1979 Malibu Classic Landau LS1/4L60E Frame Off

[Malibu Jax]

Hello Everyone-

My name is Jackson and I have posted in the welcome forum and thought I would move to the project forum due to the fact that this is one hell of a project. I have had a great deal of time and effort thus far and still have a long way to go. Anyway, I have attached some pics and would love to hear from anyone who would like to add and especially those who have gone through a LS1 swap and have tips.

This is the begining of the second build on this car. The first build was about eight years ago and I had to replace the rear frame from the middle of the rear tire to the bumper. There was literally nothing there, which should give you a good idea of the condition of the body. I patch paneled the rear quarters, replace the drivers door (you could reach you hand in the door at the bottom), replaced the hood (the latch had failed on the previous owner so it flew up and was totally screwed), preped and painted it, then rebuilt the original 305 (.30 over, vortec heads, edelbrock intake and carb, etc). There are a good deal of other small things but this was what it looked like after that build and some time.
https://static1.pt-content.com/images/pt/2008/07/l_b4f406fa509aad9daee3d1ebd2ea731d-1.jpg



I started the tear down in March when I purchased the LS1
https://static1.pt-content.com/images/pt/2008/07/l_8841046bb162918206ec89b602d48b75-1.jpg

By April I had the body off the frame and was addressing some structural issues. The front two body mounts were rusted out to the point that the body busing were not touching the frame and the bolts were actually gone.
https://static1.pt-content.com/images/pt/2008/07/l_f0e0d7557f943fdf5ee806424b77d1e6-1.jpg

I took a page from a company that I found online and decided to fully box the frame and add gussets for the front and rear. I also notched the x member for the LS1 pan clearance (I tig welded the important spots and mig welded the less important ones).
https://static1.pt-content.com/images/pt/2008/07/l_e4761b9d09224a219805dd52388d1f43-1.jpg
https://static1.pt-content.com/images/pt/2008/07/l_90a9ce278a5d320353388ce278768293-1.jpg
https://static1.pt-content.com/images/pt/2008/07/l_d9a99d76214b89714a048e6114e8d653-1.jpg

As you can see the frame was pitted and rusted badly in spots so I sandblasted and cleaned it up after I was done patching and adding support. The went for a nice black clearcoat that turned out good.
https://static1.pt-content.com/images/pt/2008/07/l_574ee9b53b534e98291762fef2c2b35b-1.jpg
At this point it is the end of May and I finally got to put something back together. https://static1.pt-content.com/images/pt/2008/07/l_e255902e3ee07d0fb4fb3281bf5c83c1-1.jpg

After all of that fun I moved on to the floor pans and patches that needed to be taken care of with the body.
https://static1.pt-content.com/images/pt/2008/07/l_4ff6cd218292de9da8da4ff8109d40ba-1.jpg

I did not take as many photos of the floor pans but trust me when I say I had about 20 different patches and it sucked. This was the largest and I think that someone blew a heater core and let it set for a long time, at least thats my guess. Moving on I decided to rino line the floor pans to seal up the progression of rust.

https://static1.pt-content.com/images/pt/2008/07/l_8660614364f1e726515b428e234aafce-1.jpg

While I had the body off I decided to put in a posi and 3.73 gears replacing the stock 2.56 non posi setup.
https://static1.pt-content.com/images/pt/2008/07/l_7f7cc3c8486eb6333220b285bfb4909d-1.jpg

Skipping a few photos I clear coated the firewall and a ton of other smaller parts, cleaned and undercoated the bottom side of the car, finally reunited the body with the frame, and test fitted the LS1 to make sure I didn't screw up and measurements. That brings my project up to speed at this point. I am working of plumbing out my fuel system right now and have a laundry list of other systems and technicalities to work out but damn it sure looks good to see the LS1 sitting in the Bu.

https://static1.pt-content.com/images/pt/2008/07/l_a088e27f9efc83803dca96e6862094bb-1.jpg

Thanks for reading, let me know if you have any questions!

[CRCRFT78]

Great job with the Malibu. Keep the updates & pics coming.

[wicked67]

looking very nice. keep the pics coming

[GBodyGMachine]

I remember when my frame looked that pretty. Hard to keep clean.

Nice work.

