Project High School Sweetheart (the build of a 1965 Chevelle 300 2dr post = "POSTAL")

[sixfivepost]

Let me first say that there are some fantastic cars on here and have no illusions about my project.

I've had this car since the age of 15. I'm 35 now. It sat in my folks' garage in Arizona since 1995 when I joined the military. I'm still in and finally wanted to do something with the car. So, I had it shipped to my house in Maryland last summer and started tearing into it. Becaus it's an Arizona car, I thought it was in decent shape; however, the previous owner did some shoddy bondo work in the quarters, rear cowl, and crap floor board rivet work https://static1.pt-content.com/images/noimg.gif, so a ton of metal work was required.

I was planning on doing a frame-on resto, but one thing led to another of course and the body has been off the frame several times now... I was planning on doing all of the work myself, but due to lack of time, pending transfer orders, constant travel, and a need to finish this sooner than originally expected, I had to tap into some professional assistance in the form of Carlisle Customs and Classics in Shippensburg, PA.

I'm on a military guy's budget, so nothing crazy here. The purpose of this project is to end up with a car that handles nicely, stops nicely, is reliable, and can be driven without the worry of messing up thousands of dollars worth of crazy expensive paint and fanciness. I don't plan to auto x it (too much), race it, or etc. Just some cruising to local car gatherings and occasional Saturday and Sunday drives.

I've already started assembling the new parts and plan to install drilled/slotted disc brakes, UMI tubular upper and lower control arms, new spindles, close ratio mechanical steering box, new column, new steering linkage, 3 inch OPG drop springs, KYB shocks, OPG 1 1/4" sway bar, boxed rear arms, 2" narrowed Moser 9" rear with 3.50s, etc, etc. I'm keeping the Muncie 4sp, but will rebuild it. I'm undecided on the engine at this point. I really want an LS swap with T56, but I'm just not comfortable with my knowledge of that effort and don't want to get in over my head with unexpected costs. I may hold out on that and in the mean time install a GMPP crate 385hp fast burn ZZ4. For wheels, Jon at Driverz Inc is building me some custom 3pc New Gen Descendents in 18 x 7" and 19 x 9" (custom offset for narrowed Moser) with flat black centers, chrome hoops, and chrome hardware.

Anyway, I had planned to get the car back on it's wheels by the end of the fall because I may have to transfer out of the area and selling a house is difficult enough without a garage full of old car parts; however, that's probably not going to happen due to a project cost overrun of approximately 50%! Typical...

Pics of the progress so far:

When it arrived to my house and how I left it over 16 years ago. Looked the same.

https://static1.pt-content.com/images/pt/2011/09/65006-1.jpg

https://static1.pt-content.com/images/pt/2011/09/65009-1.jpg

https://static1.pt-content.com/images/pt/2011/09/65016-1.jpg

https://static1.pt-content.com/images/pt/2011/09/Chevelleteardown001-1.jpg

https://static1.pt-content.com/images/pt/2011/09/Chevelleteardown002-1.jpg

I stripped the old paint, rust scale, grease, and grime using a needle scaler by hand over every inch of the frame.

https://static1.pt-content.com/images/pt/2011/09/cherryblossomsandcar038-1.jpg

cutting out the smooth firewall panel:

https://static1.pt-content.com/images/pt/2011/09/cherryblossomsandcar039-1.jpg

Welding it in place:

https://static1.pt-content.com/images/pt/2011/09/cherryblossomsandcar040-1.jpg

Dan

[sixfivepost]

Car was still in my 2 car garage. I prepped the frame, sealed the interior of the frame with EW frame protectant, applied two coats of EW Rust Converter, then two coats of EW Rust Encapsulator. That stuff is fantastic to work with! I used a spray gun for everything and the RE goes on smooth and perfect! The next step will be two coats of EW Chassis Black 2K Ceramic. Started working on the firewall and compiling the front end parts...

https://static1.pt-content.com/images/pt/2011/09/frameprogresschevelle004-1.jpg

https://static1.pt-content.com/images/pt/2011/09/frameprogresschevelle007-1.jpg

https://static1.pt-content.com/images/pt/2011/09/frameprogresschevelle006-1.jpg

[sixfivepost]

Now at the shop:

Full floor, full quarters, inner and outer wheel houses, etc, etc. Everything else is being stripped down to bare metal at the moment.

