Topic: Mallett Cars

[Sting Ya]

I'm looking to get some feedback from any members who have or have owned a Mallett LS conversion .Basically your overall satisfaction or dissatisfaction with the conversion ,if you live in an area that requires an E Check any issues passing,any problems or concerns with the build, and any improvements that you have added or feel should have been added during the conversion ? Thanks in advance   

[ihawk95]

I know a guy from Michigan that owned one.  He's not on the forums much anymore, but he is still active in MKC.  I can get in touch with him if you'd like.

He didn't have it long...maybe a year or 2.  Bought it used and sold it either early last year or late the year before.

[Sting Ya]

Thanks any information would be greatly appreciated he can email me if he does want to go through the forum

[ihawk95]

No problem!  I don't think he's on here, but he was on the Solstice forum.  Toyman is his forum name.  He may still check it now and then.

[username]

It is entirely possible to get a Mallet conversion that used a 6-speed and an LS newer than the chassis (IE: LS3, 7 or 9 on a 2008-up car) certified for emissions in California. LS2 would be OK in an '06, or 07. By the way, that's a *Federal* EPA rule, not a state-specific thing, though your state's vigilance may vary.

The car runs well, stays in normal operating temperature even on very hot days with the A/C on. OEM brakes are just fine for the car, even during an autocross. Upgraded pads & fluid will suffice for track days.

Only issue that didn't come up as the result of racing was heat coming off of the exhaust system on extended drives; The car would get uncomfortably hot around the trans tunnel, and toiletries in the trunk for a roadtrip would melt! This is fixable by ceramic coating the exhaust manifolds and everything back to the tips.

Racing related needs:
I did need to add a differential cooler & better differential vent [extended tube with an inline catch can] (racing-related), upgrade to the GXP finned PS cooler (racing related). Regular cruising around, those were fine, but on track, PS would boil over a little, and the differential would lose some oil via the pretty crappy OEM venting situation. Regular cruising around didn't cause any of those issues.
Fully bleeding the coolant is very difficult, as the highest point in the system is not the coolant overflow tank. I use a MityVac hooked up with an adapter from a coolant system pressure testing kit to force out all the air after refilling.

Most V8 owners just seem to use them as cruise machines, so you'll likely never need to do any of that stuff.

If the original owner didn't spring for the 6-speed, or the upgraded radiator, you may have a different experience.

[Sting Ya]

Thank you for the information the car in question is an early build with the stock 5 speed and the rear changed out to a 3:42 .I plan on upgrading the brakes  basically Hawk pads and R1 concepts rotors and stainless steel brake lines also in the works are new tires and rims  cause we all know what trash the OEM tires  are .The radiator is something that I did not consider because from all I have read Mallett addressed that issue and yes in the future I plan on upgrading to a 6 speed and some engine mods,hot cam , headers, intake etc. I'm to a point with my 2.4 build that I want to take the next step up and my current car is where I want it to be so it's time to add to my stable . I have been in the market for a C5  Z06 and this car popped up so why not . I have always been fascinated by an LS Solstice car plus living in the Cleveland area and knowing people that had Mallett Vett builds and their satisfaction with them  peaks my interest .

[username]

Mallets generally don't overheat because they retained all the OEM ductwork in the bumper and under the car to force air through the radiator, as well as the OEM cooling fans and shrouds, in addition to properly running the various coolant lines from the heads. HOWEVER, my understanding is that it was possible to order a car from Mallet and retain the stock Solstice radiator. It shouldn't be a big deal to have a custom two or three row unit made and installed in its place. It's easy to eyeball a stock radiator (plastic end tanks.) Just budget a few hundred dollars to replace it if that's the case.

For cruising, the OEM radiator is probably fine. For any spirited driving or competition, or if you're in an area where you might see temps in the 90s, you should upgrade it. Ensure that whoever does the install doesn't leave off the important bits (ducting, undercar deflector, radiator shroud.) Don't bother "upgrading" to aftermarket fans. Waste of money, and you'll get worse cooling performance unless you actually have some real fan shrouds built around them.

I actually prefer the *feel* of the 5-speed's shifter. It's very direct and smooth. A T-56 will never feel that good, but the Asin unit will not last if you're pushing the car.

