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1968 Chevrolet Nova - Introducing Project NovaWe Picked Up A '68 Nova And Made It Swallow Our 523hp Dart SHP 400 Small-Block. Now The Fun Begins! From the June, 2010 issue of Popular Hot Rodding By Johnny Hunkins Photography by Johnny Hunkins
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For years, we've been espousing that any project car should have a plan up front. Do a rendering, research all the parts, make a list for everything, and know exactly what you plan to do with it when you're done. That's the sane way to do things, but is it necessarily the most fun? Sometimes improvisation trumps all. Take for instance those times as a teenager when your folks were out, it was a Friday night, your friends were coming over, and you had money to burn? Or a last-minute weekend trip to the beach or the racetrack? Some of the best times in life aren't scripted, and that's exactly the case with Project Nova. Heck, we don't even have a name for it, but it's shaping up to be wicked fun. Just like a spontaneous weekend getaway, you might not have a specific plan in mind, but you've already combined-mostly by happenstance-the proper ingredients for fun. In our case, we bought a lightweight '68 Nova, which just so happened to share garage space with our 523hp Dart SHP 400 small-block crate motor that we built back in the January issue (see "Power In A Package"). The Dart SHP 400 makes stupid power on pump gas with a hydraulic roller cam. And so easy, a trained monkey could build one. Hmm, light car, powerful small-block. What to do? Like star-crossed lovers, the Nova and the Dart crate naturally gravitated to each other. Over the course of a weekend, and with the help of friends-namely Andy Mitchell of Outlaw Racing Engines-we tackled the job. Beforehand, we did our best to order the basic parts we thought we'd need for the swap. We burned up the Summit Racing order hotline for a fuel pump, fuel lines, fittings, oil dipstick, air filter assembly, water pump, pulleys, fasteners, and flexplate. We found that some of the stuff worked like a charm. Some of the parts didn't work out, but it was entirely due to circumstance-and us making wild guesses. At any rate, it was a fun learning experience, and we're here to tell you all about both the good stuff, and the inconvenient stuff. The most rewarding part was hearing it fire up on cue that very first time. After a few cursory checks and an easy drive around the block, we put the little Nova through a few one-legged test burnouts in the parking lot. The incongruity of a refrigerator-white little-old-lady Nova with 14-inch tires on poverty rims, highway gears, and an open rearend fed by a maniacal small-block is too much to bear. On the street when we roll into the throttle, the Flowmaster exhaust bellows off the buildings, the left front lifts a bit, the right rear tire breaks loose, and you just steer it at the rev limit to keep it straight. The whole thing is so much fun to drive, we laughed ourselves silly. We're not totally crazy though. With 42-year-old drum brakes, bald tires, monoleaf rear springs, no sway bar, and a stock drivetrain, this thing is living on borrowed time in too many areas to count. We'd love to get it to the track for some numbers, but we need to make it safe first.  We started out with a Dart...  We started out with a Dart SHP 400 short-block crate motor ($4,184.66). Available in configurations ranging from 372 ci to 400 ci-and with options like forged pistons, forged crank, and H-beam rods-a small-block Chevy SHP short-block ranges from $2,975 up to $4,695. We checked the order blanks for upgraded forged Mahle pistons, Scat H-beam rods, and a forged crank. The Dart SHP block is a veritable fortress of strength, with siamesed cylinder walls, a minimum of .230-inch wall thickness, played four-bolt mains, priority main oiling, and a safe bore size up to 4.165 inches.  The top end of our 400ci Dart...  The top end of our 400ci Dart SHP crate motor is dressed out with Dart's top end kit consisting of Pro-1 Platinum heads, a Dart dual-plane intake, gaskets, spark plugs, valve covers, head bolts, and upgraded 7/16-inch rocker studs.  The top end of our 400ci Dart...  The top end of our 400ci Dart SHP crate motor is dressed out with Dart's top end kit consisting of Pro-1 Platinum heads, a Dart dual-plane intake, gaskets, spark plugs, valve covers, head bolts, and upgraded 7/16-inch rocker studs.  