Because full quarters for the 2dr post are almost impossible to find, coupe quarters were purchased and had to be modified to fit the body lines. The C pillar section couldn't be used.


https://static1.pt-content.com/images/pt/2011/09/photo-3.jpg

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https://static1.pt-content.com/images/pt/2011/09/rearquarter-2.jpg

https://static1.pt-content.com/images/pt/2011/09/coupequarteraltered-1.jpg

https://static1.pt-content.com/images/pt/2011/09/rearquarterin-1.jpg

[sixfivepost]

Don't worry, the drums will be departing along with the old 10-bolt. They will be replaced with a disc brake equipped narrowed Moser 9".

https://static1.pt-content.com/images/pt/2011/09/Fireside010-1.jpg

https://static1.pt-content.com/images/pt/2011/09/Fireside009-1.jpg

https://static1.pt-content.com/images/pt/2011/09/Fireside008-1.jpg

[craigs73]

you got a nice start keep up the good work and thanks for serving our country

[sixfivepost]

Update:

Not the greatest camera, but here are some pics of the progress.

https://static1.pt-content.com/images/pt/2011/09/3-1.jpg

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https://static1.pt-content.com/images/pt/2011/09/9-1.jpg












__________________

[sixfivepost]

The car has a name now. We were goofing around, joking about all the grinding work. Someone made the comment about "...going postal on that thing with the grinder..." Well, it was pretty funny given the fact that this car is a post car. So, it stuck and the name of the car is: "POSTAL" unless of course that's already been used. If so, I apologize and will scrap it. :-)

[David Sloan]

Cool build !
I think the name fits. I like it.
Keep the updates coming.

[65convertSSl79]

Love them 65's

[sixfivepost]

Thanks guys, I'll keep this updated as this progresses. I hope to have the car back in my garage by the end of October so that I can start the re-assembly of the mechanicals, wiring, interior, etc.

I think I've only ever seen one 65 Chevelle 2dr post that was given the resto-mod/PT-esque treatment. It looked really nice. Not too many of these old budget beater 300's around... :naughty: Having the extra structural rigidity of that post is pretty nice actually.

[irregal83]

Nice car and great start... hope you keep with it and keep us updated! good luck

[ProTouringCuda]

Nice work. The title caught my eye, since that's what I call my Mustang: My High School Sweetheart. I've owned mine since I was 16. I've had it for 31 years.

[sixfivepost]

Yep, I've had this car since I was 15; over 20 years now. That's rare for me because I go through new cars/trucks/motorcycles like crazy. Both of your '65s are fantastic! Watching the Orange Crate Cuda!! I would love to have a custom chassis, but surprisingly the old Chevelle is pretty rigid and that post probably has something to do with that. :-). Anyway, that 'Cuda is going to be mean!! I love uncommon cars.

Dan

[sixfivepost]

The control arms are on the way!

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[aldoini]

I also am going thru the same as you. I have a 300 deluxe and have my car on the same stages as you good luck. I will post pictures soon

[sixfivepost]

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Don't worry, it's just primer!

[sixfivepost]

Cool, yet another 65 Chevelle 300 build? I've seen more 65 300s on here in the past couple of weeks than I ever have in person over the past 20 years I've owned the car! :-)

[ChevelleNV]

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Don't worry, it's just primer!
That's too bad, I kinda like it.....its different.

[sixfivepost]

To each their own... :-P

[sixfivepost]

More updates, things are moving quickly now...

2nd coat of primer, almost ready for paint!https://static1.pt-content.com/images/pt/2011/09/hurray-1.gif

https://static1.pt-content.com/images/pt/2011/09/dash-1.jpghttps://static1.pt-content.com/images/pt/2011/09/rearprimer2-1.jpghttps://static1.pt-content.com/images/pt/2011/09/primerfinal-1.jpghttps://static1.pt-content.com/images/pt/2011/09/fnlprmr-1.jpghttps://static1.pt-content.com/images/pt/2011/09/fnlprm-1.jpghttps://static1.pt-content.com/images/pt/2011/09/another-1.jpghttps://static1.pt-content.com/images/pt/2011/09/finalprm-1.jpg

[sixfivepost]

Buddy P. sent me this today! He does excellent pencil work and I recommend him to anyone wanting a rendering like this.

