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1. Amazing imagination, execution, and detail bring this LS V-8 to the head of the class.
Beauty is More Than Skin Deep typography

A Look Under the Hood of America’s Most Beautiful Roadster for 2022

By Ron Ceridono Photography by Alan Johnson
I

t’s no secret that one of the keys to seeing your name engraved on the America’s Most Beautiful Roadster (AMBR) trophy is to build a car with meticulous attention to detail. In the case of Jeff Breault’s 2022 AMBR winner “Lucille,” the phrase “attention to detail” doesn’t begin to describe the effort put into the construction of this ’34 Chevy roadster.

Breault has been a lifelong GM guy and the idea of building this roadster has been with him for years. He describes his vision as “A car that combines the look, feel, and attitude of a traditional roadster but benefits from cutting-edge engineering and technology.” When a suitable candidate to make this vision become a reality was found, the all-original ragtop was delivered to Tim Devlin and his crew at Devlin Rod and Customs (DRC) to begin its transformation from stocker to shocker.

While there are so many facets to this automotive gem to examine, here we’ve decided to focus on the engine (Apr. and May ’22 issues of Modern Rodding covered the bare metal chassis and body and the sheetmetal modifications). Collaborating on the engine with DRC was Alan Johnson and his team at Johnson’s Hot Rod Shop (JHRS) and father-son team Keith and Jeff Dorton of Automotive Specialists (AS).

One of the goals for this project’s engine was to integrate the appearance of a vintage engine with the modern technology of a Chevrolet LS3. To that end JHRS created a fuel injection system that looked to be mechanical but uses hidden, state-of-the-art electronics. Fuel delivery is controlled by a FAST XFI ECU that also manages the ignition timing and includes traction control. The intake manifold, injector bodies, and air horns were CAD modeled and produced on a 3-D printer finalize the look and fit of all the components.

The unique cast intake manifold, designed by Johnson, is an open plenum design that allows all cylinders to feed from the same air supply rather than individual butterflies. This design also eliminates the need for vacuum lines from each injector body to supply the idle air control (IAC) manifold absolute pressure (MAP) sensor or other vacuum accessories. The eight throttle bodies and the velocity stacks with integral screens were all produced in-house at JHRS.

To complete the vintage engine, ruse custom valve covers were machined that also mount the ignition coils. Topping those are covers reminiscent of the rocker covers found on early Rolls-Royce engines that were also CAD modeled and then machined from aluminum to conceal the coils. It’s a safe bet that when the JHRS CNC machines stopped whirring there was a dump truck load of aluminum chips from those items alone.

Once JHRS was done with the fuel injection and cosmetic alternations to the engine it was turned over to AS for assembly. The block was bored to 4.125 inches and the stroke was increased to 4.125 inches with a Calles crankshaft resulting in 440 ci. For strength and longevity, the stock internals were swapped for connecting rods from Molnar and pistons from Mahle. The camshaft is a hydraulic roller, split duration design with 246 degrees of duration in the intake and 256 degrees on the exhaust. The cam makes music to a hot rodder’s ears at idle and helps make serious power. So much so that the original plan called for an engine with 500 hp but was exceeded by over 150 hp as the dyno sheet shows.

With the engine delivered to the crew at DRC, all the parts that appear to be chrome, including the throttle bodies and velocity stacks, were plated in nickel then polished by Jon Wright’s CustomChrome Plating. The process requires pre-polishing, a copper plate followed by a dull nickel-plated surface, then polishing and careful color buffing to produce the final finish that is “warmer” than chrome.

When we say that DRC pays attention to every detail we’re not kidding. Buckets of ARP fasteners were delivered to aerospace machinist Roger and Cale Nelson at FMW Inc. where the heads of each were customized with a ball mill. Kansas Coatings applied the tungsten-colored Cerakote to the intake manifold, alternator headers, and other components. Finally, to complement the polished and plated components, DRC painted the block and heads in the Chevy’s original engine blue/gray color with Diamont basecoat from BASF, followed by several coats of clear. The rocker/coil covers were painted black.

We’ve only looked at the engine, but it is representative of the craftsmanship found throughout the car. Like we said, to win the perpetual AMBR trophy takes attention to detail. And in this case, if detailing were a firecracker, this ’34 Chevy would be a nuclear explosion.

