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Kenosha, Wisconsin’s Dave Miracle has been into cars aback aerial school. Like abounding of us, he took time off to accession three kids—that is, until he apparent a bare-bones 1966 Chevelle that had laid abeyant in a friend’s barn for 20 years. “Even admitting it was basically aloof a carapace with a agglomeration of genitalia and boxes, it was too acceptable a accord to canyon up,” Miracle relates. About the alone drivetrain allotment actual was the aboriginal branch 3.73:1 12-t Posi rearend. Sparing no effort, Miracle had the anatomy and ascendancy accoutrements powdercoated. “Everything went tenfold from there: all-new interior, abeyance and brakes, bottle and trim, aqueous lines, and stainless-steel ts throughout. I capital a no-hassle artery disciplinarian but with affluence of get up and go, so I went for a 496ci Rat motor from Ateco Agent in Illinois. Behind it is a TCI TH400 and 2,800-rpm-stall torque converter.”

Kenosha, Wisconsin’s Dave Miracle has been into cars aback aerial school. Like abounding of us, he took time off to accession three kids—that is, until he apparent a bare-bones 1966 Chevelle that had laid abeyant in a friend’s barn for 20 years. “Even admitting it was basically aloof a carapace with a agglomeration of genitalia and boxes, it was too acceptable a accord to canyon up,” Miracle relates. About the alone drivetrain allotment actual was the aboriginal branch 3.73:1 12-t Posi rearend. Sparing no effort, Miracle had the anatomy and ascendancy accoutrements powdercoated. “Everything went tenfold from there: all-new interior, abeyance and brakes, bottle and trim, aqueous lines, and stainless-steel ts throughout. I capital a no-hassle artery disciplinarian but with affluence of get up and go, so I went for a 496ci Rat motor from Ateco Agent in Illinois. Behind it is a TCI TH400 and 2,800-rpm-stall torque converter.”

The Problem

“Realizing that I was not the being who took the car apart,” Miracle continues, “I anticipation putting it aback calm would be the best difficult allotment of the project—but I was wrong. Aback the car was done, it would apathetic bottomward on cranking. Aback you arise the agitation key aback it did start, it acquainted like a bang in the teeth. There was a agreeable complete as if you kept the agitation key in crank too continued afterwards the agent started. Sometimes it would backfire. This could arise at any time, but was affliction afterwards the car acrimonious up. Aggregate was cast new with all the acceptable parts, so I aboriginal anticipation there was commodity amiss with the tune.”

Key

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The able callouts at the alpha of anniversary band beneath accredit to the photo above. Any numbers or ambit of numbers at the end of a class band accredit to numbered assets and photos in the blow of this commodity below.

A] Starter/flexplate accessory cobweb (0108)

B] Voltage tests, abject changes (0910)

C] Better area and terminals (1119)

D] AWG 6 charging wire (20)

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E] Remove agitation resistor wire

F] Clean out bulkhead adapter (21)

The Automated Diagnosis and Fix

One of our go-to accomplishment shops, Norm Brandes’ Westech Automotive, is a stone’s bandy abroad from Kenosha. Aback Brandes got the car, he accepted the apathetic cranking and amateur kick-back. Was it aloof a affability affair like the buyer thought? “These affection can action if the timing was badly retarded,” Brandes explains, “So we started by putting in a reasonable abject timing of 12 degrees at the crank. That didn’t advice at all, so we doubtable a automated or electrical issue. Miracle’s Powermaster gear-reduction ministarter should accept had added than abundant cranking torque to get the job done.”

Brandes aboriginal arrested for automated arrest amid the amateur drive adhere and flexplate arena gear. He apparent chipped flexplate ring-gear teeth, a abiding assurance of a automated issue. Automated causes of drive pinion-to-ring-gear bind may include:

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Summit Racing

The Electrical Diagnosis

The amateur was no best agreeable and blame back, but cranking remained apathetic and lazy. Electrical abnormal like this are adamantine to acquisition because they arise accomplished at blow or beneath a ablaze load, but accomplish aerial attrition beneath abundant amperage draws. Powermaster architect Dave McILvaine showed up with a scattering of agenda multimeters to amount out area the agitation and charging ambit was accident current. Starting at Miracle’s trunk-mounted battery, he arrested the charging and cranking arrangement for voltage bead on anniversary ancillary of every connector, terminal, and alliance while cranking the engine. This includes the often-overlooked grounds, which are allotment of the abounding circuit.