I think I'm going with a bit darker color now, but you get the idea.

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

[sixfivepost]

Larger

https://static1.pt-content.com/images/pt/2011/10/Chevellerendering2-1.jpg

[CruizinKev]

oh yea looks great!!

[sixfivepost]

Thanks Bud! Can't wait to finish it!

[coolwelder62]

Very nice project.Look's like you are doing some awesome work.

[sixfivepost]

With LOTS of help/work from the guys at CCC. They do very nice body work! I just need to get it out of body/paint jail so that I can start assembling the hard parts!

[sixfivepost]

Well, it's painted! Still needs to be wet sanded, buffed, and polished. The body needs to come off the frame one more time to be stripped, painted, suspension and rear end installed. Kinda ass backwards, but there were reasons to hold off on the frame. I've been waiting for over 12 weeks for my wheels to be finished. We need to test fit the wheels before moving on with the frame finishing and inner wheel houses. Originally it was six weeks, but it's turned into over 12. Not sure what the hold up is, but oh well. I'm sure they'll be worth it when they finally do come in.

Excuse the dust...

https://static1.pt-content.com/images/pt/2011/10/Painted016-1.jpg

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https://static1.pt-content.com/images/pt/2011/10/Painted003-1.jpg

https://static1.pt-content.com/images/pt/2011/10/Painted001-1.jpg

[Hayden.m]

Lookin sweet! Love that color! What are you thinking for the motor?

[sixfivepost]

Thanks! As for the engine, nothing too fancy unfortunately. I originally planned to rebuild my SBC and supercharge it, until I found some significant issues with the block. I contemplated and LS swap, but the car was too far along at that point and I don't want to get into cutting up the new floor, cross member mods, etc, etc. Plus, I have access to some nice GMPP crates at very good prices. I'm probably going with an equivalent to the no longer available ZZ430 SBC for now. Basically just a Fast Burn 385 with a cam, roller rockers, and matched roller lifters.

[ChevelleNV]

Love the color, looking good. cant wait to see more porn!

[craigs73]

that looks great cant wait to see some outside pics of it

[CruizinKev]

oh yeah looks great!!!

[sixfivepost]

Yeah, the guys do great work. I could never have layed down paint like this.

Thanks for the compliments, the color choice was VERY last minute.

The rear end and tubular UMI rear control arms should be in this week!! Still waiting for the wheels though. It's been roughly 12 weeks and I'm still not sure when I'll get them. Waiting on a report back from Jon at Driverz Inc. It will be nice to get it on the ground that's for sure!

[sixfivepost]

Some progress. Got some ride height issues right now. My 3" drop springs dropped the car zero inches... Something is either binding or they sent me the wrong springs. The rear and front control arms are from UMI. The rear uppers are adjustable. Rear end is a Moser 9" narrowed 1 inch on each side. Wheels are New Gen Descendents 18 x 7 F, 19 x 9 R. Frame is not notched and wheel tubs are stock replacements. Once I get it dropped another 4 inches or so, the wheels will look pretty fantastic, but for now it looks like a donk.

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[85coupe50]

Great color... Nice build.

[CruizinKev]

the wheels already look pretty fantastic!!! sorry to hear about the non-lowering but maybe the car won't go down because there's no motor in it?

[sixfivepost]

Well, the front is pretty low already and I may need to add my spacers once the engine goes in, but the rear is the problem. I don't think the engine will affect the rear too much if at all. There's no interior or fuel tank in it yet either, but again, I don't think that will drop it down where it needs to be. Of course I'll mess with the ride height after I get all of those components in.

Thanks for the comments guys!

[sixfivepost]

A few more pics.

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[sixfivepost]

Some progress, but a long way to go...

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[sixfivepost]

Ok, change of plans... I finally made the decision to go with an LS-type of engine (sort of) instead of my original plan to use a warmed up 350 or 383. Since I have a clean slate and need everything anyway, it made the most sense and here's the best part, it's actually going to be about the same cost or slightly less to go this route.

Anyway, I've located an engine and am working on the parts list. Should have it in the garage in a few weeks or so. New plan:

All aluminum 2008 5.3L (LH8) with under 1000 miles, 243 heads, juicy cam (more on that once I figure out the grind), LS2 intake fuel rails and injectors, custom harness, ecu, and associated electronics, Mast oil pan, Doug's headers, Rick's tank, etc, etc.

