'66 Pontiac Resto-Mod Update

[wmhjr]

Progress continues (slowly). Yesterday I got the fittings I needed to make all AN/Braided stainless lines between my billet hydraulic clutch reservoir and the master cylinder. Got that installed. Then a buddy of mine and I spent the rest of the day on wiring. As of the end of the day yesterday, we've only got a few more things electrically to do. All major systems are done. We realized that we had the ignition and the power top on the same circuit with a 30amp fuse, and that if you keep the top button pressed too long (IOW, after the top is down or fully up) then you can blow the fuse. If that happened it would also kill the ignition. So, we're separating those circuits and putting a breaker in for the top and keeping the 30amp fuse line for the ignition alone. Secret Audio is also now installed and tested. Not that you will really be able to hear it if the motor is running

I've noticed the car is just a little cold blooded. It takes a little bit for the motor to warm up since there is no choke at all. No big deal - this thing won't be out in the winter anyway.

Today we hopefully finish the wiring, and I'm also hopeful that I'll have the clutch and brakes bled and functional today. Keeping my fingers crossed!

[wmhjr]

Well, the weekend went pretty well - though not as much done as I had hoped.

We didn't get around to adding the circuit breaker for the vert top pump yet, but did finish all rear wiring. We finished everything except tidying up under the dash. All gauges now work, except I have not connected the oil pressure wire to the sender. The Line Lock is also not connected completely - all that remains is putting a plug on the two wires under the dash for the switch. The remainder is wired. Need to reconnect the wiper motor wires (just unplugged) and test them, and slightly clean up one wire routing.

Hydraulic clutch is in, bled, and adjusted. Seems to work great. I used -4AN braided to connect the billet fluid reservoir to the master cylinder. It turned out nice and clean. Have just a little more work to do with brakes.

Oil drain plug is still slightly leaking. I also have a slight coolant leak around the water cross-over at #1 cylinder on the intake. Have to take care of that, but it's very minor.

I'm fabricating a bracket to mount the meziere billet coolant overflow. Then I'll used either -4AN or -6AN from the rad neck to the overflow, and then the same out the overflow for the vent.

I also have to slightly modify my go pedal connection. Should not be a big deal. I plan to have that finished this week.

Planning to finish the brakes this Friday evening as well as setting the pinion angle. Then hopefully next week I'll take the car for front end alignment.

Next steps after that? Some minor touch up on the core support and under the bottom of the hood, and then have the convertible top put on the frame (which is already functional and aligned). I also need to redesign the fuel system between the pump and carb to get clearance for a drop air cleaner.

That should just about finish it.

[droptop73]

That is one classy ride. Just finished reading the log. Very impressive workmanship.

[wmhjr]

That is one classy ride. Just finished reading the log. Very impressive workmanship.

Thanks! It's really been a learning experience! I've never done anything even remotely as in depth as this one (and never will again....)

[Jim Nilsen]

Did you leave the brakes for the last thing to do so you wouldn't drive it? I kept thinking you might go for a ride up and down the driveway once the clutch worked.

It won't be long now and you will be pulling in to get gas and having all those people tell you how nice it is and their life story because they want a friend with GTO,lol.

You will be working on a lot of details you didn't know would haunt you , so get it on the road and make sure it all is working before you totally button it up so it is hard to fix them. I had a bunch of things I left until it was all holding together and at first wished I had made it all sealed and finished and then some of them had to come out just like I suspected. I could have put together several cars on an assembly for as many times as I have had some of the parts on and off.

If you plan on taking it to a track day ever, make sure you LOCTITE every nut and screw. You will not believe how fast some of them come loose that you know you tightened and had the right washers and lock washers on and they still come loose.

You are so close !!!!!

[wmhjr]

Hey Jim, I think I own stock in Loctite! My last project was a custom build Harley with a 113" stroker motor - solid mounted (like the GTO). If you REALLY build a Harley (as opposed to those idiots at OCC who never even said the word Loctite) then you get REAL friendly with the stuff.

The deal with the brakes is a story I'll keep for another day. Suffice it to say that I'm waiting on some custom parts from a good guy who is a sponsor here, but the parts have been delayed. So, I had to temporarily move on and I'll get back to those parts in a month or so. I finally made that decision last week, so this past weekend was my first opportunity. I was far more worried about the clutch, so we spent time there first. I don't expect the brakes to be a real issue - may be a little frustrating but there is no technical reason for there to be a major problem.

I've been real careful, and have been testing and testing again everything as I go through the punch list. Example: It's taken longer than expected but the wiring is rock solid. Everything is over-engineered. I ordered the 30amp circuit breaker for the convertible top today from Ron Francis. BTW: For those who are interested, Ron Francis has a cool bladed type circuit breaker that swaps out with a regular 30amp fuse. Great for this kind of application. Never replace that fuse again!

One thing I have as an advantage is that I (now) have a 2 post lift, and the car is a convertible. Until the top goes on (which will be the last thing to be done) it's actually pretty easy to work on now.

