Dhamen's '63 Nova SS Rustbucket to PT/Autox build

[rusty63ss]

I got this car for FREE from a buddy that moved away and had no place to keep or build her. He had the car for approx 10 years and he took her apart and soda blasted, shot with junk primer and then left out in the rain. Before he got her, she was a budget drag car. No cage, subframe connectors, or wheel tubs.:scared: So the rear wheel openings were torched open for wide drag slicks and the quarter panels have cracks and wrinkles by the sail panels.
My original plans were to build a roller ZZ383 RamJet with a T56 from a '97 Camaro. Throw it together and drive it. Then reality set in. The stock suspension IS/was JUNK!
I have never got this far into a car or truck before. Yes I have stuffed a Turbo Buick in a Chevy Luv or a Monza Wagon. But those had decent bodies that made nice sleepers.:) I have always just stuffed something into an okay body. NOTHING like this before. So if you see me doing something stupid please help keep me from messing up.

So here are pics of the car as I got it in Jan '11. I started working on her in March '11.

https://static1.pt-content.com/images/pt/2012/08/IMG_1073-1.jpg
https://static1.pt-content.com/images/pt/2012/08/IMG_1072-1.jpg
https://static1.pt-content.com/images/pt/2012/08/DSC_0202-1.jpg
https://static1.pt-content.com/images/pt/2012/08/DSC_0201-1.jpg
https://static1.pt-content.com/images/pt/2012/08/DSC_0200-1.jpg
https://static1.pt-content.com/images/pt/2012/08/DSC_0199-1.jpg

So after I decided what to do with the suspension I bought this from TCI. I really wish I had stepped up and got the PT front clip, but this is 1000 times better than the stock stuff.

Good bye old JUNK!

https://static1.pt-content.com/images/pt/2012/08/IMG_1091-1.jpg

TCI's MII front clip
https://static1.pt-content.com/images/pt/2012/08/IMG_0998-1.jpg

TCI's Torque arm rear setup
https://static1.pt-content.com/images/pt/2012/08/IMG_1010-1.jpg

Front clip test fit
https://static1.pt-content.com/images/pt/2012/08/IMG_1089-1.jpg
https://static1.pt-content.com/images/pt/2012/08/IMG_1092-1.jpg

Here is a pic of the T56 bolted to my 4 bolt 350 which was my plan to built my motor.

https://static1.pt-content.com/images/pt/2012/08/IMG_0966-1.jpg

Once again reality set in after seeing what it was going to cost to build the motor the way I wanted it. So I bought this.

https://static1.pt-content.com/images/pt/2012/08/IMG_1096-1.jpg
https://static1.pt-content.com/images/pt/2012/08/IMG_1098-1.jpg
https://static1.pt-content.com/images/pt/2012/08/IMG_1102-1.jpg

It's a LS1 pull out from a '04 Corvette w/41k on it. I had it shipped over to me from TN. It came with accessories, PCM, TAC, Harness, and pedal. No I did not know anything about LSx motors when I bought it. I just jumped in with both feet. If I knew then what I have learned since I could have saved lots of money and built a lot more motor the the money spent. I'm not complaining just stating the facts. I'm happy with what I have got.

[fun2gofast]

Looks like your on track for a nice ride! Keep the pics coming on the progress.

[rusty63ss]

So here is a pic of the LS1 bolted to my LT1 T56. Thats about as good as it gets it bolts together.:( The LSx flywheel and starter will not fit inside the LT1 bellhousing. But it will work for mock-up.

https://static1.pt-content.com/images/pt/2012/08/IMG_1156-1.jpg

I wanted to use the Corvette batwing oil pan but there were clearance issues even with 1" setback adapter plates.

https://static1.pt-content.com/images/pt/2012/08/IMG_1125-1.jpg

That's a bit too close for my comfort. And when set in the new clip the pan sits on the power rack.

So when I ordered my suspension I thought I would upgrade the rear dif to a Ford 8.8. I bought one from the local wrecking yard for $200. It's from a 2000 Explorer 4.10 gears and 11" disc brakes. I'm thinking I got a sweet deal. That was until I got my new suspension and figured out that I needed to weld brackets to the center section. For something that will get beat on occasion, I do not feel comfortable welding to cast. So the search for a 9" started. I found this on CL for $75.00.

https://static1.pt-content.com/images/pt/2012/08/IMG_7757-1.jpg

I'm thinking that now I am in the clear on the rear dif. Nope. I have always been a GM guy what do I know about Ford 9"? This turned out to be a 9-3/8" from a truck and I could not get anybody to redrill the axles for me. So I went ahead and ponied up and ordered a Currie unit from TCI with all the brackets on it.

https://static1.pt-content.com/images/pt/2012/08/IMG_1181-1.jpg
https://static1.pt-content.com/images/pt/2012/08/IMG_1179-1.jpg

[tkong14]

I'm going to have to keep up with this! Looks like your well on your way best of luck man!

