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Discussion Starter #1
I can't really call this a build thread since it's more of an update thread. My car has been sitting since about 2010, when I stole the ZZ4 for my 89 step side, and it sat in the back of my barn being neglected ever since. Now, it''s never going to be show quality, and it destined to remain just a driver, but that doesn't mean I can't do some stuff to it to make it more enjoyable to drive. I started half-hardheartedly working on it again about two years ago, but now that someone south of the border is doing what I used to do for a living and I'm between jobs, I have some time to play with it again. I stockpiled a bunch of parts and am finally getting somewhere with it. Most of the following has been done since last winter.



My goal is to build a mild cruiser that can handle well, run all day, and be comfortable and safe. I'm not looking to go drag racing or autocrossing with it, just road trips and maybe the occasional spirited driving on twisty back roads. Most of what I'm doing is just basic stuff you see every day.
 

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Discussion Starter #2
The first thing I had to do was fill the empty space between the fenders. I found a 454 in a Suburban at the U-pull-it yard and got lucky. It's a gen 6 crate replacement with a casting date from 2000. It has the fuel pump provision, peanut port heads, 4 bolt mains, and was pretty clean inside. It had a collapsed lifter, but everything else looked good, so after checking a few bearings with some plastigauge, I decided to spin the wheel, clean it up a little spray bomb it and see what happens. I had to get the GM pan for it, changed it from flat tappet to a stock vortec roller cam, and added a performer 2.0, HEI, and some Hedman headers. I also replaced the oil pump. Again, it's no race car, just a cruiser.

[/url]DSC00307 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_1342 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_1357 by ZZ Chevelle, on Flickr[/IMG]
 

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Discussion Starter #3
Next up was the fuel system, so I decided to use braided teflon. This is not a high dollar setup, it's all ebay stuff. If it works out, great, if not, I learned from it. I added a return line, new sending unit with return, new tank, Holley black pump, (replacing the same) and a return regulator. The old tank had gas in it that was nine years old, so I figured I'd see the worst. Much to my surprise, the gas from 2010 was clear, and my mower ran great on it. I wouldn't try that with today's gas though.

[/url]IMG_2391 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_2396 by ZZ Chevelle, on Flickr[/IMG]
 

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Discussion Starter #4
Sitting in a barn isn't good for the interior. I like the Parchment, but always wanted to change it to black. Well, now's my chance. It's still a work in progress.

[/url]IMG_3071 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3066 by ZZ Chevelle, on Flickr[/IMG]

The car was full of walnut sheels, mouse nests, mouse corpses, and stunk pretty bad. They got up over the headliner where I found most of my missing insulation, in the kick panels, the trunk, under the seats, and yet never went after the dash. I assumed the worst and was expecting a bunch of bare wires, but it was untouched up there. I gutted the dash and at least I know what I have and was able to paint under there.
 

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Discussion Starter #6
[/url]IMG_3617 by ZZ Chevelle, on Flickr[/IMG]

Fatmat.
[/url]IMG_3631 by ZZ Chevelle, on Flickr[/IMG]

New tilt colum and wheel, rebuilt heater box, new kick panels, firewall pad, new pedals, cleaned and painted E brake, new dash pad, glove box, and dash bezel, heater box seals, vent balls, switches, and heater control bezel.

[/url]IMG_3647 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3644 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3653 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3804 by ZZ Chevelle, on Flickr[/IMG]
 

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Discussion Starter #7

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Discussion Starter #8
I had a bunch of suspension parts sitting in a pile too, so I started to tackle them too.

UMI 2" lowering spring, sway bars, upper control arms with 1/2" taller ball joints, and delrin bushings, new rotors, and brake lines. Out back is pretty much the same story, with UMI roto-joint lowers, uppers, chassis mounted (anti)sway bar, disk brake conversion, and a powertrax in the 10 bolt. I swapped the 10 bolt in place of my 12 bolt because it was only 25 bucks, and dropped my cruising RPMs with 3.36 gears compared to the 4.10's in my 12 bolt. That and no leaky C clip eliminators. I also went with a Lares 972 10:1 steering box through NPD.

[/url]IMG_3665 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3711 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3667 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3668 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3727 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_3750 by ZZ Chevelle, on Flickr[/IMG]
 

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Looks great Steve, sorry to hear about the job loss.....hopefully a better one will find you.
Your making great progress on the car and hopefully you will have it road ready in short order.
 

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Discussion Starter #11
Looks great Steve, sorry to hear about the job loss.....hopefully a better one will find you.
Your making great progress on the car and hopefully you will have it road ready in short order.

Thanks. Believe me, I'm not too heart broken. The company I worked for has been making this move to Mexico for ten years, and I'm just glad it's not hanging over my head anymore. I went through the same thing with Lucent, so it's not too big of a deal. Plenty of jobs for electro-mechanical maintenance technicians out there. I'm just being picky. :D
 

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Discussion Starter #13
...and this is where I'm at right now. I covered the seats with the Legendary Rallye kit. I was concerned about the wrinkles, but after a few hours by the door during a heat wave seems to have smoothed them out almost completely.

[/url]IMG_4062 by ZZ Chevelle, on Flickr[/IMG]

[/url]IMG_4063 by ZZ Chevelle, on Flickr[/IMG]
 

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Really nice work !

Love the pics; can't wait to see it done.

:laugh:
 

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Discussion Starter #15
Thanks Beth. I left a lot out like all the new brake lines, sound system, mouse proofing here and there. I should mention the new grille, bumper, repainted headlight buckets and new bowtie though. Oh yeah, I saw folks here using a Camaro chin spoiler and liked the idea. I like it. I have a new black vinyl top to put on soon too. I guess it can't be any harder than the headliner was to install.

[/url]IMG_3849 by ZZ Chevelle, on Flickr[/IMG]
 

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Discussion Starter #16
I should have added a little info on the tires and wheels too. They are General G-Max RS on American Racing Torq Thrust II wheels, 245/45-17, and 275/40-17. I have a new piece of trim to replace the one that came with the car in the pic too. You can see here someone just screwed it in place. It's been bugging me for 20 years lol.

[/URL]IMG_3709 by ZZ Chevelle, on Flickr[/IMG]
 

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Nice job! Thanks for sharing. And good luck finding the right job.
 

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You're doing a great job Steve and kicking some azz on that Chevelle jobs list. Looking good. Love those wheels. Give us an update what you think of the Rally covers after you've had a chance to drive it.
 

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Discussion Starter #19
Not too much to report today. I just got the console and inner seat belt ends installed. I painted the console with SEM landau black and installed a new brushed aluminum top plate and shifter lens. I put a USB socket inside the console too, and that feeds up to the Retrosound radio. I'm also putting Morris classic three-point belts in. With the extra jute and insulation, I had to shim the console mounts to get it bolted up at the shifter. The carpet didn't fit too well without doing a little buildup in the front and rear of the tunnel, but that's OK. Future plans are for a TKO or T56 swap. Also with the higher seat bolsters, a little bit of a lift to the console isn't that bad of a thing. It's about 1/2" higher than before. The shifter doesn't stick up as far now though. Hopefully tomorrow I'll cut the carpet for the seat tracks, finish putting the seat belts in, trim the edges and install the sill plates.

 

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Was yours an original buckets and console?
 
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