Hello there... What youre trying to do is suuuuuuuper easy IF you get started off right.
Im almost done with my 440 - '71 Duster and its been an absolute piece of cake install. This is actually my 3rd one and its it isnt easier because of how many times ive done it, its easier because of all the little parts that used to be hard to come by that you can now just order right out of a catalog nowadays. The first 2 times I did this swap were a nightmare because I tried piecing everything together... big mistake!!!
So heres my project and what ive done JUST WITH REGARDS TO THE ACTUAL ENGINE SWAP, nothing else....
1. starting point:
Buy a complete, running donor car!!! I bought a '66 New Yorker off Craigslist for $500... 440/727/8.75 rear end, A/C, ps, power brake car of course... interior trashed, body all rusted out but very good running condition. If youre going with an automatic, make sure you buy a '66 and later car because the pre '66 727s have a troublesome rear output section and they dont make aftermarket shifters for the early trannys so watch out if you plan on using a B&M or equivalent shifter.
2. Pick the car you want to build...
Mine is a 1971 Duster (/6 car, no motor or tranny, non a/c, non ps car) - got it off Craigslist for $600.
3. Buy all your conversion parts 1st... I got a complete Schumacher conversion package and I added a shim kit & 727 tranny mount. Total cost for that was $1100
4. Since my motor came with ps & ac, I had to order a complete pulley set for a non ac, non ps car for 3 reasons. First, I aint runnin' ac or ps on my car. Second, even if I did, the stock location of the ac compressor on my particular motor wouldnt let the hood close anyway. And 3rd & most important, the triple belt pulley set didnt leave enough room beween the front of the motor and my electric fan/shroud setup. This is where a lot of people get stuck because back in the day youd have piece together the correct, single sheave pulley set to make the set up work which was a major PITA if you didnt score a complete set. This time I simply called 440 Source, ordered a reproduction, single-sheave pulley set for a non ac, non ps 440 and presto bango, done deal. All you need is a single groove crank pulley, single groove water pump pulley, and alternator spacer & bolt kit and the belt to match. 440 Source has all that stuff in stock, total was either $138, $148 or $168 (i dont have the receipt handy @ the moment).
5. Cooling system...
A lot of guys on here get super complicated & expensive with their cooling and you really dont need to. I went a little on the expensive side just because im going to be running my car @ my local 1/8 mile track on Thursday nights and I also like to head out on long road trips. But ill be the 1st to say, what I did was definitely overkill but here we go. The mounting brackets on the New Yorkers radiator (or any radiator really) dont allow the radiator to just drop right in. I removed the mounting brackets off of it, set the radiator flush against the core support, placed the brackets back against the core support & radiator, marked the new location on the radiator and had them welded back on. From there its just a matter of drilling new mounting holes in the core support and locking it in with some good hardware. After that, go to your local parts house, mix n match yourself a set of hoses and your done.
6. Fan setup
Like I said, I went a little overboard here purely out of personal preference. I had a local fab shop make me an aluminum shroud with dual electric fans but you really dont need all that. My 1st 2 swaps, all I used was a solid-mounted 7 blade fan and a properly fitting fan shroud (just have to make sure the spacer used puts the blade 1/2 in & 1/2 out of the edge of the shroud).
And thats pretty much it as far as getting the motor & tranny in. Like I said super simple. Just make sure that youre donor car has no mechanical issues and your swap should be easy peasy. If youre donor car does have mechanical or maintenance issues, TAKE CARE OF THEM BEFORE YOU START TAKING IT APART!!!! You dont want to start trounleshooting an in issue in a cramped engine bay when you can do it in the original car, that way youre sure of where youre at before you start bolting everything in to the Duster. I had my radiator rodded out, switched to electronic ignition, rebuilt the carb & replaced the alternator before the New Yorker ever came apart, that way I knew everything was running good and working together properly before anything came apart. Once the motor and tranny did come out, i replaced the freeze plugs and serviced the tranny (easier to do out of the car) and put a water hose to the engine block and had a ton of black, sooty, muddy stuff come outta there. Not good for water flow!!! So thats pretty much it, make the donor car is mechanically sound before doing the transplant and you should be fine.
After all that, its just matter of getting a driveshaft made and swapping in whatever rear end youre going to use which im sure you can figure out.
If you want, shoot me your email address @
[email protected] and ill send you pics or answer questions to the best of my ability. Good luck man!