[GRNOVA]

Cool Nova! like the direction your headed!

[rusty63ss]

On to the harness. This is how I received the harness once I removed it from the motor. I labeled all the plugs as I unplugged them. It stretches approx. 18' from end to end.

https://static1.pt-content.com/images/pt/2012/08/IMG_1168-1.jpg

I removed the rear portion of the harness as I will not be using it. I also removed all the plastic sleeving and tape.

https://static1.pt-content.com/images/pt/2012/08/IMG_1169-1.jpg

This is all the stuff that I removed.

https://static1.pt-content.com/images/pt/2012/08/IMG_1171-1.jpg

Here is my nearly finished harness.

https://static1.pt-content.com/images/pt/2012/08/IMG_1173-1.jpg

On to test fitting the motor and tranny.

https://static1.pt-content.com/images/pt/2012/08/IMG_1159-1.jpg

https://static1.pt-content.com/images/pt/2012/08/IMG_1161-1.jpg

I bought the GM "Muscle Car" pan. Not a good fit for the Nova.:pat:

https://static1.pt-content.com/images/pt/2012/08/IMG_1153-1.jpg

This pan would not allow me to bolt in the steering rack either. Ebay'd the Batwing and the Muscle Car pan and got a F body.

https://static1.pt-content.com/images/pt/2012/08/photo24-1.jpg

https://static1.pt-content.com/images/pt/2012/08/photo14-1.jpg

Then I started trimming the tranny tunnel for clearance.

https://static1.pt-content.com/images/pt/2012/08/IMG_1165-1.jpg

https://static1.pt-content.com/images/pt/2012/08/IMG_1164-1.jpg

https://static1.pt-content.com/images/pt/2012/08/IMG_1166-1.jpg

I still do not have enough room for the T56. I left it alone for the time being.

Onto test fitting the rear suspension. First I removed the old.

https://static1.pt-content.com/images/pt/2012/08/IMG_1186-1.jpg

I used a pair of bottle jacks to hold the rear crossmember up while I bolted it in. Then slid the rear housing and T/A under the car.

https://static1.pt-content.com/images/pt/2012/08/IMG_1188-1.jpg

https://static1.pt-content.com/images/pt/2012/08/IMG_1189-1.jpg

Hung the coil overs.

https://static1.pt-content.com/images/pt/2012/08/IMG_1190-1.jpg

And here she is back on the ground.

https://static1.pt-content.com/images/pt/2012/08/IMG_1191-1.jpg

https://static1.pt-content.com/images/pt/2012/08/IMG_1192-1.jpg

https://static1.pt-content.com/images/pt/2012/08/IMG_1193-1.jpg

https://static1.pt-content.com/images/pt/2012/08/IMG_1194-1.jpg

Those are 255/60/15's without tubs. Yet.:naughty:

[rusty63ss]

Looks like your on track for a nice ride! Keep the pics coming on the progress.

Thanks for the kudo's.


I'm going to have to keep up with this! Looks like your well on your way best of luck man!

Thanks for the best wishes on my project. Yes keep and eye on it. Every time I think I have a handle on where this is going......


Cool Nova! like the direction your headed!

Thanks GRNOVA.
That's one nice looking ride you have yourself. I like the direction your headed too.

[rusty63ss]

I'm not sure where to take you now, so we are going to look at the new to me steering column. I got a tilt column from a '95 Camaro. It was too long as built by GM so I shortened it up. I sectioned the outer housing, cut the inner shaft, and made a mounting flange.

https://static1.pt-content.com/images/pt/2012/09/IMG_1276-1.jpg
https://static1.pt-content.com/images/pt/2012/09/IMG_1274-1.jpg
https://static1.pt-content.com/images/pt/2012/09/IMG_1275-1.jpg

Then I installed the column and stainless u-joints and double d shaft.

https://static1.pt-content.com/images/pt/2012/09/IMG_1277-1.jpg
https://static1.pt-content.com/images/pt/2012/09/IMG_1278-1.jpg

The u-joints are spline x DD shaft. So to get a spline on the end of the steering column I cut the shaft off a junk Saginaw steering box and drilled 3 rows of 3 holes 120* around the steering column shaft. I inserted the cut shaft inside the column and heated the whole assembly smoking hot on my gas crab pot burner. I pulled it off and with the shaft literally smoking plug welded all nine holes. Then I stuffed the welded shaft into heated sand to cool and left it until the next evening. I ground down the plug welds and reassembled the column.

