracket fabricated...

first version of TV / throttle cable bracket fabricated...

measuring up the bracket and connection point for TV cable...

measuring up the bracket and connection point for TV cable...

measuring up the bracket and connection point for TV cable...

fuel line awaiting install...

DBC throttle body and coil packs installed...

DBC throttle body and coil packs installed...

DBC throttle body and coil packs installed...

DBC throttle body and coil packs installed...

gotta change a hose here... PCV hose on this intake used a different than this valve cover wanted...

valve covers installed...

valve covers installed...

valve covers installed...

intake installed...

Summit Exhaust Manifolds SUM-G9080 coated and installed.

Summit Exhaust Manifolds SUM-G9080 coated and installed.

new replacement AC evap coil... damaged in shipping...

new replacement AC evap coil... damaged in shipping...

new replacement AC evap coil... damaged in shipping...

new replacement AC evap coil... damaged in shipping...

new replacement AC evap coil... damaged in shipping...

new replacement AC evap coil... damaged in shipping...

more fitment...

more fitment...

finished wiring up the gauges...

finished wiring up the gauges...

finished wiring up the gauges... used several of these ebay plugs and connectors in this build.

finished wiring up the gauges...

finished wiring up the gauges...

idiot light reference..

idiot light reference..

wiring up the gauges...

Summit Exhaust Manifolds SUM-G9080. Bare, uncoated. I sprayed with ceramic header paint and am curing them in a free oven...

Summit Exhaust Manifolds SUM-G9080. Bare, uncoated. I sprayed with ceramic header paint and am curing them in a free oven...

Knock sensor wiring harness rebuilt and installed. Why buy new when you can make your own?...

may as well clean this mess out while I'm here... heater core...

may as well clean this mess out while I'm here... AC evap coil...

may as well clean this mess out while I'm here... Original heater core and AC evap coil.

knock sensor wiring harness repair...

knock sensor wiring harness repair...

knock sensor wiring harness repair...

Those are BRIGHT! Glad it has a dark tinted lexan cover for it!

that should work... let's try it out...

time to start mounting the gauges to backing plate.

time to start mounting the gauges to backing plate.

Needs some fine adjustments...

Needs some fine adjustments...

While the Create-a-Dash kit came with the plastic for backing, I used some scrap I had... I felt it needed to be arched slightly for aesthetics..

I carefully measured the template several times before drilling any mounting holes in the backing plate.

CAD allowed me to print the layout for mounting...

I was going to cut an modify this electrical membrane and re-use it, but wasn't necessary to modify it... I used a marker to trace the lines around the membrane to confirm what I was going to cut and not.

Test fitting the layout. Keeping some of the idiot lights in use... brake, check engine, etc... so it took some extra work to get this all to fit.

Modifying as little as possible with rotary tool as to keep some of the functioning idiot lights. Another mix of old and new technology.

Here you see the original vs the modified version of the faceplate.

Still nervous about cutting up the original even though I spent many hours on the design and layout...

Original cluster was clean and in great shape. Showing just less than 180K

Intellitronix speed sensor is not threading on because the threads are damaged. Eventually will need to replace this housing... Found later that this gear was apparently recalled back in the 90s. New housing would only work with a new gear... So both replaced.

700R4 speedo cable connection

Intellitronix Oil pressure sender installed. Needed a brass extension for clearance.

back in and intake and valve covers mocked up for some measurements and clearance check.

back in and intake and valve covers mocked up for some measurements and clearance check.

back in and intake and valve covers mocked up for some measurements and clearance check.

back in and intake and valve covers mocked up for some measurements and clearance check.

back in and intake and valve covers mocked up for some measurements and clearance check.

a little too much distance between the flexplate and converter. added a washer as spacer.

cleaned and painted...

cleaned and painted...

cleaned and painted...

Welding up a bit of the notched member. I'm not a welder, but that is obvious...

Welding up a bit of the notched member. I'm not a welder, but that is obvious...

oem Gbody clam-shells and mounts

back in to check clearance again...

back in to check clearance again...
What type of ac condenser did you use ? I see that your lines are on the passenger side of vehicle . Also what did you use for the intake fitting for your power brakes ?
I used the Gbody Cutlass Condenser for AC to keep the install cleaner. It has connections on passenger-side whereas Malibu has driver-side connections. Intake fitting for power brakes? Everything on the brakes, from booster to lines to calipers/wheel cylinders are all OEM replacement. Hard lines and proportioning valve are from inlinetube.com
Do you have any part numbers for the ac hoses along with fittings ?
Hoses are custom fit and made. Even a couple fittings were custom made.
The tv bracket and cable ? Are they custom or replacements ? Do you have part numbers
The TV cable was oem, but I broke the housing and replaced it with an adjustable cable. The bracket was custom fabbed and the connector arm was custom fabbed. There’s a bit if information about how I did this in the write-up. See the menu for the URL.