Slow 1966 Chevelle LQ4/200-4r build

[jwatts]

I have always wanted a 66-67 Chevelle. A few years back I decided to bite the bullet and pick one up. I looked around for a while and found a good platform to start with. I found one that was in the middle of a restoration. All of the body work on the front had been done. There was some rust on the rear quarters and they needed patch panels. It had a new GM crate 350 with a freshly built TH350 trans. The brakes had just been gone through. The whole setup had maybe 100 miles on it. The guy that was building it lost his job, which happened to be at the body shop where he was building the car. I decided to buy it mid build to finish it up. Here it is on the trailer the day I brought it home. We tuned the carb a little and I drove it around that day.
https://www.pro-touring.com/attachment.php?attachmentid=112683&stc=1

Now was the time to decide what direction I wanted to go with the car. The direction has changed slightly over the time I have been working on the car. The same basic idea has stuck around though. I wanted the car to look like it did back in the 60s. I wanted it to look like a Malibu. I didn’t want to do an SS clone. I wanted to go with a stock interior, bench seat, factory color. I did want to update the running gear and suspension.
As I mentioned before, the car came with a new crate 350 and fresh built TH350. I bought the car with the thoughts of doing a 5.3/4l60e swap. After driving the car I changed my mind and decided to build the 350 and drive it a while. While browsing Craigslist one day that all changed. I found a good deal on a 2005 model LQ4. I picked it up and it started gathering parts for an LS swap.
https://www.pro-touring.com/attachment.php?attachmentid=112684&stc=1

[jwatts]

The car had the typical wiring issues a car of this age had. Various wires had been cut and spliced over the years. I picked up an American Autowire Classic Update harness and rewired it front to back. In the meantime I was still gathering parts to swap my engine out. Once I got the parts it was time to get the 350 out and get it ready for the LQ4.

https://static1.pt-content.com/images/pt/2015/05/20120615132536-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2012-06-15132536.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/20120616195058-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2012-06-16195058.jpg.html)

Now I had to decide on a transmission. I knew I wanted overdrive. The TH350 wasn’t going to cut it. I wasn’t sure if I wanted a 6 speed or an automatic. My wife wanted to be able to drive the car on occasion. I could see having to change clutches in the future if she tried to drive it with a 6 speed, so the automatic idea won. I picked up a Bowtie Overdrives 200-4r for it.

I wanted a little more compression than the LQ4 had to offer from the factory. I also wanted a small cam. I picked up an LS6 cam and a set of 241 heads. I had the heads milled a little to get me up around the 10.25:1 range. I got a set of motor plates/mounts and got to work fitting the engine in place.
https://static1.pt-content.com/images/pt/2015/05/20120809120158-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2012-08-09120158.jpg.html)
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I ended up using 98-02 F Body headers. I had to dent 2 of the primary tubes, but otherwise they fit good.
https://static1.pt-content.com/images/pt/2015/05/20120927164510-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2012-09-27164510.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/20120927181030-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2012-09-27181030.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/20120927181013-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2012-09-27181013.jpg.html)

[jwatts]

As I said earlier, I wanted to keep the same look that the car would have had in the 60s. That made me decide to ditch the factory fuel injection in favor of a carb setup. I am not completely sure I want to stay with a carb or not. My original intent was to get it going with a carb on it, then swap over to a modern, self learning, throttle body style EFI on the carb manifold. The way this car runs with the carb on it may make me stick with the carb though.
https://static1.pt-content.com/images/pt/2015/05/DSC03586-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/DSC03586.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/DSC03585-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/DSC03585.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/DSC03584-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/DSC03584.jpg.html)
Of course with any swap like this things aren’t going to go perfect. I went ahead and installed a Jeep Cherokee steering box while I was at it. The stock power steering pulley was way too big to clear the steering box. I swapped it out to a smaller diameter pulley from a Ford 300 straight 6. It was much better. I still had a little clearance issue with the steering box. I ended up turning the head down on one of the 4 bolts on top of the steering box to make sure it cleared the pulley. It is still tight, but everything clears.
https://static1.pt-content.com/images/pt/2015/05/DSC03798_zpsf56bcde4-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/DSC03798_zpsf56bcde4.jpg.html)
I have parts from all sorts of vehicles on this car. Power steering pulley from a Ford, belts, hoses, and power steering box from a Jeep, and lots of other mis matched parts. I am keeping up with all of it to make sure I know what to replace them with if I ever need to change anything out.

