1966 Chevelle Project "Thumper" Build Thread

[Thumpin'66]

Hi everyone,
I have been randomly posting since I picked up my chevelle and figured it was time to start my official build thread. My screen name reflects my prior ride of 13 years. I bought a 66 SS Chevelle and am installing the powertrain from the Monte with some mods like a Gear Vendors. Goal is to have a Chevelle that performs well on the street and at the road course or drag strip. I am going for a retro look with big ET 5 spokes and a 671 Roots style blower. I can't recall seeing a big Velle with a roots blower on a road course so this could be interesting. Who knows, maybe I won't be able to see around the blower scoop well enough and will have to go procharger after all :).

The build features:

359 Cube 740HP blown SBC with dual 1150 dominators. This engine put my Monte in the 10's in the 1/4 mile.

TH400 trans with Super Comp direct drum, Hipster's brake, 3000 stall. Trans is backed by a Gear Vendors over-drive.

Ford 9" rear features Currie Track 9 housing, iron N Case with Detroit locker, and 3:50 gears.

Rear suspension has Currectrac arms and HR bar with Budzter adjusters and 150# Hypercoils.

Front suspension features Detroit Speed arms and spindles, splined sway bar and 650# springs.

KRC power steering pump and Jeep Grand Cherokee box.

Shocks are Strange dual adjusts front and rear.

Brakes: Z51 Corvette calipers and rotors with Kore3 hardware front and rear.

Wheels are classic ET 5 spokes 18x9.5 rear and 17x8 front.

I will update this list as the build progresses and post pics.
I plan to be driving the car next summer.

[Thumpin'66]

Before I took it apart it didn't look to shabby. If it wasn't for the body rust I found in a few spots I would have dropped in my engine and had some fun.

https://static1.pt-content.com/images/pt/2010/09/3JPG-1.jpg

[Thumpin'66]

Pulling it apart.. The adventure begins..

https://static1.pt-content.com/images/pt/2010/09/10JPG-1.jpg

[Thumpin'66]

Amazing what you find when you media blast a car. This quarter looked pretty darn straight before blasting but the blasting revealed some seriously ugly patchwork and looked liked someone ran a circular saw up it for fun. This side got a new quarter.

https://static1.pt-content.com/images/pt/2010/09/21JPG-1.jpg

[Thumpin'66]

The trunk had some drainage holes created by rust so it got repaired with patch pieces from a donor car floor pan. With all repairs the idea was to retain as much OE metal as possible. The rust free pan I found really helped. My car was a factory automatic trans but someone had converted it and butchered the floor. It was nice to have a spare pan to cut patches from.

https://static1.pt-content.com/images/pt/2010/09/33JPG-1.jpg

[Thumpin'66]

On the rack at Fat Wallet Customs getting the metalwork done.
https://static1.pt-content.com/images/pt/2010/09/30JPG-1.jpg

[Thumpin'66]

Look ma, no more rust! I got the body home after all major metal work was done. The underside was coated with Lizard Skin and then I shot it with Wurth Underbody Seal.

https://static1.pt-content.com/images/pt/2010/09/89JPG-1.jpg

[Thumpin'66]

https://static1.pt-content.com/images/pt/2010/09/88JPG-1.jpg

[Thumpin'66]

https://static1.pt-content.com/images/pt/2010/09/44JPG-1.jpg

[Thumpin'66]

https://static1.pt-content.com/images/pt/2010/09/47JPG-1.jpg

[Thumpin'66]

https://static1.pt-content.com/images/pt/2010/09/49JPG-1.jpg

[Thumpin'66]

https://static1.pt-content.com/images/pt/2010/09/51JPG-1.jpg
https://static1.pt-content.com/images/pt/2010/09/52JPG-1.jpg

[Thumpin'66]

The pics posted above were of progress up until today. I had the body work done at Fat Wallet Customs in Portland Oregon and I do the rest by myself. I plan to tackle the front suspension in the next few weeks and have the DSE pieces coming UPS.

[dropped72ss]

Looks like your chevelle is coming together nicely.

[CruizinKev]

oh sweet looks great so far! :twothumbs

[1966chevelle502]

It is going to be one bad... car :smoke:

[Thumpin'66]

Front end parts arrived!! Springs were mis-boxed so waiting on the correct ones but this DSE stuff looks sweet!

https://static1.pt-content.com/images/pt/2010/09/67JPG-1.jpg

[Thumpin'66]

Today I bolted on the front control arms and spindles. Putting in the shocks first would have been a good idea since they don't fit through the lower arm..:hand: I ended up having to pull the springs back out a few times. Oh well it's just time and cotter pins.. One of the adjustment knobs unscrewed the whole valve on my Strange shocks so I had to remove it and repair it. I lost some shock oil but hopefully not enough to cause an issue.
Next time I work on it I will install the front brakes.
Here's a pic from today.
https://static1.pt-content.com/images/pt/2010/10/69JPG-1.jpg

[Thumpin'66]

Here are some pics of my Kore3 offset brackets and front brakes installed. I had to turn down the centers on my aluminum hubs for wheel clearance but it was no big deal.

https://static1.pt-content.com/images/pt/2010/10/70JPG-1.jpg

https://static1.pt-content.com/images/pt/2010/10/71JPG-1.jpg

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[rixtrix1]

Looking good. Should be a runner( turner and stopper, too). Not quite as much rust, or damage, as mine had:-). Really starting to think about returning mine from drag to street and track.