[Malibu Jax]

Hello everyone-

Thanks for the comments and the encouragement it is needed. I have had a hell of a time figuring out some of the tech stuff. I started the fuel system, worked out the power steering after getting some custom hoses built (LS1 PS has O ring type connections but G body is a reverse flare), mounted the driver side header, with the new steering box it had a different spline count & rag joint. I overcame this problem by going to a u-pull-it yard with my caliper and finding a suitable replacement (A 93 suburban LOL). Anyway I added a few photos and you probably can't tell but it has been a real bear to make any progress.

https://static1.pt-content.com/images/pt/2008/07/l_683f9e6424fb838f20ec2ac17ae31493-1.jpg
https://static1.pt-content.com/images/pt/2008/07/l_dd55f294f1534e5b2f20dfe41f89e8dc-1.jpg

[Samckitt]

Cool! G bodies rule! What kind of posi did you go with? I am debating going with 3.73 or 4.10 in mine.

[chrisw]

looking good

[Malibu Jax]

I went with the 3.73's and an eaton due to the tranny upgrade 4L60E having an overdrive. I wanted an all around good cruser and I think that combo was best. I had 3.73's in it at one point minus the posi and I didn't like the high rpms at 65 but if you are looking to have a good quarter mile/intown car you could go with the 4.10's.

[Samckitt]

I figured with the 50% overdrive of 6th gear, I could get away with 4.10's easier than you could with the 4L60E.

[Samckitt]

By the way, do you live in a neighborhood full of gearheads? I see the old red Chevy there across the street.

[Malibu Jax]

Funny you noticed, I have three good gearheads that are close. The 56 is the red one and the same guy has a 68 firebird with a sick flame job he did himself and a model A truck he has about half done. Another neighbor has a old landcruiser that he swapped out to a chevy drivetrain and just repainted. The last neighbor has a chevy 2 that is practically rust free that he just stripped to start a 454 build on. I am blessed to have people of a similar mind close to hang out drink beer and work on one of the many projects going on.

On the other note, do you know what the auto overdrive is?

[78 Type-LT]

looks nice..i've always love Malibu's

[Samckitt]

Funny you noticed, I have three good gearheads that are close. The 56 is the red one and the same guy has a 68 firebird with a sick flame job he did himself and a model A truck he has about half done. Another neighbor has a old landcruiser that he swapped out to a chevy drivetrain and just repainted. The last neighbor has a chevy 2 that is practically rust free that he just stripped to start a 454 build on. I am blessed to have people of a similar mind close to hang out drink beer and work on one of the many projects going on.

On the other note, do you know what the auto overdrive is?

I think the auto overdrive ratio is around .70, meaning the engine turns 30% less than the driveshaft.

[69LT1Nova]

I remember when my frame looked that pretty. Hard to keep clean.

Nice work.

LMAO!! :lmao:

Yeah, they sure do get dirty in a hurry. Even just sitting there in the shop.

Nice work on the 'Bu. It's always the little stuff that turns out to be a PITA (such as power steering).

[deuce_454]

wow a 2 tone, LS1/4l60e 79 malibu with boxed frame.. ... thats my kind of car! :-) right down to the rear gear ratio choice

[trapin]

Nice car indeed. Is the LS1 stock?

And welcome to the site.

[350SS]

Great build, any updates?

[deuce_454]

what harness are you using??

[Malibu Jax]

Hello everyone-

Sorry I have not posted in a while I have been busy with changing jobs and working on the Bu.

First, Thanks Deuce for the complements. I am using a stock harness as of right now with a engine fuse box out of an 04. I have yet to really get into the wiring aspect and it is coming to it fairly quick.

Second, Trapin, as of right now the LS1 is stock but does have the LS6 intake and is the same that is in the 2002 Vettes according to the castings. I have plans in the future to do a cam/heads swap but it will be a while because the build costs have gone above what I was expecting.

Lastly, I have worked out the cooling system by putting together a shroud out of a late 90"s iroc and an LS1 dual fan unit with some custom brakets and a good deal of time. I ran into a problem with my new SSBC brake proportioning block (sprung a leak from the plug above the rear out) and they are sending me another new one. The brakes will be finished next week when that shows up. I painted about twenty smaller parts and fit up the passenger side header with some modification. I also have a shift linkage coming next week from summit so that should be done. Lastly, the fuel system is still on hold due to the fuel pickup being a mother *&^%$$# to find. Anyway, I really appreciate the comments and take a look at the photos and feel free to ask any questions.
Thanks

https://static1.pt-content.com/images/pt/2008/09/DSC04102-1.jpg

https://static1.pt-content.com/images/pt/2008/09/DSC04103-1.jpg

https://static1.pt-content.com/images/pt/2008/09/DSC04104-1.jpg

I have a painless 18 circuit that I am going to put in to replace the stock melted box. Somebody really did a number on it and had like five jumpers and a bunch of bad bad wiring.
https://static1.pt-content.com/images/pt/2008/09/DSC04101-1.jpg

I will spare you all of the minor paint pictures but trust me there was a bunch of small stuff to clean up and paint. It makes you feel like your making no headway, but it looks so much better than if I skipped it.