But I'm starting to get itchy palms - I am close. It rained all this past weekend so i didn't feel too bad (especially with no top) but I would not be surprised if the car doesn't get a mile or so of road time this weekend. I may wait, however, since my buddy who has really been helping is out of town this weekend, and I think he deserves to be there for the first drive.

[Ron.in.SoCal]

Hey Jim, I think I own stock in Loctite! My last project was a custom build Harley with a 113" stroker motor - solid mounted (like the GTO). If you REALLY build a Harley (as opposed to those idiots at OCC who never even said the word Loctite) then you get REAL friendly with the stuff.

Aint that the truth! My S&S124 shook my headwinds billet headlight off the bike on the dyno! As a good friend of mine once said, "if your harley was a plane, would you fly it?" I don't think so!

Keep goin Sir. Love your car...

[wmhjr]

Aint that the truth! My S&S124 shook my headwinds billet headlight off the bike on the dyno! As a good friend of mine once said, "if your harley was a plane, would you fly it?" I don't think so!

Keep goin Sir. Love your car...

Thanks, and ain't the vibration on the dyno the truth! I'm running an S&S bottom end with R&R billet heads along with their cam on my 113". Just a shade under 130rwhp, but on the dyno even WITH Loctite it vibrated the screws holding my emblems on the fuel tanks off. Anything 1/2-20 or larger seems to stay fine on my bike. It's the little itty-bitty screws that even with loctite are a PITA.

Even though I'm using solid motor mounts and poly body bushings on the GTO and it's a long stroke 11:1 compression motor, I'm hoping it's not going to be quite as much of a "magic fingers" machine....

[Ron.in.SoCal]

Even perfectly balanced HD stroker motors vibrate if thy're solid mounted (is there really any other way?). How many times have you been in the wind and taken one hand off the bars and just shook it to get the blood flowing again? Lots I'm sure...not to mention 'butt tingle'.

The GTO will be a vibrating cupcake compared to your scoot....

[wmhjr]

It's funny. My hands are fine - maybe the gloves? But it's my FEET! I have floorboards on my bike, and my feet get tingly all the time!

[Happyfunballs]

Thought this would be a nice refresher.

Car as of May 27th, 2008


Car as of March 20th, 2010


662 days from first setting eyes on the car.

Good looking car and in pretty good time. Well done.

[Jim Nilsen]

Hey that isn't your car, noone can even get a car painted that fast, your car is still in jail somewhere, it has to be and you can't get all your engine parts in that time period much less get gauges like you want and have them work right. It's just not possible !!!!!

It's Unfair !!!!!!!!! LOL

The time frame is really impressive and I hope you are happy about it the most. Most of us dream about building a car that fast that is that detailed and made of parts that work well as a package.

The first ride is so close for you and it should be a day to have the top down and enjoy it the way convertibles are meant to be driven.

Get a pic before you leave the drive the first time so we can all see and if possible get a video.

Have you gone through your first tank of gas yet and never left the garage? I am betting you get to the 1st gas stop on what you have in it now,lol.

Your friend should be knocking on the door soon......

[wmhjr]

Hey Jim - Thanks! It's SO close I can taste it now. I expect to have brakes done Friday night, so it's drivable on Saturday. But, my buddy who has been of incredible help (and didn't know what he was getting himself into) will be gone all weekend. Fortunately, I think it's supposed to rain. Though I'm real anxious, I owe it to him to wait until he's here for the first drive.

It's funny - strange things happen during a build.

The car came back from final paint, etc exactly one year from the date that I dropped the roller off. In the interim, I had the frame/suspension back in my shop, but it's interesting that it was exactly a year.

It's not quite done yet, but it's real close - enough that I feel safe in saying it's going to get done soon. It feels like this project has been going on forever as I've been so friggin focused on the darned thing every waking minute. I will be SO glad to be done with having to focus on planning every minute and being able to enjoy the fruits of my labor. I know you realize what I'm talking about

I put 10 gallons of fuel in the tank so far, but have only run the motor for a total of about 15 minutes. Of course, that probably means I've used a couple gallons Definitely one of the first stops on my initial drives will be at the gas station!

[wmhjr]

Weekend report....

All in all, a good weekend. Yesterday I had to take advantage of the weather to work around the house and cut grass. The grass was getting so high my wife was expecting elephants and zebras to start emerging.

Today I got the following done.....

Brakes are DONE! Haven't driven the car yet but I've now got great pedal feel, VERY firm brakes, no leaks - done! I need to adjust the bias when I get a chance, but it's ready to go.

Clutch checked and good to go.

Followed the Moser procedure to do the initial rear end break-in. Done - no problems at all.

Corrected the slight adjustment issue with the gas pedal and linkage. I'll have more to show about this before too long, but it's still a secret right now..... Pedal is smooth, responsive, and let's just say it looks great

Adjusted the rear pinion angle and locked it in.

Weighed the car on a set of scales . I had a buddy over helping, and somebody else stopped by who just happened to have a set of scales with him - so we figured why not? Even with all the aluminum, etc, the car could use a diet! 3780lbs! The good news is that the weight distribution was surprisingly good! Just over 50% front and just under 50% rear distribution, with side to side pretty balanced. I was very surprised at that part. I was expecting around 3600lbs, but....