[COPO-RAT]

https://static1.pt-content.com/images/noimg.gif

What size rear tires are you running?

[Thumpin'66]

Rear tires are 295/45r18.

[Thumpin'66]

I ended up needing a 1/4" spacer to clear the C6 calipers on my wheel spokes. ET built the wheels and had the fitment template but still was off a bit. I switched to LS1 calipers and solved the issue. I can always install the C6 units with track wheels and tires if I need to.

https://static1.pt-content.com/images/pt/2010/10/dqior5yLUt1TkWUUQHgfDmR1fdbvNVzB0rVgKdNa-1.jpg
Z51 behind 17" wheels
https://static1.pt-content.com/images/pt/2010/10/80JPG-1.jpg
It sure feels good to se the chassis sitting on tires. I will tackle the swaybar and steering linkage and clean up the steering box next.

[DYNODANNY]

Cool ride, I'm still catching up on others projects before I start to tear in to my 66 chevelle. Keep up the good work.

[Thumpin'66]

Modified firewall for header tube clearance. Doug's D369 headers put one tube too close to firewall for my taste.
https://static1.pt-content.com/images/pt/2010/10/84JPG-1.jpg

Some rear brake and suspension pics:


https://static1.pt-content.com/images/pt/2010/10/27JPG-1.jpg

https://static1.pt-content.com/images/pt/2010/10/56JPG-1.jpg

https://static1.pt-content.com/images/pt/2010/10/58JPG-1.jpg

https://static1.pt-content.com/images/pt/2010/10/59JPG-1.jpg

3.50 geared Nodular Iron 9" with Detroit Locker
https://static1.pt-content.com/images/pt/2010/10/60JPG-1.jpg

HR PartsNStuff anti-roll bar and Budzter coil spring adjusters plus Strange double adjustable shocks.

https://static1.pt-content.com/images/pt/2010/10/DSCN3250JPG-1.jpg

https://static1.pt-content.com/images/pt/2010/10/62JPG-1.jpg

Currie Currectrac lower arms and Adjustable uppers with Johnny joints are sweet. 31 spline axles with 1/2" studs drive the wheels.

It is so cool to see my car sitting on the ground with the body bolted back on for good! This is a milestone moment for me..
https://static1.pt-content.com/images/pt/2010/10/93JPG-1.jpg

[Thumpin'66]

Tilt column and pedals are in.
https://static1.pt-content.com/images/pt/2011/10/103JPG-1.jpg

Lokar e-brake cables done
https://static1.pt-content.com/images/pt/2011/10/100JPG-1.jpg

Pulleys and belts finally handled for KRC pump and MSD alt. Still have to make the PS hoses.
https://static1.pt-content.com/images/noimg.gif

Fuel tank in with Robbmc pickup and 1/2" stainless hard line to front mounted CV Products mechanical pump.
https://static1.pt-content.com/images/pt/2011/10/101JPG-1.jpg

Mounted battery and cutoff today after spraying trunk.
https://static1.pt-content.com/images/pt/2011/10/102JPG-1.jpg

Cutoff switch through tail light.
https://static1.pt-content.com/images/pt/2011/10/104JPG-1.jpg

Switch in off position
https://static1.pt-content.com/images/pt/2011/10/105JPG-1.jpg

[Thumpin'66]

Crappy cell pics but here is an update from this weekend's effort. Painted the core support and headlight buckets and started clip install. I also made power steering hoses and installed the radiator.

https://static1.pt-content.com/images/pt/2011/10/110JPG-1.jpg

https://static1.pt-content.com/images/pt/2011/10/111JPG-1.jpg

[jilge71]

Dang thats a lot of motor!!! I like it though

[Thumpin'66]

Another weekend of progress.. She has a face! Hella headlights in and front clip done except for final trimming of the hood opening for the blower.
My wiper cowl cover dissapeared so I have to find another.
https://static1.pt-content.com/images/pt/2011/10/112JPG-1.jpg

https://static1.pt-content.com/images/pt/2011/10/113JPG-1.jpg

[Thumpin'66]

https://static1.pt-content.com/images/pt/2011/11/114JPG-1.jpg
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https://static1.pt-content.com/images/pt/2011/11/116JPG-1.jpg

[therobski]

I'm building a 64 F-85, in this picture there is a brace that runs across the rear cross member between the upper control arms-is that a fabbed brace of did you buy that somewhere? Also the rear meats are huge what did you do to clear the wheel houses? Does no look like you have mini tubs, did you roll the wheel lips on the quarters? I'm running a Moser 9inch.51028

[Thumpin'66]

in this picture there is a brace that runs across the rear cross member between the upper control arms-is that a fabbed brace of did you buy that somewhere? 51028
Sorry to say it but that is just dust on the frame, I can see how you thought that.