[Malibu Jax]

For some reason it is not letting me add the picks, only links. If anyone knows what I am doing wrong let me know. It is the same thing I did for the first set of pics.

[79_GBody]

Here's the thread on how to post them using photobucket...its pretty simple
https://www.pro-touring.com/forum/showthread.php?t=26620

[Malibu Jax]

Thanks for the info, I edited it and now it shows the photos.:)

[79_GBody]

No problem...I'm pretty much at the same stage with my car, minus the LS-1 of course :drool:

[turnin20s]

Very nice man, I'm still up in the air weather or not to do a BB chevy morot or an LS based motor. I'm really leaning towards a big in big block that will eventually be fuel injected and running an LT1 style T56. Your progress looks like its really turning out. I know what you mean by not making any headway with all of the small projects. Last fall/winter/this spring I was redoing the motor in my camaro and swapping the 4l60 for a T56 and thought while I was there why not clean the underside and do a bunch of little projects, then the next thing you know you aren't even close to having the car ready and the big stuff is still left and you still have 15 little things to do LOL.

But a couple of Questions for you...
Why didn't you brace in the lower control arms? I heard that is a bad place that needs some attention, but mabye thats only for the 1/4 mile cars.

Where did you find the info for boxing the frame and bracing everything? I think you mentioned something above, but if you could PM me some links or just post them here I'd appreciate it.

Also what are your plans for the interior?

Looks great man and keep the progress going and the pics coming

[Malibu Jax]

http://www.classicresto.com/mambo/content/view/96/43/

The boxing information is at the bottom of the page. I used this as an example since it is essentially the same frame.

I have an idea of what I want the interior to look like, but have not settled on a fabric. I want to have Malibu in a tribal type script stitched on the center of the seats and possibly do a five point harness. I want to keep the 50/50 bench (I know it is strange) because I like that aspect of the car. I think that the interior will have to be a as I go project because the build is tapping me out at this point. Anyway, I did some work over this last weekend and I will have some photos up soon.

[Malibu Jax]

Hello Everyone-

I finally have my fuel system worked out after finding the pickup I needed at a local yard. I have been doing a good deal of little work like cleaning up bolts, painting fender skirts/inner fenders, and all the not so fun small stuff.

https://static1.pt-content.com/images/pt/2008/10/DSC04199-1.jpg
https://static1.pt-content.com/images/pt/2008/10/DSC04149-1.jpg

I decided to go with a B&M floor shifter and made reinforcement plates for the trans tunnel. The floor shifter was the solution to the drivers side header in the way of the original linkage.

https://static1.pt-content.com/images/pt/2008/10/DSC04166-1.jpg
https://static1.pt-content.com/images/pt/2008/10/DSC04163-1.jpg

I sent my original harness and computer off to Wait4Meperformance to be reworked and reprogrammed. I should have it back by the end of the week. I have routed out the painless interior fuse block and started connecting it. Currently I am mapping out my new Stewart Warner gauges to fit in the original dash (not so easy but damn they are cool). All things considered, I should have it fired by the end of next week :yeah: :smoke:

[Tony_SS]

Sounds great so far - keep us updated!

[Samckitt]

I want to see the gauges installed. I have been trying forever to find some that will fit in the stock location.

[Malibu Jax]

I want to see the gauges installed. I have been trying forever to find some that will fit in the stock location.

I have mapped out the gauge setup (four 2 1/16" and two 3 3/8") to fit in the stock location. I will not be running any of the dummy lights and the gauges are electronic. I have started the metal work and cannot say that this is the last mock up design, but I am getting closer to making it work. I will be sure to add a final pic after I get everything lookin nice.

https://static1.pt-content.com/images/pt/2008/10/DSC04211-1.jpg

[Tony_SS]

Scot, the Malibu's had a wider shadow box than the Montes, so there is much more room.

