95 k2500 5.7 4l80 tbi build advice

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Moofus02

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I've had this truck for almost 20 years. It owes me nothing even though I've only put about 9k miles on it. About a year after I bought it it started running worse and worse. I parked it and just decided to fix it. Drove it around to verify brakes and trans were good and pulled motor out. Blown head gasket between center cylinders on drivers side. 159k mile motor and block and head are junk. I've got another 95 5.7 with 121k miles in a z71 exsb with a bad 4l60. That motor is ready to lift out but front and rear seals are leaking. So it's not a drop in without work.
Goals
1 run good no leaks
2 torque y fun to drive
3 sound good with a meaty idle

Exhaust either manifolds with aftermarket vortec no cat h pipe 2.25 mandrel bent with duels. Have this on my 99 sub and it really woke it up and sounds nice.

Or long tube headers a good y pipe and big single exhaust or true duels with an x pipe

Cam it's getting a roller. I've got 410 gears and 245 rubber. It will probably be turning 2500 rpm at speed on freeway. Would like a nice meaty sounding idle because it makes me smile but I want it to make good torque and pull hard. Open to ideas. Looking at the summit 8800

Heads and intake i don't know. Tbi heads and intake would be the simplest. I've got some older small chamber heads around that would work with a carb intake and adapter or the same for some vortec heads. It's going to spend 90% of it's time between 2200 and 2600 rpm. I know I can make more power with better heads but its not a race truck if I twist it to 5-5500 it's just to listen to it sing. In the 1500 to 4000 range how good are tbi heads?
With tbi heads is there a better intake or carb intake and adapter that would make an improvement?
Get rid of the restrictive air cleaner stuff
Tbi at the rpm in running i don't see a need for anything special. Get rid of the choke ring on top, injector pod spacer, maybe a spacer under it, a good vortec fuel pump and pressure bump.

I don't know if I'm forgetting anything. I'm trying to round up the stuff I need to tune the computer.

I really want a fun good driving truck that gets reasonable milage. Any advice would be helpful. Thanks
 

Erik the Awful

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I went with long tube headers and dual 2.5" with an x-pipe on WCJr and it sounds plenty healthy. A good cam helps.

TBI heads are the weak link in this plan. I've ported a set, but I don't even have that motor installed in anything yet, so I can't tell you if it was a good idea. I'm in the middle of building a 350 that I picked up for $150. It has L98 heads, and I massaged them a bit, but now I'm considering ditching them for some cheapskate chinesium heads. I just can't justify keeping the L98s with the other parts I have on hand to install.

It helps to think of engine building like this: Your engine size and your cam are the keys to the power potential of your engine. Everything else are overlapping constraints. Your cam may be capable of 500 hp, but the ports in your TBI heads will constrain that to 350 hp. Maybe if you port them you can get it up to 400 hp. You can put in a stroker crank and get more torque, but you're still not going to break the 400 hp wall unless you get better heads. You can put a big sewer pipe of an exhaust on the thing, but once the exhaust isn't a restriction it won't be holding back any more horsepower. The TBI itself and intake might be restricting the air going in, but putting a Dominator on a mild cammed 350 isn't going to make any significant power over a 750 cfm 4150 Holley, and have fun driving that on the street.

What is your most expensive constraint? For me, it's the heads. If I stick with the L98s, there's no reason to use the Harland Sharp 1.6:1 roller rockers I have sitting on the shelf. They'd be diamonds in a goat's @$$. If I step up to a set of chinesium heads with 2.02 valves and fat ports, it'd be stupid of me to use stock 1.45:1 stamped rockers because I'd be leaving cheap power on the table - especially if I have the Harland Sharps sitting, begging me to use them.

The engine has the stock 9.3:1 rods and pistons, and replacing them is expensive as well. I can crutch that with a thinner head gasket and get the compression up to near 10.0:1 and that becomes less of a constraint, but then I have to choose my cam with the dynamic compression ratio in mind, and then I have to go back and reassess everything that I've already mentioned. Did a previously chosen part become a constraint?

I always start by building a spreadsheet so I can see my plans at a glance and assess if any one part it out of place with the rest.
 

Moofus02

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I'd sure like to know what l31maxexpress used as a combo to make 300hp 400ftlb at crank and 20mpg with tbi heads.

All my options are a compromise unless I start from scratch. I've got a tbi motor low mile but it leaks on both ends of the crank. I hate oil leaks but as soon as I start to fix that the mods start lol.
I've got a vortec that spun a bearing from getting upside down. I could take the rotating assembly out of this blown head gasket motor and put in that but it had a miss just before it spun the rod. Think a valve might have kissed a piston and I'm not spending money on stock heads.

I've got some older heads including a nice fresh set of 416's.

Another option is drop the vortec out of my 00 Tahoe in it and 0411. I would want to keep my tbi accessories if possible if I did that.

I'm digging through my parts stash trying to figure this out. I did talk myself out of putting my 6.0l in it. That thing runs but they got no torque down low and with the can that's in it in sure it wouldn't be happy with the l low stall converter
 

Taz069

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@Eric The Awful hook me up on those headers if they fit straight plugs in a 94 k-1500. Current headers have to ditch. @Moofus02 the Tbi set up... ditch it if you can. A good motor needs a good base. In reading around this site you will find painful and time consuming avenues to bring the tbi set up to speed. At some point it's like o.k. 1 and done. Trust me in my only tread I tried and not enough air flow.
 

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Moofus02

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Anyone run an edelbrock tbi intake or holley projection tbi intake manifold? They any better than stock?
 

Moofus02

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Anyone run an edelbrock tbi intake or holley projection tbi intake manifold? They any better than stock?

i recently installed the Edelbrock TBI performer manifold and cam kit , yep notice the difference, not massive but since i collected the parts over the years (blew a head gasket so that motivated the install), definitely worth it, for me.

having to pay full price for manifold and cam ( better to go roller imo).... maybe not, but i'm in CDN so prices are crazy .....
 

Erik the Awful

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The Awful hook me up on those headers if they fit straight plugs in a 94 k-1500.
My trucks are all RWD, so I don't think they'll fit yours. I believe I have Hedman 69440s, but it's been a few years. If I were to buy again, I'd look for headers with a 2.5" collector. I don't like going down in size with my exhaust tubing as it goes out.
 

Taz069

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@Eric The Awful hook me up on those headers if they fit straight plugs in a 94 k-1500. Current headers have to ditch. @Moofus02 the Tbi set up... ditch it if you can. A good motor needs a good base. In reading around this site you will find painful and time consuming avenues to bring the tbi set up to speed. At some point it's like o.k. 1 and done. Trust me in my only tread I tried and not enough air flow.

My trucks are all RWD, so I don't think they'll fit yours. I believe I have Hedman 69440s, but it's been a few years. If I were to buy again, I'd look for headers with a 2.5" collector. I don't like going down in size with my exhaust tubing as it goes out.
Went with a set of J.B.A.' sfrom summit. Installed they shorties but low and mid rpm all I want.
 

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