Now I just need to decide on a steering wheel.:)

https://static1.pt-content.com/images/pt/2012/09/IMG_1280-1.jpg

I also picked up the wiper motor from the same Camaro that the column came from. The top is the original wiper motor. It's a two speed with the diaphragm washer pump. The bottom is the Camaro unit multiple speeds. I have not decided where to mount it yet.

https://static1.pt-content.com/images/pt/2012/09/IMG_1282-1.jpg
https://static1.pt-content.com/images/pt/2012/09/IMG_1283-1.jpg

I got the wiring for the wiper motor figured out.:D

https://static1.pt-content.com/images/pt/2012/09/th_IMG_1401-1.jpg (http://s1217.photobucket.com/albums/dd396/My63Nova/?action=view&current=IMG_1401.mp4)

I also got my PCM back from TomM with the startup tune.

https://static1.pt-content.com/images/pt/2012/09/th_IMG_1369-1.jpg (http://s1217.photobucket.com/albums/dd396/My63Nova/?action=view&current=IMG_1369.mp4)

Thanks for looking.

Dhamen

[rusty63ss]

Starting Mini tubs. I had this great idea that leaving 1/2" of material attached to the wheel tub was going to make this easier. Boy was I wrong.

https://static1.pt-content.com/images/pt/2012/09/photo17-1.jpg
https://static1.pt-content.com/images/pt/2012/09/photo27-1.jpg
https://static1.pt-content.com/images/pt/2012/09/photo34-1.jpg
https://static1.pt-content.com/images/pt/2012/09/photo44-1.jpg

And it's out!!

https://static1.pt-content.com/images/pt/2012/09/photo18-1.jpg
https://static1.pt-content.com/images/pt/2012/09/photo28-1.jpg
https://static1.pt-content.com/images/pt/2012/09/photo35-1.jpg

Here is the tub moved over.

https://static1.pt-content.com/images/pt/2012/09/photo19-1.jpg
https://static1.pt-content.com/images/pt/2012/09/photo29-1.jpg
https://static1.pt-content.com/images/pt/2012/09/photo36-1.jpg

My buddy Nate helping plate the frame next to the wheel tub.

https://static1.pt-content.com/images/pt/2012/09/photo218-1.jpg

Welding in the filler strip.

https://static1.pt-content.com/images/pt/2012/09/photo127-1.jpg
https://static1.pt-content.com/images/pt/2012/09/photo227-1.jpg

Well that is it for now.

Thank you for looking.

Dhamen

[796spdbu]

Cool build! Always liked the first gen Novas!

[rusty63ss]

Cool build! Always liked the first gen Novas!

Thanks 796spdbu!

I have always liked them too. This is my first one and I am anxious to get her assembled and on the road!

[CamaroAJ]

something to think about with the camaro wiper motor, it has a park mode that moves the wipers down into the cowl when turned off.

[dlove63]

Always a pleasure to check out your build Dhamen! Keep it up.

[rustomatic]

I like the honesty you're providing here: I thought I could save a few bucks, but... All of us who build our own stuff deal with this, and grow from it; in some perverse way, the lost money, time, skin, blood, and vanity become some kind of badge...

Then, a year later, you realize that a ton of stuff needs to come apart, or you crash the thing after the first real rain of the season, giving yourself no choice but to re-do those things you meant to do all that time ago. Fun: the three-letter word that can be spelled so many different ways. Keep at it!

[rusty63ss]

something to think about with the camaro wiper motor, it has a park mode that moves the wipers down into the cowl when turned off.

I am hoping that when it is running the wipers will not come all the way down to the bottom of the windshield. The arm length varies via a cam in the arm. So I am thinking that as long as when I install the motor with it in the parked position I should be okay. I will find out. :D


Always a pleasure to check out your build Dhamen! Keep it up.

Thanks dlove. I enjoy seeing what you have done to yours too. Last I checked looks like you are getting close.