[Malibu Jax]

I want to see the gauges installed. I have been trying forever to find some that will fit in the stock location.

I borrowed my neigbors plasma cutter and rough cut the previously posted outline. I then used a drum sander setup to finish it off and it looks really good at this point. I still need to final mock the panel itself, but I am really happy with the way it is turning out.

If you want a bit more room just pick up a Malibu setup and they bolt up the same you would need to fab up a similar setup though. I will try to have an update by the end of the weekend if everything goes well. :yeah:

https://static1.pt-content.com/images/pt/2008/10/DSC04210-1.jpg
https://static1.pt-content.com/images/pt/2008/10/DSC04218-1.jpg
https://static1.pt-content.com/images/pt/2008/10/DSC04221-1.jpg

[350SS]

Nice work. I did mine with a jigsaw...not fun.

[chevelle19700]

Nice Work Man

[Malibu Jax]

Hello All-

I have been hard at the wiring part of the build and it is not very fun. I like the painless kit, but the instructions are a bit lacking in detail. I have yet to figure out exactly what relay setup I am going to use and have another thread going in the LS1 section looking for ideas.

https://static1.pt-content.com/images/pt/2008/10/DSC04232-1.jpg

Anyway, I did manage to get the gauge cluster setup and looking good.

This is the first mockup with the shadow box held to the new cluster by ducktape :firefire:
https://static1.pt-content.com/images/pt/2008/10/DSC04225-1.jpg

Skipping a bit of welding, sanding, and a bit of puddy for the gaps.
https://static1.pt-content.com/images/pt/2008/10/DSC04234-1.jpg

[Malibu Jax]

Hello Everyone-

It has been a bit so I thought I would share some progress. First, It runs!!!!!!! and the tranny is good. This is huge since it was an ebay purchase six months ago and you just don't know untill you fire it. :thankyou:. I wired up the gauges.
https://static1.pt-content.com/images/pt/2008/11/DSC04237-1.jpg

I still have issues with the fuel sending unit, need to re-pin the tach, the volt gauge is pegging and have yet to test the spedo. They sure do look good though.
https://static1.pt-content.com/images/pt/2008/11/DSC04249-1.jpg

I am working on the relays for the fans right now and found a good place to hide them. I intend to run the wires through the fender for the ignition relay and the AC relays.
https://static1.pt-content.com/images/pt/2008/11/DSC04250-1.jpg
I made a plate to mount to the fender and mounted the computer to it with some padding between the comp and the plate. This is probably a temporary thing since it is not very pretty. I will go back and make something better, but for now it will work.
https://static1.pt-content.com/images/pt/2008/11/DSC04251-1.jpg
I expect to be at the exaust shop by next weekend and then it is test drive time:drive2:

[venturabeachpup]

That guage cluster is sweet! Good job!:twothumbs

[GBodyGMachine]

You're a busy man.!.

[Malibu Jax]

Hello All-

It has been a while since I put up some updates but I have been busy with the small stuff. I have the fans hooked up with the three relay setup to allow for high/low 12/6v speeds. Loomed up most of my engine bay and managed to hide a good deal of it in the fenders. Made a mount for my computer in the engine bay (temporary). I bought a nice aluminum overflow tank and made the mount for it. The inner fenderwells are back on and the doors are hung. I also installed the new carpet and put the interior together 3/4 of the way. I still have to put in a relay for the neutral safety signal to the computer before I can sock down the shifter boot.

I have the gauges mostly hooked up but am not pleased thus far with the performance of them. Even with Stewart Warners sending units I am not getting correct readings out of the oil, fuel, and still need to calibrate the speed and tach. Huge pain in the rear. I had to put a hole in my new tank for the fuel sender and it still is not reading right. :banghead: I also had 100lbs of fuel at the rail that took a bit to figure out the issue (return line was not correctly hooked up, lol duh move). I have the exaust done, but I had to get a different tranny crossmember due to the one I bought not being a double hump. The car does run but is not yet up to par. I can go about two blocks before it starts missfiring and running like crap. :crying: I know i left alot out but thats what I can remember at this point. I am going to put a manual oil gauge on it and the OBDII port to get diagnostics going but I am pretty sick of messing with it. :nopity:

I know the seats look like hell, they are on the list, lol.
https://static1.pt-content.com/images/pt/2009/01/DSC00282-1.jpg
https://static1.pt-content.com/images/pt/2009/01/DSC00284-1.jpg
https://static1.pt-content.com/images/pt/2009/01/DSC00283-1.jpg
https://static1.pt-content.com/images/pt/2009/01/DSC00285-1.jpg

[srh3trinity]

Engine looks at home in that bay. The guage cluster looks great. Did you say they are Stewart Warners?

