Project Grocery Getter...1983 Chevy Malibu Wagon!

[David Sloan]

Cool project Joe!
I always like that front end.

[JEFFTATE]

Carl Casanova has a good setup for in-tank fuel pumps for this application ..

[BulldawgMusclecars]

Thanks David! Great to hear from you! Stop in and see us sometime if you get a chance.

[BulldawgMusclecars]

Today was pretty productive. We got the TPI unit and front accessories off the engine, along with the valve covers (to prevent damage), and pulled the engine and transmission. There were the usual issues...a stripped u-joint strap bolt, stripped transmission cooler line fittings, etc...but nothing major. The TPI wiring is best described as a rat's nest. I'll give some credit, it DID work, but its pretty cobbled up. Looks like an original Camaro harness, with lots of added red wire and tape. I'll post pics tomorrow; my camera battery died, and my iPhone isn't cooperating either (bad signal in this old building).
We got the Musclecar Pan Kit in from Day's, along with the Corvette tensioner for the accessory drive, and the Magnaflow Exhaust. A pair of new inner fenderwells came in also, to replace the original ones damaged by the bad front lowering job (HEATED coil springs!). Once the engine is in and the car is running, we'll fit some new springs and cut them as needed for the right ride height.

[bonecrrusher]

I had to look hard for these pics - but I knew I had seen this car before:

For Sale @ the Food Lion Auto Fair back in April of 2008 here in Charlotte:


Looks like they blacked out the window trim... looking fwd to updates!

[BulldawgMusclecars]

Cool, thanks Bonecrusher! I know my customer bought it off Ebay recently, but thats about all I knew of its history. Always loved the Charlotte area...I lived in Gastonia til mid 1980, and still have relatives up there.

[BulldawgMusclecars]

Here is the X-pipe from the Magnaflow system:







The old 305. We stripped off all the shiny aluminum stuff to avoid damage when pulling the engine.



Stating engine compartment cleanup.

[BulldawgMusclecars]

Jeff from BRP/Musclerods came by on his way home from work this evening, and brought us the mount kit, transmission crossmember, and the 1 7/8 longtubes. Thanks Jeff!
I'd like to note that the BRP/Musclerods kits are made in the USA, in Cumming, GA. The Hedman/Husler headers are also USA made, in nearby Alpharetta, GA.







I just had to throw one of the headers on to see how it looked:













The Autometer tach adapter:





The engine compartment was a mess, with lots of grease caked on the supension components. Here it is after a little scrubbing and degreasing:











Here are the new plastic fenderwells, to replace the damaged originals. They came from Dixie Monte Carlo Depot, which, oddly enough, isn't in Dixie!

[srh3trinity]

I like the way that car sits. That would make an awesome family cruiser.

[Tony_SS]

Dixie was bought out by a new company.. They've always had a good selection of hard to find parts.

[BulldawgMusclecars]

Agreed, I'll be using them in the future I'm sure. I'm about to start on a G-body for my son very soon... a 1987 Buick Grand National. Its all stock right now, but won't be for long. I'm not going too crazy with the engine, but it will be built solid so that the boost can be dialed up later.

Off to gather some more parts...the torque convertor is in (GM's recommended unit for this crate engine) at Day's Chevrolet, and I'm going to get the Corvette regulator/filter assembly.

[John Wright]

Nice thick flanges on the headers...I like that, they should seal well and not warp.

[BulldawgMusclecars]

Nice thick flanges on the headers...I like that, they should seal well and not warp.

Heddman east coast makes some very nice stuff. The coating is much nicer than most on the market, too...its done by Performance Coatings in Jonesboro, GA. I use them for all my ceramic and powder coating.
I have all but given up on the other major name brand headers, due to fitment issues. These are specifically engineered to work with BRP's mounts, too, so there is no guesswork.

[BulldawgMusclecars]

The ride height looks great, and the rear is dropped properly, but the front springs are still the heated originals. I'll be ordering a new set of springs today, and swapping them out while we still have everything apart. They may have to come back out to be cut once the engine is in, though, but that is to be expected.