Equipped with A COMP Cams...  Equipped with A COMP Cams Big Mutha Thumpr hydraulic roller cam (299/319 degrees gross duration, 243/247 degrees at .050, and .533/.519-inch lift on a 107-degree LSA), COMP's new short-travel hydraulic lifters, and a Holley 850-cfm Street HP carb, our SHP 400 cranked out 523 hp at 6,200 rpm and 523 lb-ft of torque at 4,400 rpm on pump gas with a 10.66:1 compression ratio. The cost total cracked $9,400 with the premium parts we chose, but it'll be bulletproof for many years to come, and can handle a nice shot of nitrous should we desire.  We began our engine swap by...  We began our engine swap by pulling out the tired 350 that came in our '68 Nova. We have no idea what's in it, but we plan on finding out, and resurrecting it for a future issue. Having a V-8 from the get-go, the Nova came with many items we plan on reusing for the time being-or at least until it breaks. Stuff like headers, transmission, and cooling system.  We've got our eye on a nice...  We've got our eye on a nice set of ceramic-coated Hooker headers, but for now, the no-name headers from our Nova will be reused. We mediablasted them to clean off all the rust and old paint.  A coat of Dupli-Color 1,200-degree...  A coat of Dupli-Color 1,200-degree ceramic paint was applied to the cleaned-up headers. The pipes look to be a 1 3/4-inch design, which will tap a little into our power. We used 1 3/4-inch headers on the dyno, and that's the size that will eventually go on the car. For now, these refurbished pipes are already known to fit.  With the old engine out, it...  With the old engine out, it was the perfect opportunity to clean up the engine bay and spray bomb it with a few cans of Dupli-Color semigloss black acrylic enamel. We soaked the bay in degreaser, then used a heated pressure washer on the frame, suspension, firewall, and fenderwells. We did a final prep clean with acetone before hitting it with the rattle can. The improvement was amazing.  Our first misstep was ordering...  Our first misstep was ordering a short water pump/pulley kit, when the old engine was set up for a long water pump. We ordered a Summit mechanical water pump Pro Pack (PN CMB-12-0026), which contains a Weiand short water pump, water neck, Trans Dapt billet aluminum pulleys, Mr. Gasket thermostat, and fasteners. At just $215.95, it's a killer deal, but we quickly discovered that the short water pump we wanted to use wouldn't allow our traditional alternator mounting position. Turns out, we would've been OK if we had just ordered the long water pump version of the kit.  On the bright side, we learned...  On the bright side, we learned that a Weiand short water pump does indeed clear COMP's two-piece billet timing cover with room to spare. We ended up cleaning the factory cast-iron water pump from the old engine, and painting it with aluminum paint. We also mediablasted the old pulleys, and painted them with Dupli-Color satin black.  Our Dart SHP 400 short-block...  Our Dart SHP 400 short-block came internally balanced, so we ordered a zero-balance SFI flexplate from TCI, and attached it with strong ARP flexplate bolts.  Totally Stainless makes some...  Totally Stainless makes some of the strongest, best-looking fasteners around, and we like the durable, long-lasting performance of stainless steel. For all our cosmetic fasteners, we used Totally Stainless' "engine" kit, which includes fasteners for the distributor, fuel pump, intake, oil pan, thermostat housing, timing cover, valve covers, and water pump. We like how fasteners for each part of the motor are separated in different bags and clearly labeled. We got the six-point kit for stamped, perimeter-bolt valve covers (PN 6-5655, $155).  We tried one of Summit's Edelbrock-sourced...  We tried one of Summit's Edelbrock-sourced 110-gph fuel pumps (shown, PN SUM-EDL21) for $49.95, which is a screaming deal, because it's built by Edelbrock, it doesn't need a regulator, and it's good for 600 hp. The only problem is that the inlet and outlet are clocked 180 degrees, and in our '68 Nova there was no way humanly possible for both the inlet and outlet to clear the crossmember, motor mount, and engine block. We ended up using the nearly identical 110-gph Edelbrock 1721 pump with clockable inlet and outlet-for $42 more.  Time to drop the Dart SHP...  