Just thought I would start a thread to show the progress on my 72, it will be media blasted next week, here are a few pics of the stage that it is in now. Thanks for looking!

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1317.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1318.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1319.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1320.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1321.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1323.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1324.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1325.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1326.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_1327.jpg

Quite an undertaking. Keep us updated on the progress!

WOW ...........Your the man :thumbsup::thumbsup: What a MAJOR job you have :D:D Best to you :hurray::hurray:

www.howardsbackyardautobody.com :beers:

it is not so bad
http://i258.photobucket.com/albums/hh252/ss350Chevelle/chevelleiuppger195.jpg
http://i258.photobucket.com/albums/hh252/ss350Chevelle/DSC01261.jpg
http://www.kvartmila.is/smf/index.php?topic=27028.0
Keep us updated on the progress

Good luck on your project!! Looks like quite a challange...!

Good luck... we'll be watching for your progress!:thumbsup:

It can be done as you can see by all the others being shown on here! Great to see another start-to-finish project thread. Sure is easier to see it all in one thread instead of jumping around and searching to see the different stages that the car has gone through. Good luck and make sure to add pictures to this thread as you go.

Thanks guys! I will be posting progress pics frequently, and should have some pics after it is blasted by the end of next week.

You are my Hero if you finish this one:yes: - Good Luck... Love those 72's - thanks for saving one.

wow that's quite an undertaking. Plenty of good info here thouhg. Keep us apprised!

Looks like you got a good handle on what your doing, nice well lit shop also.:thumbsup:

Rob

Finally got the car back from media blasting!

Anyway here are some pics:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13004.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13005.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13006.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13007.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13008.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13009.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13010.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13011.jpg

1 more pic.

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13012.jpg

The body looks pretty good, what did they blast it with.

Rob

Looks like you have a good base to start with. Its in better shape than mine was. What are your plans for the quarters? Are you going to keep those half skins or put fulls on. Just take your time and it will come out nice. Good luck. :thumbsup:

Wow, I remember when mine looked like that. A lot of money and time.

The body looks pretty good, what did they blast it with.

Rob

It was plastic blasted, body is not too bad I guess. I want to put 2 new full 1/4's on it, inner/outer wheel wheels, see how underside of trunk floor is, and I already have a Dynacorn 1 piece floor pan with inner/outer rockers.

Good Luck, Some Day It Will Look Just Like My 72

Here is some more progress, floor pan/rockers/seat pan are almost all cut out of car.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13013.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13014.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13015.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13016.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13017.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13018.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13019.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13020.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13021.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13022.jpg

I think it's time for a new camera, these pics are very dark, shop is super bright as you can see in the first pics.

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13023.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13025.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13026.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13027.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13028.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13029.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/2008_10_13030.jpg

I think it's time for a new camera, these pics are very dark, shop is super bright as you can see in the first pics.
Check the settings! You may have inadvertently changed the settings while handling it.

Congrats on your progress!

Wow...!

You're on the right track, lotsa work!

Thanks guys! I will definitely check my settings on the camera, it is really disapointing how dark these progress pics are, they should be as bright as the initial teardown pics. Sorry for the quality, I will 'restore' my camera before the car! LOL.

Progress has been very slow due to work, but here are a few pics. Slowly starting to get rid of the rot! Also got a new camera from my girlfriend for Christmas so pics should be nice and bright again!

You can see the new driver's side toe kick in this pic.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0111.jpg

Had to weld some new metal in.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0112.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0113.jpg

Lots of rot here to deal with, currently making new pieces to weld in out of 18 gauge cold rolled steel.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0114.jpg

Driver's side rot
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0115.jpg

Here is my new 1 piece Dyancorn floor with inner/outer rockers:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0108.jpg

Here is 1 piece Dyancorn trunk floor:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0109.jpg

Here are a few pics of the new passenger side lower fender mount that I am fabbing to replace the rot.

Heres a pic of the stock rot that was cut out with cut off wheel.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0118.jpg

Pic of car from inside after rot was cut out.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0123.jpg

Pic of outside where I cut.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0122.jpg

Here's some rough shaping, used my 5" vise as a break, will need to trim this piece down to exact size still.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0119.jpg

Some time consuming work with a tape measure, vise and plasma cutter, turned out pretty good matches right up with original piece that it is replacing.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0120.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0121.jpg

My mig welder and plasma cutter - a must need for sheet metal work!
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0124.jpg

WOW!!! And I thought mine was a major project!!! Keep the pictures coming. I Have a link in my signature of what mine looked like and what it looks like today after 2 years of work. Keep up the good work!!!

Wow, a lot of work but you look like you have a good handle on it. It will look great when you get it finished.
Ray

Spent a couple hours on the car today.

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0128.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0130.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0131.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0135.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0136.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0137.jpg

holy crap.

quite a project.

that car is rotted in some strange places. all that rust and the window lips are in good shape. trunk floor looked like it was Ok, yet you replaced it anyway. you must be out to punish yourself.

looks like your doing a fine job. keep up the good work!

Looks like you have already done a lot of work. Good luck on the project.

Wow, alot of good craftmanship. Keep up the good work.

Wow! That's all I have to say. I bought my 72 over a year ago, and I want to begin cracking it open, but I'm too afraid of what I may find. Anyways, good luck. You're an inspiration to me!

Here is a few pics of the floor progress, body is now sitting on the floor and should have it all welded up in the next couple of days.

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleFloor001.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleFloor002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleFloor003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleFloor004.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleFloor005.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleFloor006.jpg

Looks good, Were you happy with the fit of the floor? just curious how it fits.

LK

Thanks guys! I will definitely check my settings on the camera, it is really disapointing how dark these progress pics are, they should be as bright as the initial teardown pics. Sorry for the quality, I will 'restore' my camera before the car! LOL.

I'm no camera expert, but will offer a suggestion based on my own experience... when you have plenty of light (outside or in the shop) try turning the flash off. Just a suggestion from pure and complete novice...

Great progress pictures!!!!! Thanks for sharing!

nice work

Thanks guys!