I like the honesty you're providing here: I thought I could save a few bucks, but... All of us who build our own stuff deal with this, and grow from it; in some perverse way, the lost money, time, skin, blood, and vanity become some kind of badge...

Then, a year later, you realize that a ton of stuff needs to come apart, or you crash the thing after the first real rain of the season, giving yourself no choice but to re-do those things you meant to do all that time ago. Fun: the three-letter word that can be spelled so many different ways. Keep at it!

I am hoping that sharing my errors to hopefully keep somebody else from repeating them.
I went into this without a budget and then came to the conclusion that I did not want a bail wire and duct tape car. I have seen, rode, and participated in those builds and they were always a PITA to keep on the road from all aspects. So I am trying to keep this from getting to much further out of control and build something that is reliable.

And I need to update this thread. I got some new parts. Hopefully this evening.

Thank you for your comments guys.

Dhamen

[Twentyover]

Be very careful just screwing the LT1 T56 to an LS motor. Another guy here did that and blew the crank thrust bearings out of his LS motor. The LT crank is a different length than the LS,addressed in the input shaft and bellhousing. The traditional way to get an LT to convert to an LS is to change bellhousing, input shaft, and mid-plate. Not possible with early LT boxes as the tooth count on an early box is differnt thanthe later LT boxes.

Just be sure you get this investigated, I hate it when oversights cause painful fubars.

[rusty63ss]

Be very careful just screwing the LT1 T56 to an LS motor. Another guy here did that and blew the crank thrust bearings out of his LS motor. The LT crank is a different length than the LS,addressed in the input shaft and bellhousing. The traditional way to get an LT to convert to an LS is to change bellhousing, input shaft, and mid-plate. Not possible with early LT boxes as the tooth count on an early box is differnt thanthe later LT boxes.

Just be sure you get this investigated, I hate it when oversights cause painful fubars.

Yes I am aware of this. I had looked into converting this one but by the time I got done I would have more invested than buying a new Magnum. I found a sweet deal on a TR6060 with 5k on it. With some mods to this tranny and I will still be WAY cheaper than the Magnum.

[Twentyover]

Yeah- I asked about using an early LT1 T56 on my LS2 here,and was told can't be done. Fortunately, there are other boards with some people who try different stuff. By the time I'm all in I'll have spent an incremental $600 adapting my early LT1 transmission to the LS2.

[Glenn]

Chevy II's RULE :)

[rusty63ss]

Chevy II's RULE :)

X2!!

Last pic I saw of your wagon Glenn it looked like you are getting close to driving! It looked great!!

[rusty63ss]

I cut more of the floor out so the driveline does not rub anymore. Also need to cut the loop and make it taller. I'm thinking I will remove the bump stops, and pull the coil overs from the back of the car. Set the frame down on the rear axel. Then set the loop so it touches the driveline. This way when the bump stops are back in they will not be able to hit each other.:) Once I get that done I will build my new tranny tunnel.


https://static1.pt-content.com/images/pt/2012/11/photo211-1.jpg


I moved the motor back 1" from neutral. This made the tranny crossmember bang against the back of the tranny when I had it in the last hole on the subframe connectors. When I moved the crossmember back so it did not hit the tranny one bolt hole hung off in no man's land with nothing to bolt it to. I do not know if it was on purpose or not but TCI made it with two sets of slots. So I cut off the front set and used the back set. Now if I decide to put a shallow dog house in the firewall I could move back another inch!


https://static1.pt-content.com/images/pt/2012/11/photo110-1.jpg
https://static1.pt-content.com/images/pt/2012/11/photo210-1.jpg
https://static1.pt-content.com/images/pt/2012/11/photo37-1.jpg
https://static1.pt-content.com/images/pt/2012/11/photo54-1.jpg

Before.


https://static1.pt-content.com/images/pt/2012/11/photo115-1.jpg
https://static1.pt-content.com/images/pt/2012/11/photo215-1.jpg


After I added 3/4" on each side of the loop.


https://static1.pt-content.com/images/pt/2012/11/photo311-1.jpg
https://static1.pt-content.com/images/pt/2012/11/photo49-1.jpg


Before I send my parts in for powder coat I will weld the inside and grind my welds down.