[jwatts]

The next step was to replace the fuel tank. I picked up one with an in tank pump, got my new fuel lines and regulator, and got to work. This is where the whole build turned south. We dropped the old tank to find a piece of wood paneling below the trunk pan. It turns out the trunk pans had rusted out before. The previous owner had put a piece of wood paneling down, laid the new trunk pans over that, and fiberglassed them in. This was a good indicator of things to come for the body work on the car.
https://static1.pt-content.com/images/pt/2015/05/20130316105230_zps35313b4d-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2013-03-16105230_zps35313b4d.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/20130316105236_zps76df1851-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2013-03-16105236_zps76df1851.jpg.html)

I went ahead and got the tank swapped and lines run. I was still going to get the engine running and take it for a spin before I started tearing into the body work to see how bad it really was.
https://static1.pt-content.com/images/pt/2015/05/20130326103903_zpse3569fe7-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2013-03-26103903_zpse3569fe7.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/20130326103928_zps281423b3-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2013-03-26103928_zps281423b3.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/20130326103936_zpsf4fb8cee-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2013-03-26103936_zpsf4fb8cee.jpg.html)
https://static1.pt-content.com/images/pt/2014/01/20130408163711_zps5eddb4a1-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/2013-04-08163711_zps5eddb4a1.jpg.html)
The tired old 10 bolt rear end was bothering me. I looked for a decent deal on a 12 bolt and had no luck. Finally I decided on a 9 inch. I picked up a 9 inch setup for a Chevelle from Quick Performance. While I was at it I installed UMI tubular upper and lower control arms and rear sway bar. The ride after swapping the old arms and bushings out was a night and day difference over what the ride was before. I had that installed for roughly a month before I took the car to the body shop.

[jwatts]

I dropped the car and some cash off with the body man. He was going to start stripping the car the next day to see what all we needed to do. A few days later he called and wanted me to come look. The car was in a lot worse shape than we had thought. The previous owner had patched the car several times before. Rather than using patch panels, he cut new pieces out of another car. None of it was welded in. It was all glassed in and smoothed out. It was a wonder the car hadn’t fallen apart. I honestly never would have fooled with the car had I known it was that bad. In the end every piece of metal from the doors back was replaced.
https://static1.pt-content.com/images/pt/2015/05/IMG_5317_zpsxpijekcl-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMG_5317_zpsxpijekcl.jpg.html)
It has been in the body shop close to a year now. He has all of the metal changed out. I went ahead and had him paint all of the interior metal while he was at it. I should be getting the car back in a week or so. That is when the fun will start. Between reading on here, helping him on the car a little, and having my son out of school for the summer, I plan to put some hours in the car over the next few months. Here it is with the new metal, prior to being primed.
https://static1.pt-content.com/images/pt/2015/05/IMAG0533_zpsioncemis-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMAG0533_zpsioncemis.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/IMAG0534_zpsddrahsvl-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMAG0534_zpsddrahsvl.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/IMAG0536_zpsxl3tf8ag-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMAG0536_zpsxl3tf8ag.jpg.html)
https://static1.pt-content.com/images/pt/2015/05/IMAG0837_zpsaff0le4j-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMAG0837_zpsaff0le4j.jpg.html)
My plans for it now are:
Finish the interior wiring. I plan to do a pushbutton start setup with RFID and power locks. I will also get the stereo wired up and package tray cut for speakers.
Upgrade the brakes. I still have the manual drum/drum setup on the car. I have about 90% of the parts for a power disc/disc setup. I am doing LS1 Camaro brakes on the front. The rears (since I am running a Ford rear) will be from a 2000 Explorer. It has the integral parking brake setup. I will be using the booster and master from the Camaro as well.

Replace the rear springs and get the ride height right. It has a set of Chevelle wagon springs on the back now. The back end sits way too high. The shocks are shot. I also need to move my exhaust a little so that I can clear the rear control arm braces.

Go through the front suspension. I intend to swap the front springs out since it still has the sagging factory springs. I am going to install a different sway bar while I am in there. I will also be changing the upper a arms to the UMIs with tall ball joints.