There's no need to do anything to the pads/rotors/lines unless they're ready to be replaced. Wear 'em out first.

OEM tires need to go, just because they're probably dry-rotted at this point, but the car be entertaining that way.

[Helios]

My build of materials (BOM) cost is just under $4200 right now for what I think I need for a swap. The cost of an upgraded radiator is around $250 of my budget. I am going to use a 5.3L in my swap and retain the Aisin AR5 and rear diff. Hoping to get around 400-500 whp and comparable torque without having to change those. Upgraded DDM Works stage 3 clutch is good for 450 hp according to DDM's website. So, I think I'm good there. There are a few things I haven't accounted for, but I think they're minimal. Biggest problem for me will be figuring out the wire harness, programming the ECM, and tuning. I'm glad SC is a state that doesn't care what engine I use in my car and they got rid of the vehicle inspections long ago.

[cbr6]

anyone ever consider a tremec 5 speed trans? they come in 500 and 600 ft/lb torque rating's.  in street machines a lot of people go with these instead of t56 6 speeds. doubtful you'll miss the .50 overdrive. it's also smaller then a t56

[username]

My build of materials (BOM) cost is just under $4200 right now for what I think I need for a swap. The cost of an upgraded radiator is around $250 of my budget. I am going to use a 5.3L in my swap and retain the Aisin AR5 and rear diff. Hoping to get around 400-500 whp and comparable torque without having to change those. Upgraded DDM Works stage 3 clutch is good for 450 hp according to DDM's website. So, I think I'm good there. There are a few things I haven't accounted for, but I think they're minimal. Biggest problem for me will be figuring out the wire harness, programming the ECM, and tuning. I'm glad SC is a state that doesn't care what engine I use in my car and they got rid of the vehicle inspections long ago.

The 5.3L isn't legal in a car anywhere. You may not have inspections in SC, but the rules about not putting truck engines into car chassis are Federal rules. I wouldn't count on the remainder of the states being able to neglect emissions inspections lasting much longer into the future.

[username]

anyone ever consider a tremec 5 speed trans? they come in 500 and 600 ft/lb torque rating's.  in street machines a lot of people go with these instead of t56 6 speeds. doubtful you'll miss the .50 overdrive. it's also smaller then a t56

The T56 fits (with some opening up of the firewall), and the 2nd overdrive has a major impact on economy. 5th gear in a 6-speed Mallett is still a passing gear. (TBH, 6th is usually pretty good for passing too, but sometimes you're in more of a hurry.)
Generally for street driving, even though I don't have a skip shift, I'll either do 1-4-6 or 2-3-6 (if the roads are slick.) I very rarely use 5th, unless I'm trying to pass in a hurry and near the top of 4th already.

[Dave@DDMworks]

The TR6060 is even nicer than the T56 though and shifts much nicer, has the built in ports for a trans cooler and is just a much more pleasent transmission to drive over the T56. We are usually using the one from the SS with the following ratios -

1st - 3.01
2nd - 2.07
3rd - 1.43
4th - 1
5th - .84
6th - .57

6th is definitely for cruising, but it would be neat to do a build with the ZL1 gearing which changes it to -

1st - 2.66
2nd - 1.78
3rd - 1.3
4th - 1
5th - .80
6th - .63

I think that would make 1st gear much more usable in the V8 builds and the little bit higher 6th wouldn't hurt fuel economy much, closer to the T56 we used before -

1st - 2.97
2nd - 2.07
3rd - 1.43
4th - 1
5th - .84
6th - .56

CBR6 - Are you talking about the old T5 trans? That is not a bad little setup and it is pretty light also, we have a friend that is using it on a V8 swap with a 302 on a first gen RX-7 and it is amazingly small and compact little setup in there.

[ihawk95]

I have a message into Toyman about his Mallet.  I asked him if he had an early build, his thoughts, any improvements he would have liked, etc.  I'll let you know his feedback!

[Helios]

The 5.3L isn't legal in a car anywhere. You may not have inspections in SC, but the rules about not putting truck engines into car chassis are Federal rules. I wouldn't count on the remainder of the states being able to neglect emissions inspections lasting much longer into the future.