[rusty63ss]

So I have started putting the driveline and tranny tunnel back together. Started by sandblasting all the edges and painting with weldable primer. I made these pieces of angle from a sheet of 16GA flat stock. Not bad for not using a brake. Sure wish I had one it would have been faster and easier.

https://static1.pt-content.com/images/pt/2012/11/photo119-1.jpg

I took the piece of the driveline tunnel and screwed and welded it on top of the angle I made. Then split the back 4" and shrunk it down to meet the original piece.

I then took one of my wife's old sewing tapes and measured for my tranny tunnel templet. I took measurements at each major width change of the tranny added 2" and transfered it to a piece of card board. I put a sheet metal screw at the bottom of the templet front and back. The pass side turned out perfect.

https://static1.pt-content.com/images/pt/2012/11/photo219-1.jpg

The drivers side needed a little work.

https://static1.pt-content.com/images/pt/2012/11/photo314-1.jpg
https://static1.pt-content.com/images/pt/2012/11/photo411-1.jpg

I started by making flanges for the tranny tunnel. I made these the same way as the driveline tunnel flanges. A piece of angle iron and a hammer. I would rather have a brake just cannot justify it.

https://static1.pt-content.com/images/pt/2012/11/photo221-1.jpg
https://static1.pt-content.com/images/pt/2012/11/photo121-1.jpg

Went to my buddies place and used his sheet metal roller. When I got home I began fitting it into the car. I used a bunch of screws to attach it and massage the new metal.

https://static1.pt-content.com/images/pt/2012/11/photo220-1.jpg
https://static1.pt-content.com/images/pt/2012/11/photo120-1.jpg

The real thing sure looks a lot better than my cardboard templet!! Time to pull the motor and tranny again, sandblast the edges and weld!:)


And sorry for the poor pic's. I had dust and junk all over the lens of my phone.
Tranny tunnel is welded back in!!:)

https://static1.pt-content.com/images/pt/2012/11/photo55-1.jpg

And I started on removing the bumps from the firewall.

https://static1.pt-content.com/images/pt/2012/11/photo122-1.jpg

I went out to finish welding in my filler panel.

https://static1.pt-content.com/images/pt/2012/11/photo222-1.jpg

I did not get finished. I ran out of gas for the welder.:(
So I decided I'm making decent time tonight so I will get some grinding done.

https://static1.pt-content.com/images/pt/2012/11/photo315-1.jpg

[rusty63ss]

Ok I plugged the hole for the heater motor and I hate the way it turned out. It looks like crap!

https://static1.pt-content.com/images/pt/2012/11/photo123-1.jpg

So I broke out the grinder and cut that eyesore out. Here is the patch piece tacked in.

https://static1.pt-content.com/images/pt/2012/11/photo223-1.jpg

Here is the finished repair. Ahh much better.:)

https://static1.pt-content.com/images/pt/2012/11/photo316-1.jpg

Now I just need to find a replacement rivet for the cowl tag. While I was cleaning up the inside I accidently cut it off with the flap wheel.


I plugged the original hole for the fuse box.

Here is the patch piece in the hole.
https://static1.pt-content.com/images/pt/2012/11/photo124-1.jpg

Tacked and straightened.

https://static1.pt-content.com/images/pt/2012/11/photo224-1.jpg

Welded and ground back down.

https://static1.pt-content.com/images/pt/2012/11/photo317-1.jpg

I cannot make up my mind if I'm going to plug the hole for the 3 speed column or the hole for the master cylinder. That is all that is left to decide on the firewall.

Before

https://static1.pt-content.com/images/pt/2012/08/DSC_0199-1.jpg

After

https://static1.pt-content.com/images/pt/2012/11/photo413-1.jpg

All I have left is a little hammer work and some filler this part is done!!

I was planning on just replacing 1/4 of the center pan and the PS wing. There is a few other spots that are thin so I will replace the whole thing. I already have the three piece trunk kit. I might as well use it.

https://static1.pt-content.com/images/pt/2012/11/IMG_1567-1.jpg

So while I have the trunk out I might as well get the DS tub done.

Once those are done I will be at a stand still for a while. There are so many small issues with my quarters I have decided to do full quarter replacement. I will have to save up for awhile for the new quarters.

While the quarters are off the outer wheelhouses will be a piece of cake.

[no go nova]

Any updates?

[rusty63ss]

Any updates?

I have not worked on my car since November. Stupid priorities.
If you want to see more check out my thread on Steve's Nova site same screen name. I kinda lost interest in getting this caught up to where I was when other things became more important. One of these days I will get back to work on the old girl. Thank you for your interest in my build.