Alwhite00 - Floor fits great I am really happy with it, it was 1 piece Dynacorn with rockers, if your floor and rockers are toast this is the ONLY way to go in my opinion, expensive but saves a lot of hours in the long run.

markfromark - Good camera tip I will definitely do that once I finish the welding and take those pics!

I just got my 71', and will be doing a lot of the same work, starting with floor pan. Many questions I have!!! For starters, did you dry fit the floor until the body set back on?

On the blasting with the body, am I better off cutting out what i know is bad before having it blasted?

Your car looks great. Your pics are gonna be of great help to me :)

I just got my 71', and will be doing a lot of the same work, starting with floor pan. Many questions I have!!! For starters, did you dry fit the floor until the body set back on?

On the blasting with the body, am I better off cutting out what i know is bad before having it blasted?

Your car looks great. Your pics are gonna be of great help to me :)

Hey Cody,

I did do a dry fit for the floor, but it is the Dynacorn 1 piece with full inner/outer rockers, so it fit like a glove, I just drilled out all the factory spot welds and rebuilt all the lower cowl and body mount areas with new metal, basically the pics are what I did once the old floor was out and metal work was done - just lay car on top, fit great, clamp it down and weld.

For blasting your body, it might be a good idea to cut out what you know is bad (make sure it stays braced really well if you cut big parts out), you will save some money. I left mine alone and told the blaster not to blast the rockers and floor because I knew they were rotten.

Hey Cody,

I did do a dry fit for the floor, but it is the Dynacorn 1 piece with full inner/outer rockers, so it fit like a glove, I just drilled out all the factory spot welds and rebuilt all the lower cowl and body mount areas with new metal, basically the pics are what I did once the old floor was out and metal work was done - just lay car on top, fit great, clamp it down and weld.

For blasting your body, it might be a good idea to cut out what you know is bad (make sure it stays braced really well if you cut big parts out), you will save some money. I left mine alone and told the blaster not to blast the rockers and floor because I knew they were rotten.

I have all the same issues, and plan on the Dynacorn floor come tax check time. I gotta fab both my lower-cowl areas as well. I will make sure to brace it well. Did you use 1/4" angle iron on the bracing?

Man looks like you are making some great progress on this one.Nice job. Can't wait to see this one finished up.

Alright here are some updates:

Cutting out old trunk floor:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Jan14072.jpg


http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Jan14072.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Jan14074.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Jan14077-1.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Jan14079.jpg

New Trunk Floor in and secured with a couple of sheetmetal screws:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010001.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010004.jpg

Inner/Outer Wheelhouse Test fit:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010005.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010006.jpg

Close up of wheelhouse test fit.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010007.jpg

Trunk drop off test fit:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010008.jpg

Drop off needs a little trimming as it is pulling the wheelhouses away from the floor (you can see a good 1" gap) - easy fix.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010009.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleFeb112010010.jpg

All in all I am very happy with the fit of all my Dynacorn pieces. I was worried about the wheelhouses and the trunk floor drop offs due to previous posts I have read but they will work just fine.

My next step is to install the passenger door and get it aligned as good as possible with what is left of the passenger 1/4 panel. I will also install the trunk lid and create the original gaps. Then I am going to cut out all the spot welds and remove old 1/4 panel and get new on in place. Everything will be attached temporarily (1/4 panel, wheelhouses to 1/4 and wheelhouses to trunk floor, and drop offs) with sheet metal screws until I am happy with the fit/gaps - then I will be welding. Then off to the driver's side! It's really starting to come along now and it feels like I am making big progress and a ton of new sheet metal will be going in at once!

Just a quick question if someone sees this: what are you guys doing to remove the factory lead on the sail panel to roof skin seam to get at the spot welds?

Thanks for looking!

Sweet Jesus. That's one heck of an undertaking. I'll say that your 72 rotted in some weird places that mine did not, and mine rotted in some very typical places that yours's did not. How the heck did the area below the rear window not rust?

I'll add a big thank you fro posting pictures of the lower rear fender mounting. Mine is shot on both sides and I don't think you can buy those parts. I will be fabbing those up for sure. If you have any other pics of that area, I would be happy to see them!

Great work so far. Keep us posted on your progress.
Ray

Sweet Jesus. That's one heck of an undertaking. I'll say that your 72 rotted in some weird places that mine did not, and mine rotted in some very typical places that yours's did not. How the heck did the area below the rear window not rust?

I'll add a big thank you fro posting pictures of the lower rear fender mounting. Mine is shot on both sides and I don't think you can buy those parts. I will be fabbing those up for sure. If you have any other pics of that area, I would be happy to see them!

Mine is rotted below the rear window in the corners, but it's not all the way across, who knows why? I know I am going to have to replace the package tray as well (stock one is crunched from a previously hit on the passenger side), I was going to rebuild it but I figure with the time involved it will be easier to cut it out and replace.

I will look for any other pics that I have of that area where the rear fenders mount too, but I think I have posted everything I have. I still have to drill holes for the mounting bolts, but that will happen when I actually get the new fenders mocked up.

None of my business, but what did you pay for your 72 and how much do you think you'll have into it when you're done? I'm also doing a frame off nut and bolt restoration on a 72 chevelle.
Good Luck!
murph182

None of my business, but what did you pay for your 72 and how much do you think you'll have into it when you're done? I'm also doing a frame off nut and bolt restoration on a 72 chevelle.
Good Luck!
murph182

I paid $1700 for the car which came with a new passenger outer wheelhouse and a passenger 1/4 skin which i cannot use (going with full 1/4).

So far I have about $3600 in new metal purchased for car (full floor w/rockers, full truck, drop offs, inner/outer wheelhouses, rad support complete, passenger full quarter, toe kicks, and rear tail panel).

I also spent $500 getting the shell media blasted with plastic beads.

I still need to buy: driver's full quarter, 2 x front fenders, hood + trunk lid (probably going fibreglass for both), and not sure about doors or door skins yet. So by the time all the metal work is done on the car I will have a good $7000 into it just for parts. This is all canadian prices, which are really close to US right now - our dollar is doing good.