These tests allegation be performed with the array absolutely answerable to 12.6 volts. To be abiding you’re not aloof seeing a array apparent charge, about-face on your headlights for 2 account with the agent off. Shut aggregate down. If the changeless (no-draw) allegation is still 12.5 volts, you’re acceptable to go. If not, you may accept a array issue. Downstream from the battery, a 0.10.3V bead beyond best connectors is acceptable; annihilation added is account for concern. Collectively, beneath crank at the amateur solenoid array (B ) terminal, you should see a minimum 1010.5 volts (see electrical diagram, analogy 10). On the Chevelle, voltage sagged as low as 7 volts at the B terminal and the readings fluctuated. “We were accepting inconsistent high-voltage bead from poor area and bad crimps,” McILvaine says.

However, the continued “Solenoid S” agitation cranking ambit that runs from the amateur “B ” terminal to the alternator allegation wire, agitation switch, aloof assurance switch, and aback to the S terminal—often a botheration on old GM cars—surprisingly arrested out OK already the adept firewall bulkhead adapter was purged of balance sealing goop.

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As for the array cables and allegation wires, Miracle’s No. 2 AWG array cable admeasurement was acceptable for the system, but he was still relying on the aboriginal branch 12-gauge alternator charging affairs with a abundant added powerful, late-model, 105-amp CS130 one-wire alternator, an advancement Miracle installed to abutment high-draw avant-garde accessories including air conditioning, electric fans, and an electric ammunition pump. And the agitation wasn’t operating at abounding ability because the MSD standalone breakerless benefactor was still accepting accepted through the aboriginal 1966 ballast-resistor wire. Like GM’s big-cap HEI, the MSD assemblage allegation accept a abounding 12 volts at crank and at atomic 13.7 volts in Run to be all it can be.

The Fix: Electrical

Ground candor was compromised by a powdercoated anatomy and sheetmetal arena screws. Westech installed captivate nuts—blind, self-upsetting, internally threaded inserts—in the anatomy to serve as ground-terminal hook-ups. Brandes says the install action application his hydraulic ambience apparatus provides abundant metal-to-metal contact, while the captivate nut’s feature “real” accoutrement admittance use of accepted ts and washers. NAPA’s electrically conductive Sil-Glyde multipurpose, silicone-based adipose added added arena integrity.

Miracle’s array cable terminals were too baby for the cable size, and ailing crimped. The terminals were cut off and replaced with high-quality, crimp-style terminals application a affection crimping tool. Two added arena straps were added to absolutely tie the agent to the frame.

Powermaster offers preterminated alternator charge-wires; a new 6-gauge allegation wire was run apart from the solenoid B ambit to the alternator. The aboriginal 12-gauge branch allegation affairs were larboard complete to abutment the absolute accouter access and administration arrangement that admirers out from the (typical for old Chevys) horn broadcast busbar. Overlaying the branch red affairs instead of advancing or replacing them additionally kept the banal ammeter working, admitting it does apprehend hardly high.

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The banal ballast-resistor-wire-to-coil-positive-“run” wire was replaced by a accepted 12-gauge high-temp GXL wire, ensuring full-power agitation output; no best required, the old solenoid R-terminal bypass wire was eliminated. Genitalia Hound sells the awe-inspiring Twin Lock terminal bare for the firewall bulkhead adapter end of the new wire.

The Results

It’s a Miracle! Already Westech aerated the array cables, grounds, and charging affairs into appearance so Powermaster’s ministarter could crank at its abounding 200lb-ft capacity, the Chevelle now starts appropriate up with basal cranking continuance and no kickback. The agent additionally runs a lot smoother now that the agitation runs at abounding power.

Lessons Learned

Powdercoated frames attending cool, but crave that added absorption be paid to arena integrity. Sheetmetal screws do not accomplish for a acceptable arena point. “If you booty affliction of the grounds, 90 percent of your electrical abnormal go away,” Brandes says. “Voltage bead adds up, so pay absorption to every terminal and adapter in the system. Beware of poor terminations!”

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Need Junk Fixed? If your car has a abecedarian that aloof won’t quit, you could be called for Hot Rod to the Rescue. Email us at pitstop@HotRod.com and put “Rescue” in the accountable line. Include a description of your problem, a photo, your location, and a daytime buzz number.

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