Wheels and tires. I picked up a set of C6 Corvette 18s/19s. I need to measure for the wheel adapters and get them on the way. The wheels have a little curb rash that I need to fix and then paint the wheels.
https://static1.pt-content.com/images/pt/2015/05/IMAG0824_zpsyw1klnik-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMAG0824_zpsyw1klnik.jpg.html)

After all of that I will move on to completing the interior.

[cactuss4]

Ahh nice project, thanks for sharing.

Tory

[Motown 454]

All to familiar story on the body, but it looks great now its come a long way already. Its a nice project, my first car was a 66 SS I still love the body style.

[jwatts]

I am anxious to get it back and get started. I have had the car since early 2012. Now that the body work is almost done it is like I can see the light at the end of the tunnel. I still have a lot of small stuff left to do. The good thing is my list is getting smaller and the majority of the work left is stuff I can do myself. I don't have the skill nor patience for body work. The rest I can handle though.

[Justin@EntropyRad]

want to see this together!

[jwatts]

One more thing I did was upgrade my factory gauges. Shiftworks makes a kit to convert the dummy light setup over to the SS gauge setup. It replaces the fuel gauge and clock with a water temp gauge, an oil pressure gauge, a volt meter, and another fuel gauge.

It went from this
https://static1.pt-content.com/images/pt/2015/05/2012041220144819_zpsxtkldomv-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/2012-04-12%2014.48.19_zpsxtkldomv.jpg.html)

To this
https://static1.pt-content.com/images/pt/2015/05/2012041220172845_zpsd9udrqmn-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/2012-04-12%2017.28.45_zpsd9udrqmn.jpg.html)

[Motown 454]

Nice!

[bonecrrusher]

Based on the flags on those Corvette wheels - those are off of a C5.

Car is looking good - sucks about all of the hidden metal work!

[jwatts]

Based on the flags on those Corvette wheels - those are off of a C5.

Car is looking good - sucks about all of the hidden metal work!

Thanks. I brought the dash and various interior pieces home yesterday. The body man is putting all of the new door glass and vent window seals in now. Once the doors are built I will be picking it up and starting on the brakes.

They very well may be C5 wheels. I haven't really looked to make sure. I guess I need to so I can determine the offset.

[jwatts]

I got a call from the body man this morning. My car was ready. I got there as he was finishing up lining up the glass,

https://static1.pt-content.com/images/pt/2015/05/IMAG0878_zpsdmhotafo-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMAG0878_zpsdmhotafo.jpg.html)

As soon as he wrapped it up it started raining. As soon as it quit I fired it up and drove it home.
https://static1.pt-content.com/images/pt/2015/05/IMG_4165_zpsvukkjh1t-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMG_4165_zpsvukkjh1t.jpg.html)

And now I have it in the garage awaiting the brake work to start. I will get to work on all of that in a few weeks.
https://static1.pt-content.com/images/pt/2015/05/IMAG0881_zpscplyeewc-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/IMAG0881_zpscplyeewc.jpg.html)

[cactuss4]

Sounds like you lucked out on a body man, a year sure, but my guess is he was more than reasonable and seems to have done a quality job. If you can only have 3, being Quality, Cost and Turnover/speed, I pick Quality and Cost every day and twice on Tuesday. Even a year!

Tory

The black and the big tire/wheel totally makes me think Charger

[jwatts]

He was very reasonable. He was also very meticulous with the body work. He is restoring a 67 Chevelle for himself. He brought it in the shop to pull measurements for my body panels to make sure it was all in spec with a car that had factory metal on it. I couldn't ask for a better job. All of the panel gaps are perfect. He said the only drawback was that the more he worked on mine, the more he wanted to work on his. I was very willing to wait for a quality job.

The funny thing is I had 2 other body men I wanted to do the job. I called them both and told them I had cash in hand. They both said they would come by the next day to look at the car. Neither showed. I haven't tallied up just what I paid in labor, but it wasn't anything to turn your nose up at. I am glad they didn't work out. This guy went above and beyond.

[cactuss4]

Tell him I have a garage with a lift and he can pull an RV/ camper into my RV pad., if he wants to play with another 66 ;). But I would be intrigued just for reference what it cost , can pm or if that's too personal, totally understand just trying to get an idea on costs and the only sure fire way right now is the AMD calculator by Craig.

[jwatts]

I am going to get the notebook he kept up with all of the time and materials in so I can scan it. i am keeping all of my receipts from this build and want to have a detailed breakdown on the body work. As soon as I get it all scanned and totaled up I will let you know what it ran.