It is really tough to say how much it will cost me when I am done because I would figure another 10g's to get the final bodywork and paint done, plus all the interior, motor, diff, front/rear suspension, cage, wheels/tires, trim, glass. It seems overwhelming to even think about it right now - this is why I am buying parts as I can and as I need them.

WOW!! I must say you ain`t afraid of anything. Most guys would have hauled that thing to the scrap yard. Glad to see your saving another one that probably would have been gone. Just think how proud your going to feel the first time you pull up to your 1st car show in it. That`s going to be pretty da.... cool. Keep up the great work, will all be watching this one.

Wow, after seeing these cars, my 70 is a dream. I was bummed because I have a rear dog leg rusted on the passenger side.
Glad we don't get rust like that here. We are spoiled here as we would junk those bodies in a heartbeat. You couldn't even sell those on the west coast. God bless you boys for the fortitude, yer saving a bunch of lost "souls" with literal miracles. :beers:

http://i133.photobucket.com/albums/q46/1goatboy/6-18-09005.jpg

http://i133.photobucket.com/albums/q46/1goatboy/1115081457.jpg

Really nice, Trevor. :beers:

Here are two pics of my wreck job on the roof/qtr area. Doing the passenger side first was my "learning side". I expect, seeing how its on there now, will make doing the driver side a million times easier. I did a lot of chiseling, there must of been at least a quarter inch of lead on mine. I was getting bark sized pieces breaking off. Don't know if that is normal, but it seemed almost excessive.


http://farm3.static.flickr.com/2742/4381195438_2a265c6ffe_b.jpg (http://farm3.static.flickr.com/2742/4381195438_2a265c6ffe_b.jpg)

http://farm5.static.flickr.com/4067/4381195400_6a93d01a8a_b.jpg

Seem like I was just there! I kinda dont miss ,keep up the good work though, the pay off is awesome!

looking good. i just got motivated to work on my 71 again. doing a rough test fit of the rear quarters, deck filler and tail panel. by the way i used a torch set, and a stiff wire brush to remove the lead, and reveal spot welds. probably wasnt the safest way,although i kept the area ventilated. worked very well.

Trevor - I know it's been said a few dozen times, but WOW! You are ambitious... Outstanding work!

Makes me feel even more fortunate about our '72 build. It about killed me when they cut the quarters out, but after seeing your 'project', I have a whole new respect for what can be done.

The firewall was filled last week, the second coat of primer should be on any time and then the undercoating.

http://72malibu.chambersohana.com/graphics/body_top_14jan10.jpg

Good luck! - Doug

Trevor - I know it's been said a few dozen times, but WOW! You are ambitious... Outstanding work!

Makes me feel even more fortunate about our '72 build. It about killed me when they cut the quarters out, but after seeing your 'project', I have a whole new respect for what can be done.

The firewall was filled last week, the second coat of primer should be on any time and then the undercoating.

http://72malibu.chambersohana.com/graphics/body_top_14jan10.jpg

Good luck! - Doug

Thanks Doug and everyone else! This is by far the best forum that I have joined as far as knowledge and support goes! I have never done anything this extensive before, but this forum has given me a ton of confidence, and once you get at it, it's not that hard. About a year and a half ago I was making an appointment to get all the metal work done by a body shop, I am glad I am doing it myself, just giving me a ton of satisfaction.

Once I can get some earlier days with work I will post some more progress as it comes.

Here are a few updates. I have now attacked the passenger quarter and got it fitting fairly decent with decent gaps with the truck lid and passenger door.

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010010.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010011.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010012.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010013.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010014.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010001.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010004.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010005.jpg

Couple more close ups.

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010006.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar152010007.jpg


I am still waiting for my tail panel (on backorder :mad:). I also just ordered a driver's full quarter and the filler panel a few days ago.

Tomorrow I am going to start ripping the driver's quarter out and get the new wheelhouses and trunk floor drop off in position on the driver's side. I must say seeing that quarter on the car sure makes a big difference! I can almost feel the end of the metal work coming soon! Only 100 more hours to go! LOL.

Looking good Tevor!

Here are some pics from todays progress. Mounted driver's door and got driver's quarter and inner/outer wheelhouse cut out. Next step is to get remaining pieces of quarter out (at roof, window channel and trunk channel) then grind all rust out and hammer dolly everything nice and straight.

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar162010001.jpg

Gotta love the plasma cutter - took about 2 mins to cut this off!
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar162010002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar162010003.jpg

Inner/Outer Wheelhouse now gone.
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar162010004.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar162010005.jpg

Hey you are making great progress!!Just thought I would stop in and say hello from a fellow canuck,I'm 2hrs south of you in Lethbridge.

Been there, done that!It does get better.Get'er done!

Awesome, and ambitious! Great work from the foundation which is the most important thing you could have done to get this car resurected. Looking forward to some new progress reports and pictures. Stay focused, don't make it a job, keep it a hobby and keep it fun.

Thanks guys! I apologize for the lack of updates over the last few months as car has been literally on hold most of the summer - I was focusing on having fun with my 86 Olds Cutlass and tossed a 8 point roll bar in, and some nitrous.

Anyways back to the Chevelle...Just started back on it full time last week - finished cleaning up and primed below filler panel area, fit filler panel, rear tail panel and quarters.
Also finished up homemade lower cowl patch on drivers side, and did some package tray work.

I am very happy with the fit of the driver's quarter, tail panel, and filler panel is ok. Passenger quarter needs some work still... the quarter is not fitting the outer wheelhouse very well at the fender lip (where it is to be spot welded). It looks like I need to pull the outer wheelhouse lip a good 3/4" to 1" outward towards quarter so I can actually weld it....I am kind of stuck on ideas right now and need to get some pictures up here to show you what I am talking about.

I need to get to the store and order up some door skins and front fenders and I should be done purchasing body panels...hopefully in the next couple of months I can get these parts on the car and get in in epoxy primer!

Alright got off my butt and took some pics tonight...