Also the rear meats are huge what did you do to clear the wheel houses?
I had the rear housing cut shorter than stock and had my wheels cutom built. I can dig up measurements but you don't need them. There is another car on this site with the same size rears 295/45R18 and no mods that I know of.

[therobski]

Do you how much additional backspacing is on the rims you had made? Are they 8 inches wide. I want stay with "granny car" look with dog dish hubcaps. Thinking Wheel Smith or some one can build a couple of stock looking rims, maybe 16 inch that will give me alot more tire choices other than 15's

[Thumpin'66]

They are 18x9.5" in the rear with 4.75" back spacing.

[craigs73]

where you get that undercoating? how did you like it? and of course price..

[Thumpin'66]

I buy the Wurth products at http://www.goodspeedmotoring.com/ it works great and is the same stuff as used on European cars from the dealers.
https://static1.pt-content.com/images/pt/2011/11/85JPG-1.jpg

[rfalker1]

Wow... that a lot of engine. Looks cool!! Keep up the good work

[craigs73]

wow thats pretty cheap!!! how many of those lil cans did it take you to finish?

[Thumpin'66]

It has been a while but I am thinking 4 cans? I had already Lizard Skinned the underside first so the Wurth coating was a top seal. I also had to buy a schutz gun to spray it with.

[Thumpin'66]

Hey guys, just wanted to let you know that this build is still in progress, just slow going due to lack of time and money. I have a custom aluminum dash going together and will post pics as soon as I get it in and painted. I also swapped the front c6 calipers for LS1 units to gain wheel clearance so I could ditch the spacers. I found a set of Larson valve covers (you either love em or hate em) so I will now have to make changes to alternator mounting, pcv system, throttle linkage, etc. I only want to build this car once so I am doing what I want the first time even if it takes longer due to funds. I am debating spraying the dash, package tray and door trim with rattle can SEM trim black, does anyone have any input on that?

[Thumpin'66]

OK, here's a few teaser pics of what I am up to.

[Thumpin'66]

https://static1.pt-content.com/images/pt/2012/08/photo2B42B28229JPG-1.jpg

[Thumpin'66]

Hey guys,
My Chevelle has smooth as glass black paint on it and my paint guy is still finishing the front clip pieces but I have started assembly. The headliner, front and rear glass and quarter glass are in. I have a ton of work to do still but the underside is all done except for hooking up the fuel sender wire, welding a bung in the x pipe for the wide band sensor, and setting the pinion which I will do when the wheel alignment is done.

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The rest of my album can be seen here with a bunch of recent progress pics. Hard to believe it has been four years in the making already.
https://picasaweb.google.com/103924580243849816647/RussSBlown66ChevelleSS

[Thumpin'66]

A few more pics from yesterday - rear door panels, rear bumper and trim, rear view mirror, etc. Front windows and door assembly are some of the goals for today.

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[Thumpin'66]

Had a great vacation last week and worked on the Chevelle every day. I got everything on my immediate hit list accomplished last week. Wiring to rear of car, interior install except the dash, widows in, zolatone the trunk, weatherstrip, etc. It is looking like a car again! I should be able to get back on it in about four weeks to mount the dash and hopefully hang a freshly sprayed front clip. I will keep you guys posted on the progress. Thanks for your support!

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[Thumpin'66]

Front clip is painted and installed. Still a few trim pieces to install but the paint and body portion of this project is quickly coming to a close.
The hood turned out great. I included an unfinished pic so you can see the metal work done to give the cut area for the blower. The bracing gave it strength and a smooth finish around the lip. What's left to do? Wiring the dash and installing it. All wiring for the front of the car. Alignment, pinion angle set. Front wheel and rocker molding installation. Wipers, VC gaskets, fuel, throttle linkage, belts and hoses, etc.

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[Crestronwizard]

looking great!

[Thumpin'66]

Hey guys,
Thought it was time to update this thread. After logging about 1300 miles last summer in the beast I started focusing on the driving experience. The BDS scoop looked very Muscle Machine but I had to slide over in my seat and lean to peek around it when cornering. I put together a fiberglass unit for a classy hot rod look that gives me a much improved line of sight. My exhaust was just a bit too loud at freeway speed to allow for windows down conversations. To fix the sound, I installed a second set of mufflers (Borlas) behind the Dynomax mufflers and it sounds sweet. My next project is to swap out the 3.50 rear gear for 3.0 gears so I can spin 2000rpm at 72mph with the gear vendors engaged. With the torque of this roots blown engine the tall gears will not hurt performance and maybe I will find an event to test the top end speed.. :naughty:
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