Re: '66 Malibu N/SA
 

Before we had PCV a high mileage engine had 60,000 miles on it, was full of sludge and waiting for an overhaul.....................

Re: '66 Malibu N/SA
 

I've been feeling guilty from ignoring the Chevelle so much... between multiple trips for various family obligations and prepping for the Summit finals at Las Vegas. But today was one of my more productive days.

I finally got the bottom section welded in for the rear firewall. I needed to do that before I could finish wiring up the tail lights and fuel pump, since their wires go through a grommet in this panel.

http://i.imgur.com/2SKkFS9.jpg

http://i.imgur.com/rkYw4xy.jpg

Much of the work I did do in recent weeks was wiring. I now have everything done except the wires to the shifter and the brake pressure switch (which I don't have yet). Much of it has been tested. Everything I tried (fan, water pump, lights (front and rear), ammeter, ignition and fuel pump) worked.

http://i.imgur.com/BdB8qSE.jpg

Maybe tomorrow I'll get the shifter in. But I'll also spend some time loading everything up for Vegas. I can hardly wait for that event!

Re: '66 Malibu N/SA
 

I've got most of the details of the shifter mount worked out. Assuming it's stable enough when it's done, if not I'll have to add to it. This is a test fitting, I made four spacers out of conduit that you can see on the floor. They put the knob or tee handle in just about the same location relative to the steering wheel as I have in my Camaro, which I find very comfortable.

http://i.imgur.com/GgwH2TR.jpg

I wound up using bolts from the bottom so there would be minimal protrusion toward the driveshaft. I have lock washers on both sides and a nut tightened down on each, giving the effect of a stud coming up.

Re: '66 Malibu N/SA
 

I used a piece of 4" C channel Aluminum. You can get it at davis salvage in phx. Bolted it down to the tunnel (it fits right over it) the bolted the shifter to the flat top side. Works and fits perfect. Very sturdy. Just a suggestion.

Re: '66 Malibu N/SA
 

Not a bad idea, I may yet do something similar.

Re: '66 Malibu N/SA
 

I tried adding the spacers for the shifter mount and once I trimmed them to a more even height I'm satisfied that this will work. No trace of movement that I can detect when I bang it through the gears.

Then I got to work putting the cable in. They say it should be straight for the first several inches, and I think I achieved that okay.

http://i.imgur.com/S5QL4vz.jpg

I would have welded up this hole but I'm not entirely sure this won't have a stick shift someday, so I just used screws and RTV to seal it up.

http://i.imgur.com/8i1MHAs.jpg

The TH-350 hardware worked fine at the other end too.

http://i.imgur.com/reV4Z5J.jpg

My next step was rigging a switch to disable the 2 step in high gear. For a while I was working on ideas for mounting a micro-switch above the shifter so the gear indicator arrow would hit it. That was the plan until I woke up at 1 AM the other night and thought maybe I could add a little bit of sheet metal to the slot for the back-up light switch (the upper switch). I cut out a piece and tacked it in, and it works fine. The switch is active now in reverse, first and second gears. Ideally it would be active in first gear only, but I should never be hitting the brakes hard at high RPM in the others anyway.

http://i.imgur.com/tVk0pOc.jpg

The next step is prepping Johnny Red to go in and get started!

Re: '66 Malibu N/SA
 

Ah, one step forward, two steps back...

I decided for a couple of reasons to set up the breather and PCV on the red engine the same as on the black one. So I removed that baffle in the lifter valley, removed the oil filler tube from the front of the manifold, and since the red 283 valve covers weren't set up for breathers I removed them and the valve cover spacers. Then I went to remove the long valve cover studs that I won't need any more. When I got to the intake side between #1 and #3 I was starting the first nut when I saw a flash of silver and heard a couple of "clinks". I had dropped the second nut. Damn I'm a klutz. I thought I'd see it in the lifter valley but no, and I didn't see it anywhere on the floor. Then I realized that the number 3 intake was open. I turned the motor over on the stand and sure enough I could hear "Clink, clink" from number 3 cylinder.

So here's what I see when I pulled the head:

http://i.imgur.com/nxiu6Pt.jpg

And there's a double dose of klutziness here, I went to the Washingtin, DC area recently for a family wedding and took a couple of days extra for some sightseeing. On the second day I tripped on the last step going down a staircase in the library of congress. My left foot was a bit stiff afterward, but I walked away and it seemed fine. Then it got worse...

The bottom line is that after a couple of times when it seemed it was almost all better, only to get worse again I finally broke down and went to a doctor. It's broken. So this will slow things down for a bit:

http://i.imgur.com/Ma0JNUL.jpg

Re: '66 Malibu N/SA
 

No worries Dave...I know several guys who use hand controls in their race car lol. :p

Re: '66 Malibu N/SA
 

I'm still limited on the amount (and type) of work I can do in the garage but I've managed to get the red engine back together again. Plus the intake is on as well.