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0968.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0953.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0954.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0955.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0956.jpg

Here is where the gap is I was talking about on previous post...
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0960.jpg

Another pic of gap:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0958.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/IMG_0965.jpg

Thought I would share some pics of the 8 point bar I installed in my 86 Olds Cutlass:

http://i55.photobucket.com/albums/g156/Trevor454/IMG_0866.jpg

http://i55.photobucket.com/albums/g156/Trevor454/IMG_0867.jpg

http://i55.photobucket.com/albums/g156/Trevor454/IMG_0868.jpg

Looking sweet! :thumbsup:

Nice welding.

What company is the 8 point bar from?

Trevor - Welcome back! The progress looks great.

Our '72 is starting to come back together. Engine, transmission, radiator, fuel tank, and wiring harness are all dropped in place. Our goal is to have the engine started before the end of the year. It's been a couple of months since it came off the dyno and we want to keep the seals in good shape while we wrap up the build. Here are a couple of shots from our '72 build;

http://72malibu2.chambersohana.com/72Malibu2/Pictures/Pages/PowerTrain_files/Media/engine_assy02/engine_assy02.jpg

http://72malibu2.chambersohana.com/72Malibu2/Pictures/Pages/PowerTrain_files/Media/IMG_3512/IMG_3512.jpg

Keep the pictures coming!
-Doug

http://72malibu2.chambersohana.com/72Malibu2/Pictures/Pages/PowerTrain.html#16

Can you grab the outer WH and the 1/4 and pull together? How much pressure does it take? Measure from the inner to the outside on the LH side and compare it to the RH side and see if it's the WH or the 1/4 - Report back.

LK

Engine looks great!:thumbsup:

Tub the wheelwell an inch to get the clearence needed!!!

Wow! What a great job you have done with the car. Gives me some inspiration to get back on my 71. Will be doing a lot of the same work you have done.
Keep the updates coming!

Thanks for the replies and compliments guys!

I went out and measured the drivers side, and from inner fender to outer lip on wheelhouse was 13 1/4", measured passenger and it is 13 1/8" so pretty close - this is telling me I need to push the 1/4 in closer to the outer wheelhouse, but it does not seem to be moving?? I am going to rip the passenger 1/4 off the car and see if I can find anywhere it is binding.

Cody - the idea of tubbing the outer wheelhouse was my first thought - it would definitely get the clearance I need but I wanted to check on here to see what others thought...would be nice to make it fit without tubbing due to the extra welding/grinding involved.

Yea, Your measurements are very close so it is either formed slightly wrong (imagine that) or hitting something like you said. Are you able to push it in at all?

LK

was only throwing it out there as a joke somewhat, but if all other ideas have been exasperated, then it would be what I would consider... that, and my wheels could require it anyways!

Just picked up my Glasstek 4" Cowl hood and new front fenders today - so currently have all the body pieces I need to finish the metal work...

Tomorrow I plan on finishing up alignment on all rear sheetmetal and want to start working on door skins.

If I need some motivation I might bolt on the fenders and new hood!

I am VERY impressed with the quality of this Glasstek hood it is a NICE piece! I have heard the fit is supposed to be really good as well...

The trunk looked surprisingly good. These cars can really turn into rust buckets when they come from certain states. My So Cal car had surface rust but was mostly solid thanks to the factory undercoating. Still doing body work on it. Got everything pretty much done but body paint interior. Got the car for 900 and another 7000 to 8000 so far. The car with the roll cage must be for the ol lady?

The trunk looked surprisingly good. These cars can really turn into rust buckets when they come from certain states. My So Cal car had surface rust but was mostly solid thanks to the factory undercoating. Still doing body work on it. Got everything pretty much done but body paint interior. Got the car for 900 and another 7000 to 8000 so far. The car with the roll cage must be for the ol lady?

Ya trunk looks fine on top just very fine surface rust will can be sanded off no problem, but part I am worried about is the rear lip is rusted underneath (similar to where door skins/shells rust on bottom). Not sure if I can save it, does anyone make a patch panel for this or do I need a whole new dynacorn trunk lid?

Also on a side note I switched local parts suppliers for all my restoration parts and I am way happier! I order parts, and get them in usually a week! I can't believe it, answer I got from other place was always: "it's on back order, or it will be 6 weeks, etc."

Tomorrow I will be hitting this thing hard and taking some new pics, I really want to get the metal work done in the next few weeks so I can get this to a body shop.

Update:

Well as it sits now I have drilled both quarters, wheelhouses, filler panel and tail panel and prepeped them with weld through primer where needed for the spot welds. I removed driver's door and removed hinges and knocked out old pins/bushing and cleaned them up to bare metal and shot them with a coat of black self etching primer - they look sharp now.

Tomorrow going to install the new door pins on drivers door, reinstall all rear panels and get them positioned then change all my old body mounts out for new ones I bought.

Then start installing rad support, front fenders, hood and old decklid and get doors aligned so I can prepare for door skins.

I received my Moser M9 Housing/axles and rear Wilwood 4 piston dynalite disk brakes as well so anxious to get started on frame/suspension!

Hopefully

.wow with all you are doing, maybe they can issue a new title to you with your own name ....Trevor SS.. OR MAYBE CALL it an SST!
I looked at where you have come with this and I am speechless .. Not lacking the vocabulary, but the exhausting methodical maniacal jeckel and Hyde pschotical mind numbing universe tossing ... Thing ya got going! (add commas to the previous long winded sentence for clarity)..;)

I look at where mine has been for the past several years .. Ok ten, ok, maybe 12... And I go GET OFF YOUR AXX.. Well I will as soon as the cast is off from the motorcycle axxident from new years...
Mine was nowhere near as .. Intimidating as yours is..

Truly an Inspiration.. Digging where most would just drop the shovel..

Here is an update with a couple of pics:

Mounted all rear sheetmetal that I prepped for welding. Aligned driver's and passenger doors as good as possible to new quarters. Toss fenders and rad support on just for fun - still need to toss all my new body bushings then I can work on lining up the fenders/rad support and toss the hood on.