[maldo]

nice keep us updated thx

[malibu9in]

Nice bu !!!! you have given me some motivation to get mine together!

[mone]

Same here!!What kind of booster is that?Im right up th road from you in Brunswick,Id like to see that car one day!!

[Malibu Jax]

Same here!!What kind of booster is that?Im right up th road from you in Brunswick,Id like to see that car one day!!

Hello Mone-

The booster is a (clp-8dsrb-mc-c, $300) Classic Performance Street Rod Series Diaphragm Brake Booster that i bought from summit. It took some modification to adapt it to the pedal inside but not all that much. If you want details let me know and I can tell you the procedure.

Thanks for the complements, I can't wait to put up a burnout photo:6gears:

[Malibu Jax]

Engine looks at home in that bay. The guage cluster looks great. Did you say they are Stewart Warners?

Hello srh3trinity-

Yes, the gauges are stewart warners power series to be specific. Summit sells them in 5 and 6 gauge sets in three colors. My set is part number sww-82245 you can find them on the website. They look alot cooler in person than on the page.

Thanks

[malibu 79]

any updates? great g body.

[twfurst]

Looks really nice, have you completed the build?

[pmgm]

Nice build, Do you have any updates? Is your build finished please update with pics..
Thanks

[gstock8732]

Geez Mann. That's is a super clean Malibu. Wish I had the space and welder to complete all that funkie doo opp. I'm settled to send to local auto shop class to weld all of my nonesense together. Love the guages. Keep it up Mann. Ima be checking this thread often can't wait to see the burnout picture too. I will be starting a thread soon for my 78 boo build. I'm doing a frame off aswell.

[502bu]

Are those inner fenders stock painted?

[Malibu Jax]

Hello All-

I started a new job a while back and have had little to no time to post/do anything. I am not finished with the BU yet and do have updates that I will post soon.

*The inner fender wells are stock with a great deal of cleaning and sanding with a plastic adhesive promoter before paint. They are rigid enough to work without flex additive, or at least we will see.

[CruizinKev]

subscribing. very nice project man! thats something what I want to do with my monte :twothumbs please login at photobucket then maybe we can see all the pics again..

[CruizinKev]

what kind of headers are those? what do you think ofBRP Hot Rods' swap kits? (http://www.brphotrods.com/monte carlo LS1 kit.html)
this is the stock 7.5" axle you using with the LS1?

[Malibu Jax]

Hello-

The headers are pace setters slightly modified on the passenger side to clear the frame. I am BRP's least favorite fan, I have it posted under completed LSx swaps. They sell you a kit that is way two expensive and does not fit and then do not return your call. Go with Jeggs for the tranny cross member and check around for a good engine mount, but don't use BRP. :machine: The axle is the stock 7.5 for now, we will see how long she lasts.

[CruizinKev]

hm okay I thought BRP is good - they're also PT forum sponsors?!

[Malibu Jax]

If they want to talk with me about my experience I would be more than happy to explain to them the issues with the swap kit and why I am not recommending them to any G body owners. You might want to look at the know lsx swaps in the lsx forum for more info on the kit. Sponsor or not I had a very bad experience with BRP.

[craigs73]

anymore progress on this:)

[cl08]

Stew Warners look awesome!!!! Nice Cluster as well, impressed!!!
I want a BU now



I borrowed my neigbors plasma cutter and rough cut the previously posted outline. I then used a drum sander setup to finish it off and it looks really good at this point. I still need to final mock the panel itself, but I am really happy with the way it is turning out.

If you want a bit more room just pick up a Malibu setup and they bolt up the same you would need to fab up a similar setup though. I will try to have an update by the end of the weekend if everything goes well. :yeah:

https://static1.pt-content.com/images/pt/2008/10/DSC04210-1.jpg
https://static1.pt-content.com/images/pt/2008/10/DSC04218-1.jpg
https://static1.pt-content.com/images/pt/2008/10/DSC04221-1.jpg