Just thought I'd make a thread since I've finished. I appreciate everyone's help through it all! I can't believe how well it runs on the stock tune. And nothing is more rewarding than having it be a father son project that was a success. It feels good to tell people I didn't pay someone to do it for me. Taking it apart: What a mess: Heads on: Test fitting the intake:

1.6 Pro Magnum rocker arms on:



Intake and valve covers on:



Waiting on a waterneck and intake:




ALL DONE!

Videos:

First start:
http://www.youtube.com/watch?v=wVk-C8jOEmQ

Warm Idle:
http://www.youtube.com/watch?v=7BAocE35AhI

http://www.youtube.com/watch?v=ReO4ycnrrCA

Drive away:
http://www.youtube.com/watch?v=EvSuL_VHwvw


And for anyone that comes across this thread in a search, some information. Obvious stuff, but I figure I'll post it:

Mark each connector you remove. I'm pretty sure there are not two of the same connector types. But it just makes your life easier.
Take pictures of everything before you remove it.
Replace your timing chain. Mine was kind of sloppy with only 74,200 miles.
There are grounds on the back of the heads that are a pain to get to. I removed all the head bolts, lifted the head, put a towel under it, and slid the head forward to access them better. There are not fun putting back on either.
You can remove your timing over with your oil pan still bolted in. If you try and put your timing cover back in, without dropping the pan a couple of inches, there is a very high risk you're going to tear your oil pan gasket.
Put thread sealer on ALL your head and intake bolts.
Don't be afraid to lay a thick bead of RTV on your China walls (don't forget the corners where it meets the head).
All the holes in the heads were not tapped deep enough. I had to use washers on all the bolts that went into the front of the heads (Power steering bracket...etc)
If you're using the stock throttle bracket, you're most likely going to have to put a few washers in between the intake and bracket to get proper alignment.

I'm surprised nobody every replied to this. That was awesome work! How long did it take you to do the whole project? Any other hangups besides the bolt holes not being deep enough?

Gah that cam sounds absolutely isnane. What is it?

Really cool build. I was actually debating this or go ls1
What hp and torque ratings are you looking at before tune and after tune? (If u have any)

looks good!