Noticed one mistake I made when rebuilding the lower cowl section - I didn't make the piece where the fender bolts to long enough, will have to chop it out and make a new longer piece or add some metal to it - not a big deal, just time.

I also ordered up 90% of my front suspension parts:
TRZ Chromoly a-arms, TRZ manual rack and pinion steering setup with billet aluminum steering arms, TRZ 1.5" chromoly drop spindles
Recieved my rear diff last week as well: Moser M9 w/ 35spline axles, back brace, 5/8" screw in studs, Wildwood dynalite 4 piston rear disk brakes
Rear suspension is all Wolfe Racecraft chromoly with double antiroll bar.

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleFeb102011008.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleFeb102011007.jpg

Small update:

Finished off driver's door skin and installed driver's fender to see how close alignment is. Still needs a little work on fender gaps, but overall I am happy with the fit!

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar302011002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar302011003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar302011005.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar302011007.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar302011010.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/ChevelleMar302011011.jpg

Today I finished rebuilding passenger hinges (minus detent repair kit which I picked up for both sides today), I also removed skin from passenger door and noticed the passenger shell needs a lot of attention compared to driver's. :mad:

I have to put about 4 patches in it, so going to take a couple hours to get it prepared for skin, so hopefully by end of day tomorrow passenger skin will be done and door will be back on car!

I am starting to see the end of the metal work and just taking it one panel at a time and I can hardly wait to do the frame!

Thanks for looking!

Here are some shots of my front and rear suspension parts:

Moser M9 Rear w/35spline axles:
http://i55.photobucket.com/albums/g156/Trevor454/ChevelleMar302011015.jpg

Wolfe Racecraft Chromoly rear suspension:
http://i55.photobucket.com/albums/g156/Trevor454/ChevelleMar302011016.jpg

TRZ Chromoly front suspension with manual rack/pinion steering:
http://i55.photobucket.com/albums/g156/Trevor454/ChevelleMar302011014.jpg

New Update:

Finished off the passenger door skin - had to make 4 patches to fix rotted metal on the shell, was in much worse shape than driver's side.

Also installed detent repair kit on both lower hinges.

I loosely bolted up fenders and rad support so I can make a measurement to see how much metal I need to add to lower cowl where lower fender bolts up, starting making new metal for that fix.

Tomorrow I plan on finishing the lower cowl metal, bolt on both fenders and rad support and shim them as good as I can (passenger side isn't fitting near as well as driver's). Hopefully I will have time to bolt on the hood and trunk lid then weld all rear sheetmetal (quarters, filler, wheelhouses, tailpanel).

Should be a busy day!

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleApril42011001.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleApril42011003.jpg

Alright a small progress update:

Built a rotisserie out of scrap steel I had laying around, mounted car on it.

Finished cleaning up all welds on rear sheetmetal, and trunk to floor seam underneath, as well as toe kick to trunk seam.

Still have to fix a stripped door hinge bolt hole on car, finish up the driver's toe kick to trunk seam underneath, then put body back on frame and reassemble with doors, trunk lid, front fenders, and rad support, and bumpers.

Then it will be ready for the body shop!

Thanks for looking, here are a few pics!

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle001.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle004.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle006.jpg

Thanks for the update on the '72!:beers:

That is some excellent work you are doing there! Nice job!! Panel fitment looks great!

That is some excellent work you are doing there! Nice job!! Panel fitment looks great!

Thanks!

Panel fit is not too bad, door to 1/4 gaps need some working, as well as fender to door gaps, but what can I expect from all repro sheetmetal? The only original sheetmetal left on this car is the firewall and roof!

Today I finished up the spot weld grinding, and fixed the stripped door hinge bolt hole. I also removed the car from the rotisserie and put it back on the frame.

Tomorrow I will be bolting in on frame, reinstalling doors, deck lid, front fenders, and rad support and hope to get it half assed aligned for the body shop. I would also like to tackle the bumpers and make a list of the oddball parts I need to buy that the body shop will need.

So far on my list is: fender braces, inner front fenders, and rear valence panel.

So made a visit to body shop to get a game plan. They want the car back on the rotisserie so they can strip the entire thing, and epoxy prime inside/out, then finish the floor and get car mated to frame.

So as it sits I need to get the frame closer to completion, as I have to put a roll cage in the car which gets welded to the frame.

So I ordered up the last suspension parts I needed: AFCO Double adjustable coilover shocks/springs for all 4 corners, and going to order the Wilwood front brakes later today.

I started stripping the frame, we removed the rear end, now just have to remove the front suspension and I should get my front chomoly spindles powercoated before I install anything for mock up (due to balljoints seating - don't want to remove them twice).

Starting to get excited because I am on to the fun stuff! :D

Alright here are a few shots of the body sitting 90degrees on the rotisserie, and stripping the frame down.

http://i55.photobucket.com/albums/g156/Trevor454/2011_07_13004.jpg

Here is dad having fun with the plasma cutter on the stock control arms.
http://i55.photobucket.com/albums/g156/Trevor454/2011_07_13001.jpg

Bare frame
http://i55.photobucket.com/albums/g156/Trevor454/2011_07_13020.jpg

Fabbed up some 1/8" steel plates to box in rear lower control arm mounting points.
http://i55.photobucket.com/albums/g156/Trevor454/2011_07_13015.jpg

Passenger plate welded - ran out of argon while welding the driver's side. :mad:
http://i55.photobucket.com/albums/g156/Trevor454/2011_07_13021.jpg

Hopefully tomorrow my front brakes will show up, also waiting on the coilovers - any day now. I plan on adding some strength to all the rear suspension mounting points and possibly fully boxing the frame rails from the rear suspension forward.

Starting to get really fun now! I was getting sick of the metal work on body, this metal work is more up my alley!

That is some really nice work you are doing there Trevor. Yer patience and persistence will pay dividends on this build. Seeing this type of work and your comments is giving me more confidence in doing the same metal work onmine. Keep up the good work!

-jeff

That is some really nice work you are doing there Trevor. Yer patience and persistence will pay dividends on this build. Seeing this type of work and your comments is giving me more confidence in doing the same metal work onmine. Keep up the good work!