I am going to go a slightly less common route with the transmission. I just had my M21 rebuilt and beefed up by Jerry Macneish (upgraded synchros, new internals, new center shaft, upgraded sliders, etc.), so I'm going to use it. It should safely handle 450hp which is one reason I went with the 5.3 instead of a 5.7. With the cam, intake, and etc, I should be around 400 hp or so, maybe a bit more 430 depending on what I decide for duration and lift. I'll be using a retrofit kit to mate the older transmissions to modern engines. The Muncie is relatively small, light, and simple. I may change it out one of these days, but for now, it will do just fine for how I'm going to use the car. Plus, I won't need to modify the already finished floor.

I'll be installing the rear control arm braces and may be boxing the frame (one step forward and two steps back... lol).

Everything including mounts, headers, and misc. is still significantly less than a crate 383. Not too shabby. Just thought I'd share because I'm pretty stoked about this! It's been bugging me since day one of this project. Decent suspension, nice body, leaning towards pro-touring, but with an old 350 or 383 just didn't feel right. I'm tired of the oil leaks, carburetor tuning, cold starts, etc, etc. Gas mileage isn't a big deal since this is a toy, but it will be nice to get decent mileage for those long cruises.

[sixfivepost]

Exterior is nearly finished. The old interior is just sittin' in the car for transport reasons. The old taillight lenses are also just temporary. Still no engine, trans, tank, or etc. in the car which is one reason it isn't at ride height. Also, because the rear was narrowed 2 inches, the e-brake linkage is hitting the frame. Not good. Gotta figure that one out.

Anyway, the pics at least show how the color scheme looks as well as shows off the beautiful paint and body work the shop did for me.

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That's it for now until engine and etc...

[shawnvan]

love the color the car is coming along great, good luck

[sixfivepost]

Crappy phone pics of car's first show. It was shown as a project. Yep, there is a car in these pictures... :-)

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Still no engine, trans, or interior (just some old seats for placement tests).

[BuddyP]

Looks great! Looks darn close to that rendering you had done ;-)

[sixfivepost]

It sure does! Thanks for putting my mental picture/design onto paper Buddy! Your rendering helped me decide to go with a darker color than I had originally planned.

[shawnvan]

I see from the car show pictures that some aftermarket headlight may have been installed, they are a nice fit for that chevelle

[Rols574]

whats the name or number of the color? love it!

[68vert]

Saweeet! 65 is my favorite year Chevelle and yours is awesome.

[65chevelleboys]

Very nice 65 Chevelle.Have Enjoyed looking at your pics,more please.Helps me with my 65.

[CruizinKev]

WOW looks GREAT!!! :twothumbs

[sixfivepost]

Well, it has been a long time but I've been documenting over at team Chevelle.

Long story short, I've had a hell of time with this project. Always one step forward and ten back. Issues with vendors, engine in and out a few times, etc. I had to redo a some mistakes by the body shop as well as some things I wasn't happy about due to my own piss poor planning and early cost cutting cheap outs that I decided had to go.

I can finally see the light at the end of the tunnel and I hope to have it on the road by mid summer and fully completed by end of summer IF I don't run into any more bad luck.

Here is the status: engine is installed... again.
Wiring is 98% complete
Fuel system is installed (tanks inc. Tank, Walbro Pump, Corvette FPR, Fragola PTFE lines and fittings, and etc.)
Muncie is gone and a new TKO 600 is ready to go in. I modified tunnel to fit the trans.
Dakota digital dash is in along with stereo system
Pulled the KYB shocks and am installing viking dual adjustable
Full UMI suspension is installed
Pulled the chepo brakes and installed front and rear wilwoods and master cylinder is on hand to replace current stock type
Now using a Tilton hydraulic clutch release bearing
Now using a McLeod rst twin disc clutch
Been busy despite a 6 month delay due to an engine fiasco.

