Muscle Factory Chevelle: Bill Dannels’ Diesel Powerhouse
When your business is named The Muscle Factory, any project car you build needs to seriously impress. Bill Dannels understood this perfectly. After experiencing his friend Mike Racke’s Duramax-powered 1970 Chevelle, Bill knew he needed a diesel muscle car of his own. Unlike Mike’s completely custom build, Bill aimed to keep his ’70 SS Chevelle largely original in appearance, creating a resto-classic showcase for his El Camino and Chevelle restoration parts business. Crucially, Bill decided his Muscle Factory Chevelle would feature not only a Duramax engine but also a manual transmission, adhering to the old-school hot rodder’s mantra: “real hot rods have three pedals.”
The Genesis of the Build
The project commenced with a rolling chassis and an ’06 Duramax LBZ engine. Fitting the substantial diesel powerplant into the classic A-body chassis was the first major task. Fortunately, the Chevelle’s generous engine bay simplified the process somewhat. Friend Mike Racke fabricated custom motor mounts that utilized the factory Chevelle frame mounting points. To ensure adequate ground clearance, two inches were carefully trimmed from the bottom of the Duramax oil pan. Up front, big block Chevy springs were installed to support the additional weight of the diesel engine. Pacific Performance Engineering (PPE) provided a complete wiring harness and a performance race tune tailored for the application.
Engine bay view of the Muscle Factory Chevelle showcasing the custom-fitted twin-turbo LBZ Duramax diesel swap.
Powertrain: Handling the Torque
With the PPE-tuned Duramax estimated to produce a stout 550 horsepower and a massive 1,000 lb-ft of torque, the original Muncie 4-speed transmission was clearly inadequate. Bill opted for a robust G-Force 5R manual transmission, a unit commonly found in demanding road racing and drag racing environments. To manage the diesel’s immense torque delivery, a dual-disc clutch assembly from South Bend Clutch was installed. The rear axle assembly also required a complete upgrade; the stock GM unit was replaced with a durable Chris Alston Fabricated 9-inch differential, loosely based on the Ford design, built to handle the power.
Close-up of the polished twin Garrett GTX2860 turbochargers mounted on the Duramax engine in the Muscle Factory Chevelle.
Twin-Turbo Setup and Engine Bay Details
The Chevelle spent several weeks at PPE, where expert technicians fabricated the intricate exhaust and intake plumbing necessary to mount the twin Garrett GTX2860 turbochargers. This custom setup, polished to a brilliant shine, not only looks impressive but also provides room for future power increases up to 800 hp. To cool the boosted air charge, a universal intercooler was neatly integrated behind the classic SS grille.
Front view showing the universal intercooler mounted behind the SS grille of the Duramax-powered Chevelle.
One of the engine bay’s most striking features is the individual runner intake manifold topped with twin plenums, perfectly complementing the twin-turbo arrangement. High-end Wiggins clamps secure the connections between the turbo outlets and the intake manifold, ensuring leak-free performance under boost.
Detailed shot of the custom individual runner intake with twin plenums on the Duramax engine in Bill Dannels' Chevelle.
Close-up showing a high-end Wiggins clamp securing the boost piping connection on the Chevelle's Duramax intake.
PPE also crafted custom headers from durable 304 stainless steel specifically for this application, routing exhaust gases to the turbos. Tucked beneath the turbochargers, these headers lead to custom 3-inch downpipes that channel the diesel exhaust under the car. Mike Racke added a finishing touch with custom valve covers.
View of the custom PPE-fabricated 304 stainless steel headers tucked below the twin turbos on the Duramax engine.
Underside view showing the custom 3-inch downpipes fabricated by PPE leading from the Duramax engine's headers.
Despite the large diesel engine and twin turbos, there was sufficient space for a factory-style Chevelle radiator from Champion Radiators, paired with twin Spal USA electric fans to keep the Duramax cool during hot summer cruises.
Factory-style Champion Radiator with twin Spal electric fans ensuring cooling for the Duramax swapped Chevelle.
The brake system features an innovative setup from ABS Power Brakes, utilizing a master cylinder paired with an electric vacuum pump. This provides consistent and ample brake pressure without requiring an engine-driven vacuum pump or a hydroboost system.
ABS Power Brakes master cylinder with electric vacuum pump setup providing braking power for the diesel Chevelle.
Engine height is often a concern with Duramax swaps. However, with the minor oil pan modification and a protective skid plate, the diesel engine fit comfortably under the factory SS cowl hood.
Profile view showing the Duramax engine fitting neatly under the factory SS cowl hood of the 1970 Chevelle.
Attention to Detail: Blending Muscle and Modern
What truly elevates Bill’s Muscle Factory Chevelle is the meticulous attention to detail throughout the build. From the upgraded Wilwood disc brakes at all four corners to the custom 18-gallon fuel tank designed for extended range, numerous bespoke components enhance the car’s performance and usability without compromising its iconic muscle car aesthetic.
View of the manual transmission shifter inside the restored Chevelle interior, highlighting the three-pedal setup.
Rear undercarriage view showing the robust Chris Alston fabricated 9-inch rear end housing beneath the fuel tank.
The interior was fully restored to SS specifications using parts sourced from Bill’s own Muscle Factory business. The only significant deviation from stock is the dashboard, which now houses a set of modern gauges from Dakota Digital to accurately monitor the diesel engine’s vitals.
Restored stock-appearing interior of the Muscle Factory Chevelle featuring Dakota Digital gauges in the dash cluster.
Custom 18-gallon fuel tank installed to provide extended driving range for the diesel-powered Chevelle.
The exhaust note is managed by a pair of 3-inch, two-chamber Flowmaster mufflers, giving the Duramax a deeper rumble than typical diesel trucks.
Underside shot showing the dual 3-inch Flowmaster mufflers providing the exhaust note for the Duramax Chevelle.
Performance and Presence
Shortly after completion, the Chevelle made its debut at the prestigious 2014 SEMA show, captivating attendees with its innovative diesel powertrain swap. Since then, Bill has thoroughly enjoyed driving his creation on the street. He emphasizes that the best aspect of owning this twin-turbo, manual transmission, diesel tire-shredder is its drivability. With shift points between 4,000 and 4,500 rpm and ample power from 2,000 rpm upwards, spinning the tires through the first three gears is effortless.
Bill Dannels' finished twin-turbo Duramax 1970 Muscle Factory Chevelle parked outdoors.
While Bill hasn’t yet taken the Chevelle to the drag strip, he confidently estimates it’s capable of running easy 12-second quarter-mile times on street tires. Perhaps even more impressively, he anticipates achieving over 30 mpg on the highway. Combining stunning show car looks, exhilarating all-around performance, and relentless diesel torque, Bill Dannels’ Duramax-powered 1970 Muscle Factory Chevelle is set to deliver countless miles and smiles for years to come.