-jeff

Thanks Jeff!

I picked up my Wilwood front brake/hub kit, and my AFCO Coilovers showed up as well, also my chromoly TRZ 1.5" Drop spindles are ready to be picked up from powdercoaters.

Just working on removing the upper bushings in my Moser M9 housing so I can install the Wolfe solid bushings - going to take a little work as I need to trim the mount a bit as the wolfe bushing are shorter than stock mount is.

Should be able to get the diff hung soon and get the Wolfe antiroll bar tacked in soon.

Couple Updates on the chassis:

Front spindles back from powdercoating:
http://i55.photobucket.com/albums/g156/Trevor454/August152011002.jpg

Wolfe Racecraft double antiroll bar back from powdercoating and welded into frame:
http://i55.photobucket.com/albums/g156/Trevor454/August152011003.jpg

I will get some more pics of the diff mock up, just have to weld 2 more tabs on housing for the antiroll bar links, then I will bolt it back in and repost.

Thanks for looking!

:thumbsup: on the progress. That's the first time I've seen that particular Wolfe bar, looks interesting. I'm going to go to their website and check it out.

:thumbsup: on the progress. That's the first time I've seen that particular Wolfe bar, looks interesting. I'm going to go to their website and check it out.


Thanks, thats just their typical antiroll bar, but the 'double' option, has 2 links going to diff on each side. I want to go fairly fast with this car so I didn't want to skimp on the rear suspension setup, have double adjustable lower control arms, and adjustable uppers with solid mounts on diff.

Next step if figuring out a coilover mount for 'stock location' rear coilovers. Going to have to make some big tabs and get some bushings so it will work nice with no binding.

Few more updates:

Here is pics of finished antiroll bar and tabs welded on diff:
http://i55.photobucket.com/albums/g156/Trevor454/August152011007.jpg

http://i55.photobucket.com/albums/g156/Trevor454/August152011008.jpg

http://i55.photobucket.com/albums/g156/Trevor454/August152011010.jpg
Some shots of front suspension mockups:
http://i55.photobucket.com/albums/g156/Trevor454/August152011014.jpg

http://i55.photobucket.com/albums/g156/Trevor454/August152011015.jpg

http://i55.photobucket.com/albums/g156/Trevor454/August152011016.jpg

Just in the process of modifying front frame for the coilovers now.

Holy bejeezus...those suspension parts mean business.

That is looking really good Trevor! Very nice craftsmanship!

Thanks guys!

Finished cutting out upper spring pockets and fabbing tabs to mount the front coilovers.

Got them tacked into place - will need to put body back on frame and set my ride height before I final weld these tabs JUST in case my measurements are wrong for the installed height...but I should be close!

I will get some pics up tomorrow and hopefully finish off the rear lower coilover tabs I am making for a stronger mount to the diff housing.

I am trying to source out a junk 454 block/heads and a 4L80E core so I can do the mockup for motor mounts and build myself a custom chromoly transmission crossmember.
I will also order up the Lemon's 2 1/8" primary headers that should let the future motor breathe. My right stuff stainless steel brakes lines and flaming river steering column have now arrived as well, so I can tacked the steering mockup at the same time.

I want to do this properly and I am thinking of everything I possibly can to install in the frame before I get this thing powdercoated and the body to the body shop.

Got the tabs all fabbed up for front coilovers and tacked in place:

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Aug312011001.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Aug312011003.jpg

Here is a shot of the rear coilover tabs I made, they are stock location AFCO coilovers, but I wanted a stronger mounted point vs. the stock style 'bolt'.

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Aug312011004.jpg

Here is a shot of the rear coilovers all finished and installed:
http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Aug312011010.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Aug312011011.jpg

Looking great! Keep us posted!:thumbsup::beers:

Very nice work, Can't wait to see the finished product.

A few updates:

Just a shot with a-arms, steering arms and coilover shocks (no springs on them) mocked up...
http://i55.photobucket.com/albums/g156/Trevor454/Sept42011001.jpg

Center section is all built up with full spool and 3.70 gears in aluminum Strange case:
http://i55.photobucket.com/albums/g156/Trevor454/Sept42011005.jpg

Rear lower coilover mounts are complete and rear Wilwood brake and mocked up:
http://i55.photobucket.com/albums/g156/Trevor454/Sept42011007.jpg

Another shot of rear brakes:
http://i55.photobucket.com/albums/g156/Trevor454/Sept42011006.jpg

I am very happy with how the entire rear went together, no clearance issues/surprises whatsover.

Next step is get the front brakes mocked up and work on the rack/pinion steeering.

Here is a few small updates, been going hard on the front suspension, brakes and mocking up steering:


I cut out the center of front crossmember and built a tubular section out of chromoly, for weight savings, as well as more room for headers/oil pan clearance. Also makes it nicer for steering rack mounting.
http://i55.photobucket.com/albums/g156/Trevor454/Oct102011SteeringMockup004.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Oct102011SteeringMockup003.jpg

Here you can see the Wilwood front brakes all mocked up. Everything fit GREAT with the TRZ Chromoly drop spindles, this was truly a bolt together front suspension with no surprises or mods.
http://i55.photobucket.com/albums/g156/Trevor454/Oct102011SteeringMockup002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Oct102011SteeringMockup005.jpg

Next step is to build some gussets to support upper coilover mounts on the back side (below where the a-arm bolts up), box the frame rails, build a steering shaft, trans crossmember,...lots to do!

Thanks for looking!

Moving right along. Nice work.

So got a little done on the car in the last little while:
- boxed frame
- pulled motor out of other car and mounted on new mounts in frame
- installed lemon's headers
- installed mock up 4L80E trans
- built a custom chromoly trans crossmember

Here are some pics:

Trans crossmember:
http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011003.jpg

Crossmember mounted:
http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011006.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011010.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011007.jpg

http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011009.jpg

Rear tires:
http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011013.jpg

A pile of 4130 Chromoly...for the cage
http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011015.jpg

How do you plan on removing those headers to paint the frame?