What's the difference if it's in a car or SUV? There are just as many SUVs and such on the roads as there are passenger cars. Federal rules are out dated. As a car enthusiast I know that SC residents aren't the only folks swapping in truck engines into their hotrods. They're inexpensive and easy to find with a large parts collection/ inventory support which is what makes them so desirable. Read LS1Tech forums and you'll see there are many 5.3L engines going in hotrods. Anyway, if SC happens to re-institute a state vehicle inspection there will be shops out there that will do your inspection and sign off on it as long as you have the $$$ for them to look the other way. It happens in CA all the time, one of the most Nazi vehicle inspection states if not THE most Nazi state when it comes to ridiculous rules and regulations.

[username]

What's the difference if it's in a car or SUV? There are just as many SUVs and such on the roads as there are passenger cars. Federal rules are out dated. As a car enthusiast I know that SC residents aren't the only folks swapping in truck engines into their hotrods. They're inexpensive and easy to find with a large parts collection/ inventory support which is what makes them so desirable. Read LS1Tech forums and you'll see there are many 5.3L engines going in hotrods. Anyway, if SC happens to re-institute a state vehicle inspection there will be shops out there that will do your inspection and sign off on it as long as you have the $$$ for them to look the other way. It happens in CA all the time, one of the most Nazi vehicle inspection states if not THE most Nazi state when it comes to ridiculous rules and regulations.

Trucks have different economy and emissions requirements than cars; the federal rule allowing that is what is outdated. That's why the EPA disallows truck engines in passenger car chassis. Just like the EPA disallows putting older drivetrains in newer chassis. Just because 'everyone does it' doesn't mean it is legal. For a hotrod built on some 30s or 40s Ford or whatever, I'm sure a modern truck engine that hasn't been stripped of all its pollution controls is a huge improvement, for both pollution and efficiency, but I don't ever think I've seen a hot rod leave that stuff on. For a modern passenger car, a truck engine will be a downgrade.


The rules and regulations with regards to vehicle emissions in California aren't ridiculous. The results are as clear as day, specifically with regards to how far you can see on a clear day as compared to what it was like in the '70s and '80s. The air smells and looks better. It is undeniable. The requirement that aftermarket parts and modifications prove that they don't negatively impact the output of a vehicle isn't unreasonable, the aftermarket is just generally unwilling to take on that expense. To compare laws and regulations that improve the quality of life and health of all state residents at the expense of allowing any random Joe to 're-engineer' or just fail to maintain systems that dramatically reduce vehicle emissions to the Nazis' attempted extermination of the Jews and other minorities, or any of their fascist ideals is disgusting and disrespectful to the memories of those murdered as well as completely unfounded hyperbole. I ask that you retract that statement if you wish to remain in polite company.

It is entirely possible to do an engine change in California and be totally legal. It's not a big deal. It is a bit of a time consuming process, but it is achievable if you do research in advance and don't try to skirt or bend the rules.

As for paying to get your car passed in California, that's not really feasible, not unless you have a clean 'tester' car (that has a similar emissions profile) to run in place of what you want. Smog testing in California involves the state-approved smog testing machine sending reports back to the state DMV electronically. There is not a window to fudge the numbers. You need to supply an actual clean exhaust, make and model may not need to be identical, but RPM at a given speed on the dyno and emissions profile need to be within expected ranges for the car you're trying to pass (so a stock example is your safest bet.) Later OBD2 cars (02-ish and up) can skip the sniffer if the ECM reports everything is operating properly, but the ECM also reports the VIN, so your substitute needs to report the correct VIN.

Clean-piping doesn't work any more, at least not in the sense where you can just pay a guy. You need to basically own a 2nd car for smog purposes AND pay a guy. On top of that, they hold Smog techs accountable (ie: their license) if cars they pass fail their next test more often than is average, so you're not going to see some random test station be willing to pass anyone who flashes a few hundred extra, even if they're not worried about a sting operation from the licensing agency.

