509 Big-Block Engine Install for 1968-1974 Chevy Nova's - What A Drag, Part 2

Another cool thing from Summit is this stainless steel radiator hose kit (SUM-390148). It's claimed to dissipate heat better than rubber. Cutting and bending the hose to shape makes for a neat-looking install, but the clamps included in the kit are wimpy. We ordered a stronger hose clamp kit (SUM-390500) that offered a tighter hold of the hoses onto the radiator, pump, and thermostat housing. Nobody needs a radiator hose to pop off under high pressure. (It's a little blingy for some, but the author liked it.-Ed.)

Here are a few major components of the fuel system for an adequate supply of petrol to the thirsty 509. The Holley HP125 (HLY-12-125) is quieter, more efficient, and delivers more fuel volume than the old Holley Blue pump. It features a 125 gph rating of free flow to feed engines up to 700 hp. The Mallory fuel pressure regulator (MAA-4309) is a three-port, return-style regulator needed for the existing return fuel line that goes back to the 15-gallon fuel cell in the Nova's trunk. Aeromotive's adjustable fuel log (AEI-14201) has telescopic logs, dual inlets with ball and socket assemblies that swivel 20-degrees in all directions to provide additional clearance for throttle stops, nitrous plates and other accessories.

We plumbed the Holley HP125 fuel pump into the existing -8AN braided fuel line. Necessary parts for the job were two 8AN to 3/8 NPT adapters (SUM-220846) and two 8AN hose ends (SUM-220890, straight; EAR-809108ERL, 90-degree swivel). The Fram fuel filter was another included part of the Nova purchase. We only replaced the filter element (FRM-HPGC1) inside the fuel filter housing.

Up front, the rest of the fuel system was installed along with the aforementioned stainless steel radiator hose kit. The Proform 950 cfm carburetor (PRO-67202) will provide the large rat with plenty of air and fuel flow. We used the existing 8AN braided fuel hose to the Mallory regulator. From the regulator we needed two 8AN to 3/8 NPT adapters (SUM-220846), 3-feet of 8AN braided hose (SUM-23083) with 8AN hose ends (SUM-220890, straight; EAR-809108ERL, 90-degree swivel). At the Aeromotive fuel log, two 10AN O-ring to 8AN flare fittings (SUM-220162) and an 8AN flare cap (RUS-66197-0) were used. For the regulator return, a 6AN to 3/8 NPT adapter (SUM-220648) was used to hook-up the preexisting 6AN return hose. The brass plugs on the sides of the regulator were purchased from the local parts palace.

We wanted to use the stock power-steering pump (early style) that came with the Nova. Fortunately, TCI has a power steering hose kit to hook up the stock pump to the rack-and-pinion steering...

...In the kit is a flow valve (center of picture at left) for the right steering feel. It was easy enough to follow the instructions to do a neat-looking installation.

Before firing it up, we wanted to hook up the exhaust so as not to disturb the peace. Since we were using the same type of Hooker headers as the old 396, we didn't understand why we were short by a couple inches. Perhaps the new Hookers have a shorter collector.

We cut-off the reducer and ordered a set of 6-inch long reducers from TTI Exhaust. Take notice how an exhaust shop had the 3-inch pipe all the way up to the 3 1/2-inch flange restricting exhaust flow. The new TTI reducers will flow much better.

Now exhaust length was right, but the height was not due to the transmission crossmember interfering and preventing us from raising the 3-inch exhaust high enough to hook up to the collector. We could have bent the exhaust but would have lost ground clearance and exhaust flow. The TCI crossmember is designed for a 2- to 2.5-inch exhaust.

We measured then cut larger cutouts for the 3-inch exhaust. Our buddy Bill M. came to our aid again and welded in flat plate steel with gussets in the corners for strength...

...We painted it with Eastwood Chassis Black for rust protection and to match the rest of the TCI front clip.

For enough header/exhaust ground clearance, we raised the ride height (3/4-inch) using a spanner wrench for the 12-way adjustable TCI coilover shocks. As a reminder, the TCI front clip features 2-inch dropped spindles for better steering and handling, which lowers ground clearance. Sitting at rest, the Nova measured 3-inches of ground clearance at the header collector flange area...

...If you want more ground clearance, an easy big-block installation, and not go through what we did, just order a set of the new TCI 2-inch headers, use 2.5-inch exhaust, and it'll make life a lot easier.

Quaker State Ultimate Durability 5W-40 synthetic oil was used to fill the crankcase and the Fram HP4 high performance/hi-flow oil filter. Since the motor was broken in on the dyno, we didn't hesitate to use synthetic lube. The Fram HP4 will easily flow more oil than regular oil filters-notice the larger flow holes in the HP Fram filter. The Q oil is said to offer unsurpassed protection against friction as temperatures increase.

We love the look of the 509 Dart nestled in the engine compartment, along with the TCI tubular front end components. The Proform 950 has vacuum outlets, which enabled us to run a 3/8-inch vacuum hose to the brake booster and the PCV valve. Other 950 carbs don't feature timed and full vacuum tubes. You can hear the 509 running and see the Nova's first drive on the Super Chevy magazine website-click on videos section.