How do you plan on removing those headers to paint the frame?

Those headers are Lemon's Race headers...every tube is separate with a slip on collector. The collector stays on with tabs welded to the primary tube which gets bolted to the tabs on collector. They were the easiest header I have ever installed! And they fit perfect with 2 1/4" primary tubes!

Frame is almost ready for powdercoating, today I plan on getting the body back on the frame so I can finish the steering shaft mock up.

Alright so installed body back on frame so I can do a proper steering shaft mock up and setup the front coilovers with the springs to make sure my measurements are correct for proper ride height...and it looks like I am going to need to massage the trans tunnel for clearance. Body is sitting on trans right now, and it about 1/4" off of front mounts, the big 4L80E takes up a lot of space and the trans tunnel in Chevelles is not that big! Oh well I will do some cutting today and see what I can do, I also have to factor in that I will be putting a trans blanket and flexplate shield on to meet safety requirements for ET/MPH goals of car.

Lots of fun!

Trans crossmember:
http://i55.photobucket.com/albums/g156/Trevor454/ChevelleDec282011002.jpg

Nice job on the crossmember!

I've been following this thread for 3 yrs now as I am starting with a car that is far worse than the condition yours was in, and all i can say is, you're my hero!

I need a better paying job!

I've been following this thread for 3 yrs now as I am starting with a car that is far worse than the condition yours was in, and all i can say is, you're my hero!

I need a better paying job!


LOL, thanks Cody. 3 years! Man I need to get this thing done, it definitely takes a lot of time!

A few updates:

Today I almost finshed the new trans tunnel surgery. I had to basically cut the stock tunnel out and start from scratch, either the 4L80E trans is BIG or the A-Body tunnel is TINY! Either way, I made big progress and should have it finished up tomorrow.

My ABC smooth firewall panels showed up, as well as the wheels! The wheels definitely give me more motivation! I am hoping to start on the firewall tomorrow once the trans tunnel is 100% complete.

So order of operation for next few days is:
Trans Tunnel
Firewall
Chromoly Driveshaft loop crossmember
Steering Shaft Mockup

I will post some pics up tomorrow when I take my lunch break.

Ok here are some pics of the trans tunnel mockup and mostly welded in. I am heading out after this post to put the body back on rotisserie so I can clean up the underside of the tunnel and finish all welding.

http://i55.photobucket.com/albums/g156/Trevor454/TransTunnelJan192012003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/TransTunnelJan192012005.jpg

Trevor that turned out really nice! Excellent work! Might i ask why you made the tunnel in three pieces? Was it just easier to work with the smaller pieces due to the length and radiuses? Either way, it looks kick ass!

Trevor that turned out really nice! Excellent work! Might i ask why you made the tunnel in three pieces? Was it just easier to work with the smaller pieces due to the length and radiuses? Either way, it looks kick ass!

Thanks Jepprox! I am pretty happy with how it turned it considering the pain it was! The reason I went with 3 pieces is because the sheet I ended up buying was only 2' x 4', and my original plan was to just 'modify' the stock tunnel, until I started cutting and realized how tight that trans was sitting in there! It was easier to work with the shorter pieces, and since the metal I ended up buying as 20gauge (they did not have 18 gauge), I think the extra seam adds a little strength. It feels nice and solid once I finished all the welding, so I am going to call it good.

Here are some pics of the finished tunnel after welding and cleanup grinding underneath.

http://i55.photobucket.com/albums/g156/Trevor454/TransTunnelJan192012010.jpg

http://i55.photobucket.com/albums/g156/Trevor454/TransTunnelJan192012008.jpg

I started on the firewall but cutting the lip around the heater box and blower motor opening, to prepare it for my ABC smooth firewall panels. Should be done the firewall in just a few hours as it looks fairly simple.

That's awesome Trevor! I am jealous of the rotisserie! I have a 69 and i am cutting out the rockers and the cowl. I will be smoothing my firewall with a kit as well. Very nice work! Keep it up!

-jeff

Here are a few updates from today's work:

Started fitting the smooth firewall kit from ABC Performance:

http://i55.photobucket.com/albums/g156/Trevor454/SmoothFirewallJan212012001.jpg

http://i55.photobucket.com/albums/g156/Trevor454/SmoothFirewallJan212012002.jpg

Got firewall cleaned up and primed with self etching primer, just in case for rust.

http://i55.photobucket.com/albums/g156/Trevor454/SmoothFirewallJan212012005.jpg

Backside of panels coated:
http://i55.photobucket.com/albums/g156/Trevor454/SmoothFirewallJan212012006.jpg

Just waiting for primer to dry then I can start welding it in.

Update from today:

Got smooth firewall panels tacked in:
http://i55.photobucket.com/albums/g156/Trevor454/SmoothFirewallJan232012001.jpg

http://i55.photobucket.com/albums/g156/Trevor454/SmoothFirewallJan232012001.jpg

Got it all welded in and most of the grinding done:
http://i55.photobucket.com/albums/g156/Trevor454/SmoothFirewallJan232012004.jpg

http://i55.photobucket.com/albums/g156/Trevor454/SmoothFirewallJan232012005.jpg

Still need to finish the bottom area near the trans tunnel, need to massage the stock firewall a bit to get it fitting tight for a good weld (there is about a 3/8" gap there right now.

I am also going to spot weld the stock firewall to the smoothie panel from the backside, just so there is no vibration or rattling.

Whats next? LOL. Still lots to do on this thing! :D

Trevor that is looking really good! Not running wipers eh? Either way, your engine bay is gonna look really clean! Since you are going through all this effort, you might look at one of those billet steering column brackets that mount on the firewall. Flaming River makes them as do others. They look "trick" and clean things up some more on the firewall. Just an idea. I attached a couple of pics of the one I put on mine. -jeff

Trevor that is looking really good! Not running wipers eh? Either way, your engine bay is gonna look really clean! Since you are going through all this effort, you might look at one of those billet steering column brackets that mount on the firewall. Flaming River makes them as do others. They look "trick" and clean things up some more on the firewall. Just an idea. I attached a couple of pics of the one I put on mine. -jeff

Thanks Jeff! I might look into that, but I wish I saw this post before I ordered the new OEM steering column firewall plate...I will see how good it looks and how much the booster and master cylinder hides it I guess.