The plug on the truck alternator I purchased is different than on the harness, so I have a Corvette alternator on the way. I could change the plug out, but I'd rather not start modifying a brand new harness. I also ordered a sending unit/fuel pump bracket assembly and the Vette regulator/filter assembly; both should be in on Friday.

The fuel tank and lines are out, as is the TPI wiring and computer. We'll do some detailing on the front suspension, frame, and brakes while we are at it.

Here is the original tank. I was surprised how small it is.



The TPI harness:



More underhood shots...in progress








Caliper, rotor, and dust shield removed for detailing. The brakes are all stock. They are in serious need of an upgrade, especially with what is going in this car.

[BulldawgMusclecars]

This afternoon was mostly spent cleaning, painting, and detailing parts. The lowering springs will go in tomorrow. Since we are this far in, and have to break the spindles loose anyway, we will remove, clean, and repaint the a-arms, spindles, sway bar, steering linkage, and the steering box.The whole underside is getting pressure washed, and freshened up before any parts go back on. We should also get the new battery box in tomorrow.

[Jims78elky]

Great G body project! I love those headers, Iam in the (very slow lol ;-) process of doing a Ls3 upgrade in my 78 Elco, can you give me a part number on those headers? Wow..that little wagon will just fly with that new engine going in some big brakes on all corners will be a next update soon for your build, keep up the great work and level of detail.

[BulldawgMusclecars]

Great G body project! I love those headers, Iam in the (very slow lol ;-) process of doing a Ls3 upgrade in my 78 Elco, can you give me a part number on those headers? Wow..that little wagon will just fly with that new engine going in some big brakes on all corners will be a next update soon for your build, keep up the great work and level of detail.

Thanks Jim! The headers are BRP/Musclerods/Hedman # 45036. They sell them direct for $699, but I am a dealer for them and can knock $20 off that (Summit sells them for $879.95!). If you want a set, send me your address and I'll get a shipping quote from BRP.

As you can imagine, this is already an expensive project (everything is new), but the owner is interested in doing a brake upgrade if we can do it affordably. I have some ideas, including possibly C5/6 parts in the front, and 4th gen F-body rear. That way, if there is ever an issue on the road, repairs are not a big deal.
We're going to look into selling all the takeoffs. That should easily pay for the whole 4 wheel disc conversion. The 305 and TH700R4 wouldn't be cost effective to ship, but if anyone is interested in the other components (the complete TPI, the Concept One accessory drive, the ball milled aluminum valve covers, a like new radiator,etc), let me know and I'll see what I can do.

[BulldawgMusclecars]

I don't know how I missed your post, David, but it was great meeting you too! Give me a call if I can help with anything.

David has an awesome Macho T/A with a Butler-built engine and EFI...really makes me want to get back to my Pontiac-powered TT 87 Trans Am project!

[The Stickman]

What springs are in the rear and what's going in the front? Thanx. I need to start getting springs for the wife's car.

[BulldawgMusclecars]

Neil,
The front springs are from Hotchkiss, part # 1902F. They are going on the car now. The existing front springs were heated originals, which are being trashed. I'm not sure what brand the rear are, but I'll find out.

We got a lot done today. The whole front supension and steering has been removed, and all the components have been cleaned up and painted. Chris and I took off to the local Pull-A-Part after lunch, and got the spindles we will be using. They are from a 2002 S-10 Blazer 2WD, and are a direct bolt in replacement for the G-body (and earlier S10) spindles.





Going on the car:



The front crossmember after cleaning and painting:



One of the control arms after cleaning and painting:



A shot of the underside, before any cleaning was done. The 8.5 Buick GN rear (3.42 posi) with Edelbrock control arms and a Hotchkiss sway bar, and Air Lift bags, were installed by another shop right before delivery. The shocks are Bell Tech.







The gas tank's stock location, removed for cleaning and painting. The straps will come off for painting as well.



Another underside shot...the dirt daubers will have to go!



One of the original front springs, which appears to have been cut down severely, rather than heated as I initially thought.



Another shot of the front end going back together