[HappyRtFt]

Update...

Not sure where the time has gone...oh wait, I do...it was spent on bloody spot welds...good lord and baby jesus I can't stand those things! So still makin progress though:
Started by takin the rusty makeup off my pig so I can see what I have to work with

Built a new rack for her...one that would keep everything in place during surgery. Made sure the rack was level and the body was as well once I put em together. Probably going overboard with the bracing, but since I'm not a professional, hopefully the time spent on prep will pay off down the road when she starts goin back together. Going through this process has opened my eyes and given me tremendous respect for the true professionals who spend the time ensuring these american icons get back on the road.

Started surgery:

a few other small items were fab'd as well...

So now its out with the old and in with the new

Other items done: wheel tubs on both sides are out, package tray is gone, started rebuilding rear window frame, went on a rust hunt armed with vinegar/water mix, wire brush & naval jelly....oh cant forget the hours spent just staring at the car and trying to plan the next steps.

 

[66Broke]

Wow you win the award for tearing your car down the farthest. When its finished you will know literally every square inch of the car!
Good work, don't lose the faith!

 

[busterwivell]

Holy cow, Andy! Take a break next weekend and go to GoodGuys. I'll be there with my 66.

 

[chriscraig73]

Wow! Now that is a total teardown. Looking forward to seeing it come back together.

 

[HappyRtFt]

Yeah it was one of those "the more you remove, the more you find" situations...so while its been a lot of work, I'll know when its done, there wont be anything lurking below the surface. The cool(er) weather seems to be approaching so looking forward to making some good progress in the next 4-5 months....thanks for checking in guys.

 

[all4sho]

you got a "REAL" project right there, WOW
GOOD LUCK!!!

 

[1965_ss]

WOW!! You've got some skills for this! Can't wait to see it progress.

 

[BigBlock1969]

This should be a fun build to watch. Devotion my friend... thats what you have.

 

[MKE300D]

by chance you still have the tail housings? from what i can tell they are from a 300, or have been patched in the malibu/ss holes.

 

[HappyRtFt]

Thanks for the feedback guys, will certainly keep the post updated as possible. I'm on the home stretch bustin those dang spot welds, just have the passenger A-pillar and a few along the roofline. The focus now is the driver side so I added the first bit of new metal and test fit the new rocker and A-pillar the last couple days, both seem to line up pretty well....hoping to have some picture updates after the weekend.

Mike, I do have the tail housings and its quite possible they were added to this Frankencar. What difference does the 300 have?

 

[jph66]

Very impressive build! I'll definately be following it! Living in Wisconsin all my life many of the cars I've come across are in this condition (dang salt!) and unfortunately there are a lot of "body men" that "repair" cars like this one was

 

[YankeeRodder]

Whew! I'm getting tired just looking at all that fabbing. Best to you Andy, your a better man than I! LOL My 70 looks exactly as I bought it 8 years ago, can't get into bodywork.

 

[66Broke]

I do have the tail housings and its quite possible they were added to this Frankencar. What difference does the 300 have?

I know there are some drilled holes in the Malibu and SS396 that hold the clips for the tail light moldings. These moldings are not on the 300 Deluxe.

Here is a photo that I took of my Malibu that shows the holes pretty good.

Brian

 

[NReilly]

Looks like you are doing pretty good so far! But you are going to have one hell of a time putting new metal in. Not saying you did it wrong, but you made a lot more work for yourself. You are pretty much going to have to tech screw your whole car together now before you weld any body panels. To make sure everything will fit properly. Since you cut off any kind of guides for the 1/4's.
What is your plan for putting it all back together?

 

[HappyRtFt]

So even the best laid plans.....blah blah blah....long story short, my wife and I came up with an idea last year that is now turning into a business and things are moving quickly, so time with the Malibu has been minimal. Needed to build a workbench and clean/reorganize the garage in order to move some parts out of the house (extra bedrooms and front room were serving as storage) since brother in law, sister in law and mother in law will be here next week thru Xmas.

Brian, I don't think mine have the holes, but the housings are covered in pancake batter or something like that, so I'll clean em up and see what lies beneath.

Nick, thanks. Yeah its a hot mess, but I'm not in a hurry. At any rate, I have just under 700 pictures, multiple measurements, drawings and markings on the old body panels, so while its not perfect, at least I have something to work with. I cut the panels off to expose the bad metal so it can be replaced. The intention was to do some basic cleanup, but that turned into much more. The reality is that I have to weld in a bunch of new metal to what's left of the structure, so that's next in line. Screwing things together before welding is the plan for sure. Yes, you’re correct about creating additional work, but its all relative for me...I love the car and enjoy the learning process…..besides, nobody has ever accused me of being bright. It’s been an enjoyable endeavor and will be that much more satisfying when I finally get to drive her in 2043.

Here's how she sits now

A little fab for the channel that sits on the rocker...gotta do the psngr side also

 

[HappyRtFt]

So about 60 days later doesn't seem like I've made much progress (more staring and planning than doin, guess that's part of the game), but bought
the following pieces (merry xmas to myself)

Got the new A-pillars tacked in place...just enough to keep em in position while I fit the remaining cast of characters..1st little win...attached the lower windshield channel (just with vice grips...no welding yet) and measurements were right on the old pieces that I removed...and everything was level. The long level at the bottom of the picture is just laying on the bracing

Next had to redo the rear psngr channel that sits on top of the rocker...tried 3 times to do it in one piece, then said nuts to that and made 3 sections

Spent quite a bit of time on the driver side inner kick panel/inner cowl shoulder (heard it called both, not sure which is correct), the local bone yard wanted $700 for both, so I've been rebuilding it, still got some trimming and shaping, but overall ok at this point...psngr side, well that's a different story

Psngr side...any suggestions are certainly welcomed

Also built a metal workbench that can hold some of my parts and I can weld on, it's been perfect, got tired of welding on the floor. Will keep pluggin away and post more updates when I can.

 

[Mike McMasters]

Andy,

I commend you on what you have going there. I love projects as much as anybody but I don't know if I have it in me to go this far. Subscribed for sure, I can't wait to see how it turns out!!!

Mike

 

[HappyRtFt]

Thanks Mike, I appreciate that. I love the car and this process is awkwardly cathartic, so I'll just keep at it and stay focused on the day she starts up and pull out of the garage....even of I'm 90years old when it happens:beers:

 

[tommycomfort]

Yep, you have bit off more than I would have been willing to. When this is done I'd like to shake your hand and buy you lunch!

 

[Alwhite00]

Hell of a project but.looking.good.