Found a slight coolant leak where the radiator petcock was not completely tight.

The only real problem I ran into so far is that there's something wrong in my steering column where turning the wheel honks the horn. I pulled the wheel and adapter, and here's what I see..



I think maybe the screw on the left is hitting/grounding against that ring. Not sure why. I've got to think about this one.

The good news is that the car (other than the horn issue) can now move, start, stop and turn under its own power! I have an appointment for the front end alignment this Tuesday afternoon!!!!!

[Jim Nilsen]

I hope the alignment went well and the drive there was a good one. Did you get to take your buddy for a drive?

I am looking forward to hearing how it goes.

I just got done bleeding my clutch and I have some wiring to attach along with the exhaust and cooling. So you better be out with a pic or video of your first drive before I get one up of the new engine starting, it might be tonight yet?

BIG SMILE day for you , ENJOY

[wmhjr]

Hey Jim,

The alignment shop was too far away for me to drive the car considering the front end was nowhere close to aligned.

But, I DROVE THE CAR OUT OF THE GARAGE AND INTO THE TRAILER!!!! Then backed it out of the trailer, across the street and onto the rack, etc. It's the very first time the car has moved under its own power since I bought the donor and started the project, so BIG DAY!

I do have a couple issues. Thought I got all the break leaks. Not so fast. I've got a leak somewhere around the line lock - got to figure that out. I've got a slight clearance issue between the Hellwig front sway bar and the passenger end link so I need to adjust the end link. The steering box is still not free of air. The brakes need bedded. The brake light is sticking on a little so I need to adjust that.

But, the clutch is awesome. The motor runs great. Cold blooded to start, but NICE.

I'm taking a short dinner break and my buddy is coming over. If we can clean up the brake leak, we're going for a quick ride tonight.

It's all good! What a feeling to actually drive the car! BTW, when I started the car in the trailer to off-load it, it seemed like a bunch of gophers popping out of their holes. People started appearing like it was magnetic. Next thing you know, there's a cluster of people following me over to the alignment rack and BSing for about a half hour. I'm sure it was a productivity killer at the shop!

[Jim Nilsen]

Sounds like you had an interesting and fun day.

I found 4 leaks after the initial outing on my brake lines but they were just a bit of a turn away is all.

Put your car up so the front wheels are hanging and you can turn the steering back and forth at the tire. I do this everytime on mine and it clears the air out in about 7 or 8 times back and forth. You can hear it go thru the box if it is quiet in your shop.

You really need to learn to do your own alignment with the string method. Once you get a baseline you will be changing it until you get it right for your driving. I am ever so thankful to Matt Altamore for helping me learn what to do and the link to the string method and how to make the fixtures.

It's no wonder they didn't charge you double but then you could have charged admission and broke even,LOL.

Keep it legal and have fun on the 1st drive

[wmhjr]

Well, it was a great day!

Fixed the minor brake line leak (just one fitting) and realized the large leak was the high pressure steering line in the box which was leaking. I "think" I've fixed that, but it may be seeping a little.

My buddy and I took the car for a drive

First stop? Gas Station LOL. I had a little crowd there while filling up. A guy was SURE it was a '62 GTO. :bsjerk: Nice guy. Not a car guy.

Motor ran flawlessly. Tranny shifted perfectly. Clutch was superb. Brakes were "OK" - I need to adjust the bias. I have the black coated wilwood discs and noticed after the drive that the pads had swept the front rotor contact area down to shiny silver. Not so for the back, meaning my prop valve is too tight. No big deal.

Car also handled excellent. Very firm and tight in the corners. No rattles, knocks or squeaks. Just beautiful V8 music. Boy do I love the sound of the exhaust.

Steering is now quiet. Actually, the Second Skin stuff is really working well. The car feels very solid and tight, with no drone, vibration, etc. I'm extremely happy.

Performance is wonderful. Throttle is very responsive. You can drive around in 3rd gear at low speed (1500 rpm). Smack the gas just a little and it just launches. Surprisingly, the combination of the Currie Currectrac rear suspension with the Nitto 505s feel very stable when power is applied.

You can tell it's a '66 Detroit car by noticing the hood shaking a little.

I still have things to do. But at this point I know the worst is over. The car drives extremely well, with no bad surprises at all. I turned it over to my buddy to drive the end of the test drive, and he was just grinning the entire time. What a blast!

[Jim Nilsen]

Sounds like it all went well and the smiles didn't make you suspiscious characters.

Get out there and drive it the way it is for about 300 miles. By that time most all of the gremlins will appear. You find yourself concentrating on one thing and then you find another.

It won't be long before you get to the track and you need to be ready for the relentless attack on the car from all that power !!!!

It's a BEAUTIFUL car !!!!

[wmhjr]

Thanks, Jim! I'd say we were no more suspicious than before, so all is good. I'm going to keep working on the details and fix things as I see them, but it's about DRIVE TIME! The car has to visit the paint shop briefly for a couple things, but other than that it's time for me to make some final changes and to drive it!

I may or may not be able to run it on the track because of the vert lacking a cage. We'll see.