Falcon in-line 6 to V8 conversion

[xafalcon]

Hi there

I'm thinking of converting an E series falcon from inline 6 to V8, by using an unroadworthy V8 of the same model as a parts donor. I've been talking to a couple of certifiers and they both say I need to certify the vehicle. Now I don't necessarily have a problem with this, but I do have a problem with an estimated cost of $350-$400.

Falcons came out from the factory with either I6 or V8 powertrain options. Brakes were the same, the diffs were the same, the bodyshell and suspension was the same. The only difference was engine, trans, steering rack, engine cross-member and front coil springs.

So I'm wondering why there is such a high cost to certify this when factory parts are being used for the whole conversion. It is following the manufacturers build design to the letter, and so this is an already approved combination of parts for New Zealand roads.

From my view the certification process should be very straight forward, simply checking that I have in fact used the factory parts that I said I was going to use. This should then be reflected in the certification cost, allowing an hour for checking and whatever the "documentation fee" is. This must surely be less than what I've been quoted.

Can someone enlighten me where I'm going wrong?

thanks

PS I couldn't get the "threshold modification limits" pdf to download. So appologies if this is contained in that document.

[kendall]

Hi XAFalcon

Well done for talking to a couple of Low Volume Vehicle (LVV) certifiers before you start doing your mods. They are correct with the answer they have given you, in that your Falcon will require LVV certification.

Any vehicle that differs from the manufacturer’s configuration and is not covered by the LVV Threshold Schedule, is required to comply with the Low Volume Vehicle Code and the relevant LVV Standards.

I can understand where you're coming from in regard to the engine being a factory option. There's a couple of reasons that LVV certification still applies to a vehicle that is fitted with an engine that was a factory-installed option. There still needs to be a process to ensure that the factory parts are in fact fitted (and fitted correctly), and if they're not the OE parts, that the aftermarket parts are going to work well. You might know what you're doing, but believe us - not everyone does!

The other reason is that, although as you say, most components are the same, vehicle manufacturers often make a number of very subtle differences to model variants. For example, master cylinder bore diameters and wheel cylinder sizes can vary, brake proportioning valves are fitted to some variants and not others, and even proportioning valves between different variants can vary in size. These changes can lead to a brake imbalance or other characteristic that wasn't intended by the vehicle manufacturer. The thorough one-off brake performance test, and cyclic brake fade-resistance test specified by the LVV certification process will identify all of these issues, and with the expertise and experience of the LVV Certifier, a good plan can be made to get the vehicle right.

There are a few reasons that the figure seems high for the amount of input from the LVV certifier that you see. The LVV system requires that the LVV Certifier inspects the complete vehicle to ensure both compliance and safety, not just the mods. The certification charge is determined by the LVV certifier and covers not only the time and expenses involved in the inspection, but also the time involved in completing the documentation and the fitting of the LVV plate when the process is completed. As well as the LVV Certifier getting paid for his time, there's also the regulatory fee for the Government that applies to all certification types, the fee to manufacture the LVV certification plate (along with the associated functions that go on in the background with that), and the operating fee that comes to LVVTA from which we develop, operate, and continuously improve the LVV certification system. While none of us want to pay any more for something than we have to, the LTNZ and LVVTA fees enable the LVV certification system to operate - without which, you wouldn't be putting your 302 in your Falcon! And hey, it's still cheaper than the set of headers you'll buy for it!

Hope that helps you a little.

Cheers, Kendall.