I don't plan on running with them on, but those valve cover spacers are great for running the oil pump without oil spilling all over the floor.

http://i.imgur.com/Z6RXJir.jpg

Re: '66 Malibu N/SA
 

You going to make it by Jan 28th?? I hope your luck turns around, I know how bum ankles are and don't wish that upon anyone!

Brad

Re: '66 Malibu N/SA
 

Yeah, I expect I'll join you guys part way through the season. I'm looking forward to it though, it sounds like a great program.

Re: '66 Malibu N/SA
 

I'm still not up to doing any work under the car (getting up and down like that really seems to annoy my foot), but I was able to get a little done this weekend.

I finally got the pressure switch and got it installed into the brake line:
http://i.imgur.com/O2DDOIw.jpg

And I have the red engine closer to being ready to run. I do still need to pull the distributor again. It seems that this intake manifold has been severely milled. I suspected as much when the bolt holes didn't line up very well with the heads, and it was confirmed when I put the distributor in, and it bottomed out on the oil pump while still 1/8" off the gasket and manifold. And it was confirmed when I examined the back edge of the manifold and compared it to the black engine. So I'll have to get a shim to raise it up a bit.

http://i.imgur.com/v2A7Py6.jpg

Re: '66 Malibu N/SA
 

If that intake has been cut is it still legal?

Re: '66 Malibu N/SA
 

Well I don't see anything in the rules that says it isn't. But I probably won't run this manifold in competition anyway, as I think the alignment between manifold runners and ports isn't very good. And the other manifold doesn't look milled to me.

Re: '66 Malibu N/SA
 

Dave, Give me a call and I tell you what I think is going on here.

Re: '66 Malibu N/SA
 

This is a .120" thickness gasket that I tried out today. It does a world of good for my alignment issues! Unfortunately the port openings are rather large for a little 283.

Does anyone know a manufacturer (hopefully with part number) that makes gaskets .120" thick with port openings in the 1 7/8" to 2" range? I can use these if I have to, but I'd rather find something that is a little closer to the actual port size. So far my search has come up empty.

http://i.imgur.com/weQCRLg.jpg

Re: '66 Malibu N/SA
 

see about a fel-pro 1245.

Re: '66 Malibu N/SA
 

Oh, that looks great! Thanks.

Re: '66 Malibu N/SA
 

Cometic made me some thick intake gaskets for my 327 stocker that had a similar issue.
I never did any for my 283's but I am sure if you gave them specs and ordered a few they would do it

Re: '66 Malibu N/SA
 

This looks a lot better!

http://i.imgur.com/3KWhFuY.jpg

Re: '66 Malibu N/SA
 

Okay, the manifold is back on, and as a test I dropped in the distributor with no gasket. I measure an .026" gap between the bottom of the distributor and the manifold.

http://i.imgur.com/v2A7Py6.jpg

Here it is with an .030" shim and a gasket.

http://i.imgur.com/n7Pa8rV.jpg

Hopefully it'll stay together a little longer this time.

http://i.imgur.com/YJbMKVG.jpg

Re: '66 Malibu N/SA
 

If you don't think that gasket material will hold the distributor at the right clearance, I have seen valve spring shims used for clearance. Might have search to find one the right size but might give more peace of mind. Nice build.

Re: '66 Malibu N/SA
 

Seems to me, the FelPro blue distributor base gasket seems to work as well as any for a combination gasket and spacer. The cheap gray fiber gaskets swell up and get soft after a while. Great build!! The valve spring shim is a brilliant idea. Just finding one the correct ID is the game.

Re: '66 Malibu N/SA
 

If I remember we tried differential shims not sure what car but definitely was from a Chevy my partner at the time was a parts mgr so we used to shop the parts bins regularly might be worth a look otherwise depending on the ID of those spring shims they do work. FED 387

Re: '66 Malibu N/SA
 

I'll measure one this weekend, but I'm thinking 12-bolt pinion shims might be a near perfect fit.

Re: '66 Malibu N/SA
 

If you find no other solution - http://www.streetsideauto.com/p/moro...FQ-QaQode-ICIw


Moroso 26150

Re: '66 Malibu N/SA
 

Jegs, Summit, etc. offer these nylon dist. shims. -Al

http://www.jegs.com/i/JEGS-Performan...40082/10002/-1

Re: '66 Malibu N/SA
 

Now that I think more about it it was probably 12 bolt pinion shims you might get by with one or may have to stack them--- just remember consider tooth engagement between the cam and dist. gears--FED 387

Re: '66 Malibu N/SA
 

Wow, that's a lot of ideas!

Actually, if you look back at my previous post you'll see I mentioned that I already have a shim (.030") in there, and yes it's one of these nylon shims. Seems like it should work fine.

Re: '66 Malibu N/SA
 

12 bolt shim is 1.45x 2.08 diameter if it helps anyone

Re: '66 Malibu N/SA
 

I must be missing the boat but I thought everyone runs a distributor with an adjustable collar ??