a Chevrolet LS3 with Dart heads on a framerail
2. Between the framerails of the Devlin Rod and Customs (DRC)–built AMBR winner is a Chevrolet LS3 with Dart heads, a custom stack injection system, one-off rocker covers, and a host of other custom pieces from Johnson’s Hot Rod Shop (JHRS).
a machine carves new rocker arm covers from billet aluminum
3. Carved from billet aluminum, JHRS created new rocker arm covers that serve a dual purpose.
engine sideview of one rocker cover, showing the struts between the mounting bolt bosses and a groove for an O-ring
4. This engine sideview of one rocker cover shows the struts between the mounting bolt bosses and a groove for an O-ring that eliminates a gasket.
top of the rocker cover featuring provisions to mount the ignition coils
5. On the top sides of the rocker covers are provisions to mount the ignition coils.
the coils in place
6. Here the coils are in place. To hide them, faux rocker covers will be added.
a close shot shows the mismatch between the rocker cover and the head
7. With a new rocker cover in place the mismatch between it and the head is obvious, but it wouldn’t be that way for long.
a close shot shows a clean connection between the rocker cover and head
8. The head’s mating surfaces with the valve covers were rounded and all the sharp edges were eliminated.
side view of a head with now welded accessory holes
9. The unused accessory holes in the heads were welded shut then ground smooth. The results are the heads and valve covers appear to be one piece.
relief details are added between the exhaust flanges
10. Like the fronts, all the unused holes in the sides of the heads were filled, then relief details were machined between the exhaust flanges to add a unique look.
a faux valve cover, designed to replicate the look of a vintage engine, sits on a surface
11. The faux valve covers that hide the coils were designed to replicate the look of a vintage engine, like the valve covers they were whittled out of a block of aluminum.
a faux valve cover, designed to replicate the look of a vintage engine, sits upside down on a surface
12. This is a rocker/coil cover viewed from the underside. The cutout on the left end is for the necessary wiring.
a hold-down clamp at one end of a cover on an engine
13. There are two hold-down clamps on each cover machined separate from the valve covers to allow for the application of different finishes (they will be plated while the covers will be painted).
a pair of tubes built to hold the spark plug wires sit on a surface
14. DRC built a pair of tubes that hold the spark plug wires. To add detail, slots were added then filled with perforated metal that were secured with six rosette welds that were ground smooth.
one of the spark plug tubes in place
15. Here one of the spark plug tubes is in place. Like the rest of the visible wiring, the plug wires have been cloth wrapped for a vintage look.
a CAD modeled by JHRS of the intake manifold and all the injection system components
16. The intake manifold and all the injection system components were CAD modeled by JHRS. The intake was engineered to correct the inherent problems with individual butterfly per cylinder manifolds.
the intake manifold casting
17. The intake manifold is a one-off casting that uses a common air intake plenum that allows all cylinders to feed from the same air supply rather than individual butterflies.
the underside view of a manifold showing hidden fuel injectors and wiring
18. As the engine has a separate valley cover all the fuel injectors and wiring could be hidden on the underside of the manifold.
a view of the ports showing the location of the fuel injectors
19. This view of the ports shows the location of the fuel injectors (arrows). Note that O-rings are again used to eliminate gaskets.
a JHRS machined part meant to hide the throttle position sensor sits on a surface
20. To hide the throttle position sensor JHRS machined this housing from aluminum that replicates a mechanical fuel injection barrel valve.
the TPS for the FAST fuel injection in place
21. Here the TPS for the FAST fuel injection is in place. It will be operated by a lever connected to the throttle linkage and the wiring will go through a hole in the manifold.
the TPS for the EFI system mounted between the injector stacks
22. The TPS for the EFI system mounts between the injector stacks just as a mechanical barrel valve would. An arrow points to the actuating lever that hooks to the throttle shafts.
original mechanical-style fuel lines leading to each manifold runner are added to help camouflage the throttle position sensor and maintain the mechanical injection look
23. Original mechanical-style fuel lines leading to each manifold runner were added to help camouflage the throttle position sensor and maintain the mechanical injection look.
mechanic Keith installs the Comp Cams push rods
24. Keith and Jeff Dorton of Automotive Specialists (AS) oversaw the mechanical aspects of making the LS3 perform. Here Keith installs the Comp Cams push rods.
mechanic Jeff installs an electric water pump for the dyno pulls then begins assembling the rocker covers and ignition system
25. With the Comp Cams valvetrain components in place, Jeff installed an electric water pump for the dyno pulls then began assembling the rocker covers and ignition system.
mechanic Keith works on the engine specs
26. Based on his years of experience, Keith chose the specs for the Comp Cams ’shaft and worked with JHRS on developing the EFI system.
the results from the dyno test listed on a screen
27. More than a pretty face, on the dyno the 440ci Chevy recorded peaks of 654 hp and 618 lb-ft of torque.
the engine is dropped between the Roadster Shop framerails, hidden under the transmission tunnel are the fuel lines, idle air control (IAC), and oil pressure sender
28. Back at the DRC shop the engine was dropped between the Roadster Shop framerails. Hidden under the transmission tunnel are the fuel lines, idle air control (IAC), and oil pressure sender (the extra hole is for wiring).
close view of the cast stainless steel exhaust header flanges and the tight radius header elbows
29. Ultimate headers supplied the cast stainless steel exhaust header flanges and the tight radius header elbows.
the engine dropped between the Roadster Shop framerails, featuring DRC designed headers that were built by Performance Welding Solutions to have the look of manifolds and JHRS produced stainless steel exhaust clamps
30. DRC designed the headers that were built by Performance Welding Solutions to have the look of manifolds. JHRS produced the stainless steel exhaust clamps used throughout the system.
the engine painted the original color by DRC sits on an engine stand
31. After grinding every surface smooth, DRC painted the engine in the original color found on early Chevrolet six-cylinder engines.
close view of the Edelbrock Victor Series water pump, installed with pulleys crafted by JHRS
32. To convert from a serpentine system for more visually appropriate V-belts, an Edelbrock Victor Series water pump was installed with pulleys crafted by JHRS.
a modified, early style OEM oil breather sits on a surface
33. It’s the little things that make a difference, take this modified, early style OEM oil breather as an example.
the OEM oil breather cut apart with new perforated metal screens part sitting near by
34. DRC cut the breather apart, added three slots, then filled them with perforated metal screens.
mechanic holds the OEM oil breather with the new metal screen applied
35. The result is a breather that’s lots cooler than the chrome dome style seen in previous photos.
a DRC created, one-off screened fan mount and shroud sits on a surface

36. And the cool goes on, literally and figuratively. DRC created this one-off screened fan mount and shroud.

Devlin Rod and Customs
(316) 265-2088
devlinrodandcustoms.com
Johnson’s Hot Rod Shop
(256) 492-5989
johnsonshotrodshop.com
Automotive Specialists
(704) 786-0187
automotivespecialists.com
Modern Rodding

VOLUME 3 • ISSUE 22 • 2022