[Helios]

To compare laws and regulations that improve the quality of life and health of all state residents at the expense of allowing any random Joe to 're-engineer' or just fail to maintain systems that dramatically reduce vehicle emissions to the Nazis' attempted extermination of the Jews and other minorities, or any of their fascist ideals is disgusting and disrespectful to the memories of those murdered as well as completely unfounded hyperbole. I ask that you retract that statement if you wish to remain in polite company.

Sounds like a veiled threat toward me about a comment that wasn't directed AT you. However, I'm not in the business of rectifying hurt feelings. In this day and age you're bound to offend someone. If you're offended with what I said, so be it. I won't lose any sleep.

[username]

Sounds like a veiled threat toward me about a comment that wasn't directed AT you. However, I'm not in the business of rectifying hurt feelings. In this day and age you're bound to offend someone. If you're offended with what I said, so be it. I won't lose any sleep.

I'm not offended, I'm disgusted. There's no threat, veiled or otherwise. What you wrote makes it seem like you equate the acts of government agencies that curtail an imaginary "right" to toss whatever garbage a person feels like into the air that we all have to breathe to facisim and genocide. You cannot be regarded as a serious participant in a polite discussion after making, and standing by, this statement.

There's perhaps a reasonable discussion to have about the rules and regulations around vehicle emissions, but this is not it.

[Sting Ya]

Let me start off by saying that I can't thank the forum members enough  for all the insight you have given me on this purchase and hopefully I'll be able to come to an agreement and have this car in my garage when the weather breaks .Once again I'm in the early stages of this purchase and to be honest with everyone I was not looking for one at this time my current car is apart while I do some winter upgrades  and then this car popped up . One issue that I have been made aware of by the current owner is a problem with a " throttle hang at 2200rpm"his words .It's an intermittent issue that can last for a few seconds to having run over a mile without touching the gas ,pushing in the clutch   does not help, the revs do not go down . From my conversations with the current owner he seems to think it's a quirk with the Mallet car and the tune ie:the ECM any suggestions ?   

[elff]

 the hippies In CA
Just because smog is better now, doesn't mean the laws aren't stupid.  IMHO, they are over compensating to correct something that current car owners were not responsible for and is no longer an issue. 
There is zero technical or environmental reasons why a truck engine should be disallowed in a car. 
100 instances of that engine produce X amounts of pollution.
Does X change whether that engine is installed in an SUV or a Kappa?
The answer is no.

[Gentleman Jack]

As a current CA resident, and long time car fanatic, I can honestly say I have had ZERO issues with anything I ever wanted to do to my cars.

Also- there is no sniff test in CA (for OBD2 vehicles) and my last smog check (last month, 2001 Dakota with a 5.9) took 5 minutes and only cost $23.00.
The air here IS significantly better because of EPA restrictions. The air in this whole country is better as a result. On top of that, we have the most powerful, most efficient and cleanest engine ever developed available at every dealership. These technological marvels are here today because some crazy ass people decided to set standards for air pollution.
Hippies?  Really?  This state is completely ed up. No question about it. But give credit where credit is due. The little marvel that is the LNF is here because GM needed to meet CAFE standards and sell cars.

Also, another note about CA for those appearing under-educated, I have yet to see a gas chamber or a concentration camp in my 12 years here. Just trying to clear that messy discussion up.

As for the OP asking about the Mallett cars:  I think this thread went sideways and (for once) I don't believe it was the KappaPerformance drift team that did it. Good luck with your search. I am secretly looking for a converted coupe with a silly supercharged V8 or better yet, a turbo diesel. Let me know if you see one. I'm predicting 70 mpg freeway with the diesel. I don't believe I'll need first gear either.

Hope everyone is having a graceful evening.

Peace Maaaaaaannnn

[Critterman]

That earthquake that is going to drop California into the ocean can't come soon enough!

[Sting Ya]

Gee all I wanted was some info on Mallett cars or V8 swaps sorry to stir up such a firestorm !

[elff]

You sir are a trouble maker. 
gJ is a hippie

I wonder how the animals in the SD Zoo would describe their living arrangements

[Sol Asylum]

Didn't CA use the gas chamber to execute convicts?

[Gentleman Jack]

That's righteous man. I'm going to go toke up and get groovy.