Re: '66 Malibu N/SA
 

Really enjoying this build! Thank you for doing such a fine job of detailing everything. I also have a 66 and your build is making me consider going a different direction with it. Thank you again and keep up the good work!

Re: '66 Malibu N/SA
 

The nylon shims work fine. I had to raise my distributor up some after cutting the heads and intake and I think that I purchased a Mr.Gasket set.

Re: '66 Malibu N/SA
 

Along with my broken foot I seem to have gotten the flu--just as I had holiday and vacation time coming up! Fortunately I was able to have the vacation time converted to sick time, so I can get some work done on the car during a week in February.

But now I'm reasonably healthy and back out in the garage. Next thing up was an exhaust system so that I can start the engines at home without terrifying the neighbors. Here's what I came up with:

http://i.imgur.com/lGywHOM.jpg

It exits just in front of the slicks, and can double as street exhaust if I ever return the car to street duty:

http://i.imgur.com/uJZvoou.jpg

http://i.imgur.com/QTjTjdk.jpg

Next up is the driveshaft loop. Naturally if I locate the top of the loop in the spot that yields the most driveshaft clearance, it hits the under-floor cross member. So I reworked it to angle out and follow the edge of the cross member.

http://i.imgur.com/ieEh5mG.jpg

It fits in pretty nicely now. And it sure was nice to weld some thicker metal for once!

http://i.imgur.com/8ZHvOXX.jpg

And finally I put the driveshaft in, and yes! We have clearance!

http://i.imgur.com/bpxxdUw.jpg

Next weekend I only get one day in the garage, as Saturday is race #1 of the Summit series at Wild Horse, but Sunday I plan to start building the seat mounts.

Re: '66 Malibu N/SA
 

Nice work! I need to fabricate a loop myself...thinking of welding something to the crossmember to keep from drilling any more holes.

Re: '66 Malibu N/SA
 

Too much going on this weekend to spend more than a morning out in the garage, but I got a start on building the seat mounts. I'm starting with the right side so any mistakes won't matter as much. It's slow going in part because I'm making this up as I go along.

I'm starting out by getting myself a reasonably flat, level surface to work with

http://i.imgur.com/wgSMXPE.jpg

http://i.imgur.com/uyirMCL.jpg

From here I'm thinking of using 2" channel to go from the base I just made to the bottom of the seat. That'll have the bottom of the seat about 3" off the floor. From sitting there on about 3" of lumber with my helmet on, it seems like a reasonable height.

http://i.imgur.com/7QjZs2u.jpg

Next weekend I can work both days, and I hope to complete both mounts.

Re: '66 Malibu N/SA
 

I got most of the seat installation done this weekend, but not quite all. I wound up reworking the right-side brackets to stiffen them up. I shortened the one and added a vertical piece to each for strength.

http://i.imgur.com/lw85XKA.jpg

Here is the right side mocked up. I wound up moving it to the rear before finalizing it. That side is done once the paint dries on the brackets; that didn't quite happen in time to finish the install today.

http://i.imgur.com/jkKKIRu.jpg

The left side is mostly set up now, though the inside bracket still needs to be strengthened a bit more. Once I get that done I'll be ready to sit in it to determine if I have the location correct. I will also add additional bracing to the front of the seat down to the bracket so it'll be much more rigid than it is here.

http://i.imgur.com/TliuiFU.jpg

Re: '66 Malibu N/SA
 

If you don't put a brace from the seat back to the floor you will be on you back staring at the headliner the first time it hooks and leaves....Usually the seat back is connected to the roll bar cross bar behind the seat....

Just sayin'

Re: '66 Malibu N/SA
 

I have those seats in my 68 Mustang Coupe which has a really difficult floor to fit too.

You do need to add more bracing to that, you don't really have much contact area. The brackets Kirkey and others make for this seat bolt to the side of it and run from front to back about 12 inches. I would at least weld cross pieces to your brackets front and back to join them into a single unit.

You will need a back brace connected to a cross member of the roll bar behind the seat.

My seat mount is constructed from 2X3 aluminum channel and a sheet of 3/16 T6 aluminum to form an elevated platform bolted to the floor in 6 places. The seat is on Kirkey brackets bolted to this platform. I can't weld aluminum but with lock washers is seems very solid. The back brace is the one Kirkey makes. It bolts to clamps around the cross member of the cage. It's out of the car now so I can't post a pic.

Not to run on, but it's a safety thing.

EDIT: I reread your captions and edited this post. You recognize the need to strengthen the brackets.

Re: '66 Malibu N/SA
 

I'll second that...I would want some type of brace on that aluminum seat back. With a suitable brace bolted in place that would give a place to mount a good over the shoulder belt restraint system. Another perk is you are exempt from the current 2-year re-certification rule for belts. ;) Heck, I'll send you a expired set of ours for the price of shipping. I would not install a roll bar if I had plans to return it to the street someday.