Project Sten, Part IV

Ccrp 1212 Chevy S10 Project Sten Part 4 Wiring Hydraulic Clutch Install 01

This month, we’re wrangling wires, hanging the T-5 for the final time, and installing the seats. We’re tantalizingly close to having a running truck.

This month, we’re wrangling wires, hanging the T-5 for the final time, and installing the

When we last left our intrepid V8 swap S-10, we bolted the small-block in place and installed the Summit aluminum radiator, the Maradyne electric fans and relays, and the Centerforce flywheel and clutch assembly. We were about to install the bellhousing when we discovered it was cracked. This required some skilled, cast-aluminum TIG-welding we’re not qualified for, so we took our housing to Tim Moore Automotive. With that accomplished, we decided to finally face the electrical issues. Frankly, we had been dreading this part of the engine swap. If you have been following the Sten’s progress, you remember that because we live in a state that firmly believes in iron-fisted emissions controls, we were forced to follow the Bear State’s rules and swap in a ’90-or-newer engine with all the emission controls in place. We chose a ’90 350 Tuned Port Induction (TPI) engine as our swap victim, which meant we had to include all the factory emission controls and the stock factory computer.

Ccrp 1212 Chevy S10 Project Sten Part 4 Wiring Hydraulic Clutch Install 02

One of the more intimidating parts of the conversion turned out to be relatively easy (although we haven’t started the truck yet, so maybe it was just an illusion). We separated the old, four-cylinder wiring we didn’t need from those we did need using a budget wire-harness diagram from Blue Star Wiring.

One of the more intimidating parts of the conversion turned out to be relatively easy (alt

We located a factory computer in the junkyard, and then had our pals at Tuned Port Induction Specialties (TPIS) send us a rare V8 chip we combined with our Painless TPI aftermarket wiring harness, since we didn’t even want to attempt to deal with a 22 year-old harness. We had hoped the existing four-cylinder engine wiring would be separated between engine and the rest of the truck, but that was not the case. A couple of other V8 S-10 swap veterans we spoke with suggested we buy a wiring-harness diagram and sit down and separate the wiring we needed from the spaghetti that we didn’t need. To make this more complex, we had already disposed of the original engine, so we couldn’t use the old four to help us with the connectors.

Instead of buying an expensive factory wiring-harness manual, we found a budget alternative. While scouting the Internet, we discovered a company called Blue Star Wiring Diagrams that would email us a PDF of the entire truck wiring harness for $20. The instant gratification part of that deal was attractive, and in a matter of a minute or so, we had a PDF on our screen, and thus began the process of separating the wiring wheat from the chaff. The first step was to identify each connector and then separate them into two sections: those we would need and those that would be replaced by the new TPI harness. The process wasn’t really as difficult as we expected. Once we identified the engine connectors we wanted to keep, like the charging and start circuits and some of the indicator wires that connect to the dash, it came down to a question of what to do with the wires we didn’t need. Our first idea was to remove each wire from the large harness connector at the firewall. But ultimately, we decided to cut out each wire but leave enough in the harness so if we needed it later, we could replace the wire easily. Because the original engine was a four-cylinder, we had to lengthen the starter and charging system wires to connect to our new engine, but that was easy.

Ccrp 1212 Chevy S10 Project Sten Part 4 Wiring Hydraulic Clutch Install 03

Once we had the wiring trimmed, we connected the Painless harness between the engine and the stock TPI computer that our friends at TPIS had modified for us with a V8 chip.

Once we had the wiring trimmed, we connected the Painless harness between the engine and t

Next, we began installing the Painless wiring harness on the engine. You might recall we had already installed the harness temporarily on the engine when it was on the test stand. Before the engine was bolted in place, we drilled a new hole in the firewall for the new harness, since the old hole was too close to the passenger-side exhaust manifold. We’re hoping this will place our ECM somewhere near the factory mount for the original computer. We haven’t gotten that far yet.

A while back we fitted the S-10 with a pair of Corbeau Forza seats we’ve come to prefer for their affordable price and deep side bolsters. While they require a little more effort to slide into when entering the truck, the lateral support is worth the small additional effort. These seats will really pay off when our autocross adventures begin. The Forza buckets are light because they are fixed-back seats, which works for us because of the minimal recline room due to the standard cab. With the seats installed, the shifter is in a great place, and we’re looking forward to finishing the exhaust work so we can load a round in our homebuilt Sten’s chamber and pull the trigger. We’re gettin’ close.

Our factory T-5 Camaro bellhousing had a crack that looked bad enough to warrant TIG-welding. We took it to our buddy, Tim Moore, for a quick, cast-aluminum welding repair. We also replaced the stock clutch fork and ball stud that were both badly worn.
Our factory T-5 Camaro bellhousing had a crack that looked bad enough to warrant TIG-weldi
With the bellhousing in place over our Centerforce clutch assembly, we mounted the modified slave cylinder we showed you last month, and used a 24-inch -4 braided line from Earl’s to make the connection between the stock S-10 hydraulic master and the Camaro slave cylinder.
With the bellhousing in place over our Centerforce clutch assembly, we mounted the modifie
We also took the time to mount our new Bosch starter motor to the engine so we could locate and extend the original four-cylinder, starter-motor purple wire to the solenoid. We also plan to relocate the Optima battery to the bed to try and take some weight off our nose-heavy truck.
We also took the time to mount our new Bosch starter motor to the engine so we could locat

Sten Story Outline
March 2011	Project Sten Introduction
October 2011	TPI 350 Engine Build
November 2012	Installing the Engine

Parts List
Description	PN	Source	Price
Painless TPI harness	60103	Summit Racing	$413.95
Blue Star Wiring diagram	See website	Blue Star Wiring	20.00
Corbeau Forza seat	29105	Racing Seats USA	239.00 (2)
Corbeau brkt (drvr)	C22033L	Racing Seats USA	94.00
Corbeau brkt (pass)	C22033R	Racing Seats USA	94.00
Corbeau locking slider	22001DBL	Racing Seats USA	20.00
Corbeau, 3-inch, 5-pt. harness	53001B	Racing Seats USA	149.00
Gates water pump	43114	RockAuto	21.79
Bosch starter motor	SR-526X	RockAuto	53.79 + 20.00
Airtex EGR valve	4F1116	RockAuto	48.89
Airtex Dist cap/rotor	WMA3D1046A	RockAuto	24.79
Standard Prod. Ign. Module	430LX340T	RockAuto	24.79
Standard Prod. Ign. Pickup	430LX342	RockAuto	12.09
Camaro clutch fork	ZA133	RockAuto	21.79

Previously, we had removed the stock S-10 bench seat and ordered new Corbeau Forza fixed-back racing seats to improve lateral stability, reduce weight, and provide room for the T-5 shifter. We discovered, however, that the original bench is very light, with our two Corbeau seats and brackets weighing 5 pounds more than the bench itself. We used our Proform scales to measure everything, as our bathroom scale is notoriously inaccurate.
Previously, we had removed the stock S-10 bench seat and ordered new Corbeau Forza fixed-b
The factory didn’t equip our truck with bucket-seat mounts, so we used the Corbeau brackets as templates to drill new holes in the floor. We also had to fabricate spacers to adapt the brackets to the S-10’s floor configuration.
The factory didn’t equip our truck with bucket-seat mounts, so we used the Corbeau bracket
With new seats installed, we also added the Corbeau five-point harnesses. At this point, we don’t have a good mounting location for the shoulder harnesses. Our plan is to create a short bar underneath the rear window that will act as a safe mount for the shoulder harnesses.
With new seats installed, we also added the Corbeau five-point harnesses. At this point, w