[Motown 454]

The car looks great! It's nice to see it back in your hands so you can enjoy working on it.

[1968CamaroSS_Sam]

The car is looking great. Must be nice to have that out of the way and the peace of mind knowing it was done right.

[jwatts]

The car is looking great. Must be nice to have that out of the way and the peace of mind knowing it was done right.

Thanks. It really is nice to know I have a solid platform to work with now. The rest is all on me now. I am going to get back at it in a few weeks when I am off work again. I have a goal of having everything but paint done in time for Crusin the Smokies next year. Realistically I may have all but the interior ready for Cruising the Coast in October.

[jwatts]

Not a lot of progress lately. I work a 14 day on, 14 day off schedule. The past few times off I have taken my family on vacation, done some home improvement work, sold my old truck and traveled out of state to get a new one, and been generally lazy. I have very few plans for this time off so I aim to at least get my rear brakes and suspension sorted out.

Since my last update I got the car up on jack stands. I pulled all of the wheels and tires off in preparation for upgrading my brakes. I have a 9 inch Ford rear end under the car. I am swapping in a disc brake setup from an Explorer. Once I got my rear wheels off I was happy to see that my axles are dual bolt pattern, with one pattern being the right one for the Explorer rotors. I was worried I would have to get a set of rotors drilled to the Chevelle's 5x4.75 bolt pattern. I plan to swap my studs to the Ford bolt pattern holes and use Explorer rotors. I will have to run adapters to get my wheels centered up in the fender anyway, so I may as well swap bolt patterns while I am at it to avoid having to have rotors re-drilled.

[cactuss4]

thanks for the update!! 14 days on 14 days off... a shrimper, or logger or? :)

Tory

[jwatts]

thanks for the update!! 14 days on 14 days off... a shrimper, or logger or? :)

Tory

None of the above. I work on an offshore oil platform.

[rohrt]

I like what you did with the motor. Cool build. Look forward to more updates.

[jwatts]

I like what you did with the motor. Cool build. Look forward to more updates.

Thanks.

[rixtrix1]

Wow, this is coming along nicely. May have seemed slow to you, but compared to mine you're flying along. Right now I'm hampered by a cluttered garage( moving along with this), home improvement projects( gotta keep the wife happy) and the summer heat(Phoenix, AZ). By October I should be able to start stripping off all the old paint to how much exterior metalwork is needed. I already have repaired all the floorpans and window frame rust. By then yours will probably be looking pretty and keeping me inspired to keep plugging away on mine.

[jwatts]

Man, talk about a dead thread. I put slow build in the title, and I meant it. After I got the car back from the body shop I dropped the rear end out from under it to do my disc brake swap. That was postponed by a family vacation, then some work on the house, then training for an elk hunt in Montana, then the hunt itself, and on and on and on. Fast forward to a few weeks ago. The body man that did my work called and asked if I would be interested in rewiring a 48 Chevrolet pickup for one of his customers. I agreed. That gave me just the motivation I needed to get my car rolling so I can move it out of the garage and get that truck in.

This past week I got to work on the rear end. I removed my old drum brake setup and replaced it with a set of discs. This car isn't intended to be a track car. It will likely never see more than spirited street driving. Since I have a Ford 9 inch rear I opted to use a set of disc brakes from an 8.8 Explorer. It took a little slotting of the backing plates for the holes to line up. I bent up some brake lines, gave it a good coat of POR15, and it is all ready to go back into the car.

https://static1.pt-content.com/images/pt/2016/02/20160226_093430_zpsmsnpiujn-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160226_093430_zpsmsnpiujn.jpg.html)

https://static1.pt-content.com/images/pt/2016/02/20160225_111152_zpsh0zfoomn-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160225_111152_zpsh0zfoomn.jpg.html)

https://static1.pt-content.com/images/pt/2016/02/20160226_151741_zpshksxn2yd-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160226_151741_zpshksxn2yd.jpg.html)

[jwatts]

A little more progress over the last few days. I decided on tires and got them ordered. The front tires came in today and the rears will be here tomorrow. I ended up with Michelin Pilot Super Sports, 245/45-17s on the front and 285/35-18s on the rear.