Anyway, here are some pictures:

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Painted the grille
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Trap door for my fuel pump and sending unit
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[bhcustomdesigns]

Looks Awesome!!!:twothumbs

[sixfivepost]

It was a hell of a long 4 years; taxing on my marriage, my savings, and my sanity, but I stuck with it despite almost giving up a few times. I couldn't give up on this car that I've owned since I was 15 years old (38 now). Drove it all through my teens; to work, to school, to local car shows, and etc. and it never let me down. Parked it 20 years ago in my folks' garage when I joined the military until about 4 years ago when I finally had funds and a garage.

Lessons Learned:
-Figure out what exactly you want to build before starting the project. -Budget about 40% more than you think it will cost in time and $.
-Don't try to cut corners because you will end up realizing that you shouldn't have, then spend twice as much time and $$ to do it over the right way.
-Only buy parts from well-established vendors unless you do a thorough check first.
-Ensure your family is ready to deal with the time you will spend in the garage.
-Do as much of the work as you can because like the saying goes, if you want it done right, do it yourself. Plus, paying for labor sucks. I pretty much did everything or re-did everything except the body work.
-You will hit walls, but don't give up. Just take a break and come back at it when you are ready.
-You pay for what you get usually. Spend the extra cash on high quality parts if you can. See number 3 above.

Well, here it is at it's first cruise-in and actually first time on a real drive. I'm working on engine covers now (slight modifications for fuel line, finishing, and paint), so I will update this when I finish them and install. I have custom, sheet metal covers from BH Custom Designs. Brett does fantastic work and customer service is phenomenal.

Quick stats: All alum. 5.3L, LS6 heads, LS2 intake/fuel rails, Comp Cams custom ground cam, TKO 600 5 speed, Moser M9 w/ 3:50 gears, UMI front/rear control arms, Wilwood discs, Bilstein shocks, New Gen 3pc forged wheels, Tanks Inc. tank/Walbro fuel pump, Be Cool Radiator, custom stainless steel exhaust w/ X-pipe and Borla XR1 mufflers, Headman Hustler headers, yadda, yadda, yadda. No heat, no AC, all business.

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[RodZZilla]

Love it! A friend had a 65 300 about the same time you got yours. His had Blue Dots in it, too. A lot of good times in that car.

[sixfivepost]

X pipe/Borla XR1s. They are quieter than I thought, but have a very refined, deep sound with minimal resonance.

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[sixfivepost]

Had some inquiries about how it all ended up parts wise. Here's what I ended up with:

-All alum. 5.3L with custom ground Comp Cams cam, LS2 intake/fuel rails, E-38 ECM w/ custom tune, Hedman Hustler ceramic coated headers, LS7 lifters, hardened push rods, LS6 heads, catch can, drive by wire TB, C6 Vette pedal, Spectre Pro Series cold air intake, etc.
-Doug's Headers adapter motor mounts
-Custom stainless steel X-pipe and exhaust w/ Borla XR1 mufflers
-Quicktime bell housing
-Tilton hydraulic TOB/Wilwood clutch master cylinder
-McLeod RST twin disc clutch
-Tremec TKO 600 5sp / Ring Brothers shifter
-Moser M9, 3:50 gears, narrowed 2 inches
-UMI front and rear adjustable, tubular control arms, braces, sway bars, modified G-Force X-member
-Bilstein shocks / 3" drop springs
-Wilwood disc brakes/drilled and slotted rotors
-American Autowire classic update series wiring harness and custom engine harness by Modern Vintage Performance
-Nickel Copper brake lines
-New Gen 3pc forged wheels, 19 x 9.5 rear / 18 x 8 front
-Tanks Inc. fuel tank w/ Walbro 255 in-tank pump, graphite impregnated PTFE lined steel braided fuel lines
-LED lighting throughout
-Dakota Digital VHX carbon gauge cluster
-Pro-car Ralley seats (love 'em) and custom upholstered rear bench to match
-Complete Dynamat system throughout
-PST quick ratio Steering Box
-Flaming River steering column
-Billet Specialties steering wheel


That's about it.

[Bonehead]

Outstanding! The sacrifices we make sometimes slow us down in the things we want to do. Glad to see you over came your obstacles.

[Lalo Larrea]

Dude I´m totally in love with the effort and work put on this amazing car, I´m 19y/o and I´m planning on buying a chevelle (69-71) but I have a college student budget so it may take long to complete a build like this but hopefully I´ll be able to do it. Great achievement and I hope that your sweetheart from highschool is finally done.