Few updates:
Finished welding the smooth firewall in the trans tunnel area, started working the door gaps as well, might save some cash at the body shop this way, and then I have piece of mind knowing my door gaps are 100% metal. I had to massage the top of the 1/4 near the door but cutting a slit, pulling it and adding some metal to close up the gap, and I added some 1/8" tig welding rod to the rear door edge to get the 3/16" I need. I just roughed it in for now as car is on the rotisserie and I will fine tune the gaps with body on frame and weight on suspension just to be safe.

My new steering column firewall flange is in, so I can finally do my steering mockup this week and build a steering shaft from rack and pinion to flaming river column.

Here are a few pics of the door gap work I did. On the driver's side I had to add quite a bit to bottom edge of door to tighten up the gap so it can be ground to 3/16", on the rear edge of door I had to add 1/8" rod on top half, and I also had to slice and pull quarter panel closer and add some metal there to close it up properly. I just got it roughed in, it will be ground perfect once the body goes back on frame and body mounts are tightened down. Just thought I would save some hours/money at the body shop by doing this myself, and it creates piece of mind by knowing it's all metal right to the edge.


http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/DoorGapsFeb102012003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/DoorGapsFeb102012002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/DoorGapsFeb102012005.jpg

I ran into a delay on my steering mockup as I can't find the steering column mounting bracket anywhere (I have a new stramp clamp with my flaming river column), so I am going to fab one up from scratch. Going to head out this afternoon and get that done.

Finally got the chromoly steering shaft built, here are a couple of pics:

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/SteeringShaftMar22012003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/SteeringShaftMar22012001.jpg

Still lots to do! Next plans for the drop mock up motor back in with headers, torque body mounts down, and install the front coilovers with springs to mockup the ride height and make sure my mounts are good, then take it all apart to finish welding the tabs to frame.

With body torqued down I want to work on the front fender gaps/fitament as well as trunk lid.

Thanks for looking!

Thanks Jeff! I might look into that, but I wish I saw this post before I ordered the new OEM steering column firewall plate...I will see how good it looks and how much the booster and master cylinder hides it I guess.

Few updates:
Finished welding the smooth firewall in the trans tunnel area, started working the door gaps as well, might save some cash at the body shop this way, and then I have piece of mind knowing my door gaps are 100% metal. I had to massage the top of the 1/4 near the door but cutting a slit, pulling it and adding some metal to close up the gap, and I added some 1/8" tig welding rod to the rear door edge to get the 3/16" I need. I just roughed it in for now as car is on the rotisserie and I will fine tune the gaps with body on frame and weight on suspension just to be safe.

My new steering column firewall flange is in, so I can finally do my steering mockup this week and build a steering shaft from rack and pinion to flaming river column.


car looks great,

you could also do something like what i did on mine
http://i44.photobucket.com/albums/f36/snake8700/chevelle/IMG_0629.jpg
http://i44.photobucket.com/albums/f36/snake8700/chevelle/IMG_0630.jpg
http://i44.photobucket.com/albums/f36/snake8700/chevelle/IMG_0659-1.jpg
i like the billet mounts but they are costly and like you said after everything is in there its kind of hard to see. i used some exhaust pipe that is just big enough to fit my column in with a large o-ring to seal
http://i44.photobucket.com/albums/f36/snake8700/chevelle/0e91e2a2.jpg

Trevor the gaps are looking awesome! Everything is lining up nicely. Good job!

Trevor the gaps are looking awesome! Everything is lining up nicely. Good job!

Thanks Jeff! I am just working on my front upper coilover mounts right now, since I put the springs on I am going to have to redesign them and make new ones. Still have to build a driveshaft loop, and I am contemplating adding SFI 25.5 bars and crossmember to the frame now instead of later, just waiting on the rulebook to arrive.

Way cool! You did some fancy engineering and fabrication for your suspension and steering up front :) Nice parts! What class are you going to run in?

Way cool! You did some fancy engineering and fabrication for your suspension and steering up front :) Nice parts! What class are you going to run in?

I am going to run in the 'bragging rights' class, lol. Just want to build a killer street car, we don't have much for racing classes up here (Alberta, Canada) due to short season.

Sa-weet!! Progress looks great!

Here is a few updates from today's screwing around. I had to make new front coilover tabs to get the springs more 'vertical' when car is at ride height. New tabs I made will also be stronger. I have them tacked in and mockup motor in and car sitting on suspension. I need to get the rest of the front end sheetmetal together to get some weight on the front to see how it looks before I final weld the coilover mounts.

Thanks for looking!

http://i55.photobucket.com/albums/g156/Trevor454/FrontCoilovermockupMar62012005.jpg

http://i55.photobucket.com/albums/g156/Trevor454/FrontCoilovermockupMar62012003.jpg

http://i55.photobucket.com/albums/g156/Trevor454/FrontCoilovermockupMar62012001.jpg

Trevor that is bad ass! WhT is the ride height gonna be? If everything fits well, looks like you will be ready to run some lines!

Here are a few small updates. Got the motor plate and mid plate done and tabs welded to frame. Also added the 25.5 chassis cert bars to the frame. I have to redo the trans crossmember (shorten and mount to inner frame rails), relocate my rear antiroll bar (the upper control arm mounts hit the bar when car is at ride height, preventing it from sitting lower. I am also redoing the front coilover mounts and installing a TRZ cup style mount, to lower the ride height on the front end.

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle255FrameBars002.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle255FrameBars007.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle255FrameBars004.jpg

http://i55.photobucket.com/albums/g156/Trevor454/Chevelle/Chevelle255FrameBars005.jpg

Nice fab work Trevor! Goes to show how much work goes into complete custom chassis and suspension. Not to mention everything else builds off of that base. Hardly any bolt on parts there! :D