86 Monte Carlo SS super project

[redss86]

Well 10 years later, and unfortunately not a whole lot of progress. But since the website that I had linked in my first post isn't there anymore, I figured I could actually add some pics to this thread and update it while I was at it.

Why 10 years and not much progress? "LIFE" happened!!!! As I had posted, I bought a house, got married, was unemployed for 5 months, then had to save money to build a shed to be able to work on it. That took almost 4 years to complete because I did not pay somebody to build it for me. I built it myself with the help of some family and friends. So then in that time frame we ended up having two kids ( thanks for the tip "Protournova") 19 months apart. Now that they are a little older, I am trying to get out and actually work on this. So when you throw two kids, a wife, home ownership, and doing some side work at home, you don't have much time to work on what you really want to.

Now I have over 250 pictures I could share, but that is entirely too many to post all of them. Plus a lot are basically the same pic, just a little different angle. So if you have any questions for some different angles it is no problem. This will take several posts and probably several days to fully update, and the posts will probably be pretty long. So be patient on my update progress.

Tear Down, these were taken February '05



I even got the "girlfriend" (wife now) to help!




Did a mini-tub on it. I cut the entire panel between the wheel wells out, and cut a 3" section out of the center. I did this because I wanted to keep the body bushing support there. It isn't actually a "body mount", but there is a bushing there. So I drilled out the spot welds as needed and cut around the center package tray brace. I cut the section out and welded the two pieces back together, then trim the floor as needed around the wheel wells for now narrower piece. Once it was all spot welded back in place, I cut filler pieces to fill in the gap in the wheel wells. Looking back on it now, I almost wish I would have went a little bit more, but I will fit as wide of a tire as I can in there now.



I also did some rust patch work on the trunk weatherstrip flange, and remove the spare tire well.



Then, it was off to work, where I put it on the rotisserie and sand blasted and epoxied the entire body (inside and out).



While I had the body at work, I started on the frame. I had to build some sort of "flat surface" to build the frame on. I didn't have access to a frame bench, and hadn't really thought about building one at the time. So I had my Uncle bring his laser level over and we shimmed up some 4x4's, and screwed down some plywood. Seriously kind of redneck engineering, but it was all I had.



Then the "fun" began!!!
I started by re-welding the factory seams on the frame.



Had to build jigs to hold the rear frame horns in place.





Then it was time to start cutting it apart.



I put the "old lady" to work cutting out backing plates with the plasma torch for the new frame rails. I wish I actually owned a plasma torch, it sure was nice to be able to bring the one home from work at the time.



New frame rails. I did "butt with backing" welds on all joints between the axles. As you can tell, I also plug welded the backing plates on either side of the joint.



Used more 1/8" plate to make the transition joint between the new rails, and the original ones. I think they turned out really good. Also put a sleeve in the outer rail for the #3 body mount under the door opening.


I will have to get some pictures of the actual finished transitions.

Then to locate the truck arm cross-member. I had to reinstall the body to make sure I got the rear end positioned correctly. I had to cut the rear floor board out for clearance for the arms.



My help "hard at work"



She's going to "LOVE" me for posting that. Oh, well. I will continue to post as I can. The newest picture in this post is from December '05 so I still have a loooooonnng ways to go. I am actually curious what the "LIFE" gap will be on it.