I took a little time today and cleaned and scuffed up my wheels to paint tomorrow. I also have to paint my calipers before bolting everything up. I got the rear end partially under the car. I started work on it just after supper and had time to get it under the car and got the lower control arms bolted up. I have to get a jack under it tomorrow to get the uppers connected. With any luck, by the end of the weekend the wheels will be painted, tires mounted, and the whole setup bolted on the car. I also plan to have the brakes bled and the car rolling on its own by mid week next week.

https://static1.pt-content.com/images/pt/2016/03/20160322_194106_zpsv3lknqhs-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160322_194106_zpsv3lknqhs.jpg.html)

https://static1.pt-content.com/images/pt/2016/03/20160322_123555_zpshnsyjazw-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160322_123555_zpshnsyjazw.jpg.html)

[jwatts]

The UPS man came today and brought my rear tires. I got my wheels painted and should get the tires mounted tomorrow. I got a little more work done on the car today too. I got the upper control arms bolted up on the rear end, springs on their perches, and everything tightened down. I got the brake lines connected and the calipers painted and mounted. It all fit just fine. I still have to rebuild one of the rear calipers before I can bleed the brakes.

I did realize a few things I have to work on tomorrow. When I ordered my wheel adapters, I only ordered one rear. I swore I ordered 2 but I checked, and sure enough I only ordered one. The front adapters will need to be machined to fit over the front hub. Same with the rear. It needs to be opened up some to fit over the end of the axle. After I get the adapters on the lathe tomorrow I should be able to get the wheels and tires mounted to the car and see how they fit.

https://static1.pt-content.com/images/pt/2016/03/20160323_165100_zpsqwvxokje-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160323_165100_zpsqwvxokje.jpg.html)

https://static1.pt-content.com/images/pt/2016/03/20160323_164854_zpsvc8q62cq-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160323_164854_zpsvc8q62cq.jpg.html)

[jwatts]

Another update. I got my wheel painted up and ready. I got my tires mounted yesterday. In the meantime I got my calipers painted and mounted. I had to do a little work to my wheel adapters. I had to machine the inside of the front ones out a little to fit over my front wheel hubs. The rears had standard thread studs, while the fronts had metric. I put them under the press and swapped the rears out for metric. I am probably going to run the factory lugs and lug covers that match the wheels I put on it.

I did run into a few snags as expected. I went to mount the shocks and immediately saw where I screwed up. I routed my brake lines further down the axle tube than the original lines ran. With the old shocks, it would still clear but it was close. The new Bilsteins aren't even close to fitting. They hit where my rubber line joins the hard line. I have to knock off the studs I welded on to the axle to hold the brake lines and rereoute the lines. For right now it has no rear shocks. That will be addressed in the near future. Also, the front wheels may end up rubbing. I am going to wait til I get the disc brakes and new control arms on and make sure before I try to remedy a problem that may not even be there.

I was wondering about the ride height. After setting it off the jack stands I think I like it. It will take a little riding around to make my mind up for sure, but so far I like the looks. The actual driving and handling will make the final call though. I am going to move it out of the garage and into the barn for a little while so I can rewire a 54 Chevrolet truck for a guy. After that it is on to front end brake and suspension upgrades. Here are a few pictures of it right after I took it off the stands.

https://static1.pt-content.com/images/pt/2016/04/20160415_141818_zpsxtfx32dq-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160415_141818_zpsxtfx32dq.jpg.html)

https://static1.pt-content.com/images/pt/2016/04/20160415_141017_zpskfoq94x3-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160415_141017_zpskfoq94x3.jpg.html)

https://static1.pt-content.com/images/pt/2016/04/20160415_140948_zpszoutmh7c-1.jpg (http://s342.photobucket.com/user/josh_watts39191/media/Chevelle/20160415_140948_zpszoutmh7c.jpg.html)

[Pt109]

I pretty much ended up the same way with my car. but i am going to do the body work myself. Its a challenge i need to complete. this gives me more motivation to get it done. Looks like fun, and look forward to seeing it when you get it done. have fun!!

[jwatts]

I pretty much ended up the same way with my car. but i am going to do the body work myself. Its a challenge i need to complete. this gives me more motivation to get it done. Looks like fun, and look forward to seeing it when you get it done. have fun!!

Oh I am having fun. My 6 year old son loves working on the car with me. That alone is enough to keep me going. I am almost through rewiring that truck. All my son is worried about is getting the car back home and getting back on it.