Time to drop the Dart SHP 400 into the Nova, but oops, it doesn't fit. Criminy sakes, it's just a small-block Chevy in a Nova, what could be easier? We discovered that our Nova was originally a six-cylinder car that had a transplanted V-8. We don't know if the crossmembers are different, but we can say for sure that a six-cylinder crossmember does not like our big Moroso oil pan.  Our Moroso 7-quart Stage 1...  Our Moroso 7-quart Stage 1 drag race oil pan is the ultimate in engine protection for a hot street car, with an integral crank scraper and internal baffling for windage control and best power. When we built our Dart 400 SHP small-block, we knew it was destined for the street, but we hadn't bought our project car yet, so we had no idea whether it would fit our chassis. It turns out, the Stage 1 pan will not fit the '68 Nova unless you notch the crossmember, or use some kind of lifted motor mounts. We love the oil pan more than the crossmember, so the crossmember needed surgery.  We cut out a V-shaped notch...  We cut out a V-shaped notch in the crossmember using a cutoff wheel. The crossmember is boxed, so once we welded a new top piece in, it was better than new.  Here's where it helps to have...  Here's where it helps to have friends with friends. For a few beers, we lured Hunter Branson of Branson Mold Polishing to fabricate and weld in a new top piece for our crossmember. He's got this really boss Airtronics TIG welder from the 1950s that was originally built to make aircraft parts for Boeing. It's a very cool living artifact. "I've never repaired it in all the years I've owned it," Hunter says. They only made 22 of these welders.  The old part of the crossmember...  The old part of the crossmember that was cut out is 10-gauge steel, and the new section is a little thicker at 1/8 inch. We'd like to keep the stock subframe and crossmember, so we want it to be strong.  We tagged the modified crossmember...  We tagged the modified crossmember with more Dupli-Color semigloss black before taking another stab at dropping the Dart bullet into the '68 Nova.  When we purchased the Nova,...  When we purchased the Nova, we got lucky that a previous owner had installed a three-speed Turbo 400. The original car had an inline-six, so it had to originally be a two-speed Powerglide. Some inline-fours and inline-sixes ('69-71 models) even came with a crappier two-speed automatic called a Torque Drive. Note how this Turbo 400 also has the beefy (and rare) double-hump crossmember from the '68-70 big-block cars. Score! We plan on beating this old Turbo 400 and stock converter until it gives up. The trans also appears to have some sort of shift kit. The stock stall converter is the bomb on the street too. We hope it lasts.  We decided to try our luck...  We decided to try our luck with the original fan, water pump, pulleys, alternator, power steering pump, hoses, and radiator. We even reused the original coolant-for now. Much to our amazement, it fired up on the first try, and we were doing burnouts five minutes later. In the weeks since, we've encountered no problems with overheating, charging, or the transmission. We're actually rethinking our whole theory on gearing. This car/motor combo loves the two-series highway cog. The cruise rpm is low, and there's more than enough torque (493 lb-ft at 3,500 rpm) to incinerate the tire.
| WHERE THE MONEY WENT |
| Description: |
Source: |
PN: |
Cost: |
| Dual-feed fuel line for Holley DP |
Summit Racing |
SUM-220100B |
$59.95 |
| Straight fitting, -8 AN |
Summit Racing |
SUM-220890 |
$6.95 |
| 45-degree fitting, -8 AN |
Summit Racing |
SUM-220886 |
$13.95 |
| 110-gph mechanical fuel pump |
Summit/Edelbrock |
EDL-1721 |
$91.95 |
| Fuel pump pushrod |
Summit/Moroso |
MOR-65750 |
$17.95 |
| Universal oil dipstick kit |
Summit/Moroso |
MOR-25970 |
$15.25 |
| Flexplate, 168-tooth, internal balance |
Summit/TCI |
TCI-399273 |
$69.95 |
| Flexplate bolts (set of 6) |
Summit/ARP |
ARP-100-2901 |
$8.95 |
| Air cleaner, drop base & 4-inch filter |
Summit |
SUM-239443 |
$45.95 |
| High-temp ceramic aluminum paint |
Summit/Dupli-Color |
SHW-DH1606 |
$7.95 |
| Semi-gloss black acrylic enamel paint |
Summit/Dupli-Color |
DA 1603 (qty. 4) |
$6.95 ea. |
| Total: |
$366.60 |
| THE COST SO FAR |
| Description: |
Issue: |
Cost: |
| '68 Nova project car |
N/A |
$5,000 |
| Dart SHP 400 small-block |
Dec. 2009 & Jan. 2010 |
$9,478.03 |
| Engine installation |
June 2010 |
$366.60 |
| Total: |
$14,844.63 |
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