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'69 Malibu 4-Door Project

R

Raoul Ross

Member
As promised, I'm gonna post-up what started out as one thing and hopefully end up a complete stock-ish restoration. I told the owner that I would only do it if we did it correctly, and he was good with that.

First, what started this whole thing. He told me he took his Malibu to a place that said they could lift his car 3 inches so he could put some big 4-WD tires on it. I don't know why, he likes the look but this is what he got back....!
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Simply astounding. He only paid them half what they wanted as they both agreed to a price (and the lack of a lawsuit) and it's sat in his garage ever since, 5 years now. Being my next door neighbor I was always ribbing him about it. Then a month ago somebody t-boned his pretty nice Chrysler 300 and admitted complete fault (Round-About) and the insurance company gave him $8k for it. Now he had the money to put it back the way he wanted originally and asked me to help.... and I threw up my hands and said 'Sure, Why Not!', like Frank Pentangeli in the GF Pt.II...heh.

They made some really nice frame supports and thankfully didn't weld the body to them, it's actually bolted to them...whew! So the first item of business was how to get the body off this.... THING! and onto a stock chassis. He says he knows how they did it originally, with a big fork lift and 8 inch wide straps and claims to know someone who can do it. As we've gone along he's quite serious about this project so I believe him. He still wants to lift the body 3 inches off the frame so he can get some big 4x4 tires under it but I'm trying to think of a way to deter him from that notion.... we'll see. Now onto the fun!
 
Did a bunch of research on another website and came up with some chassis specs. Come to find out, the 4-door and the El Camino share the same specs except the the EC has a boxed frame and a smaller kick-up at the back end
of the frame. Something we decided could be compensated for when designing the frame spacers. Not exactly sure how we're gonna make those yet, I was thinking of brazing some big washers together.

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Dang, couldn't type after the above pic. Anyway, he found an EC frame and had it trucked in Saturday. It all looked good until I found a nasty crack in the frame/lower control arm mount on the left side. He got back about half what he paid for it as, 1. He really like the idea of the stronger EC frame and 2. we are thinking (hoping) it can be repaired.
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As you can see, whatever it hit it was enough force to pull the pad down and it cracked all the way around. Gonna need some major clamp to pull that in enough to weld it!
 
Yeah, you can fix that crack, it's not that bad (I've fixed worse). Take your time and you can make it look brand new.
 
Pulled the rear end off the original chassis. You can see how mangled up the rear of it is, that's why we decided to find another frame and then disassembled the EC chassis.
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And that's where we're at now. Finding someone to weld that crack and then ordering parts... LOTSA PARTS! Gonna do the OEM disk brake conversion for the front, new control arms for the front, all new lines, etc.

He went to Iowa today and bought a freshly rebuilt 307 (~4k miles with papers) with a TH350 attached (short shaft). Didn't get to see it yet so no pix.

Thanx for looking! Hope you enjoy this!
 
Pretty ambitious project, but if it's about the fun of the project I'm a fan. It's one thing to get the frame repaired, it's another to get the datum points back and the alignment. Hope you have a frame rack available, that's the only way I'd attempt that repair. Personally, if you have another frame available or anything in the area, I'd go that route. 4 door frames were scrapped, not sold, so if you've got a chevelle buff that deals in parts cars in your area, maybe reach out??
 
Yea, this is definitely about the fun. I've never done a 'Frame-Off' restoration before and it's just so dang easy to do it this way!

From what I gathered from the above reference points and a tape measure it seems that we've lucked-out as far as straightness. The lower control arm took the major brunt of the impact, it was a bit twisted with just enough force to break that weld. There are a few guys left that have frame machines around if it comes to that. Looking for a chassis manual now.
 
Thanks for sharing. Let us know how the build goes. I’m always interested in seeing how people choose to restore their Chevelles.

This guy is just friend of yours? I can’t even get anyone in my family to pick up a wrench and this guy has you helping him restore a car. Lucky him.
 
I should say this too... this is in no way, shape or form gonna be any kind of show quality 'restoration'. I prob'ly shouldn't use that word. He wants it to be a daily driver and that's really all I'm doing with this... just making it a safe form of daily transportation that you don't see every day. It'll be clean but not shiny, old but not showy or Rat Rod. We haven't even talked about the interior or the paint as he seems happy with it the way it is. The gauges will work but there won't be a tach. Just a solid '69 Malibu... with 4x4 tires on it maybe! LOL!

EDIT: I kinda like the Z28 wheels on it actually, but we'll see.
 
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Got pix of the engine (with Stand!) and trans today. Came with stock air cleaner, alternator, starter and P/S pump too! Also picked up a used 1 ton engine hoist for $100.
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From this stamping on the rear axle tube it looks like a 3.08. Should work just fine with the TH350. Remember this was originally a 6 Cyl car.
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...and I think I've talked him out of the body lift after I explained all the problems it'll cause... Steering column, radiator hoses/trans cooler lines, shift linkage and fuel line to tank. YAY, lol

AND, ordered $2700 worth of parts today as well!
 
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Raoul Ross said:
...and I think I've talked him out of the body lift after I explained all the problems it'll cause... Steering column, radiator hoses/trans cooler lines, shift linkage and fuel line to tank. YAY, lol

AND, ordered $2700 worth of parts today as well!
Click to expand...

Good job ! :)
A bone stock pristine Chevelle is the way to go !
 
Well it appears we'll be looking for a 4 Door (Sedan) frame afterall.... don't know why I didn't see this before or why nobody else picked it up.

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While all the other dimensions work, the rear of the EC frame is 6 and a quarter inches longer.... DOH!

There's no way to chop that off and make it shorter as the frame tapers a bit after the second to the last mount.... Haven't actually eye-balled it yet, we'll see.
 
Sorry, I thought your having both the frames in your possession implied you knew the differences and it is a common mod is to chop off the car frame behind the rear hoop and exchange it for your elky frame rear legs.
 
I had a 69 4 door post car that I redid, was a fun project but after it I realized modifications were not for me.

I will post some pics.

There are differences between the 2 doors and 4 doors. I met a guy who tried to restore his 2 door using a 4 door, did not work out. Even the front fenders are different, a wagon is the closest to one. Unfortunately 4 door stuff is hard to find. In the past the "crew cab" or "more door" cars were called names and ignored but they are an important part of Chevelle history.

For frames, don't over look a BOP car.
 
Man that sucks. Can the original frame be used if you saw off those perches used to lift the body?
 
It appears there is a section that can be shortened the 6 1/4 " pretty easily.
Gonna talk with a local restorer tomorrow morning and see if we can get him to do it.

I've seen some of his work and it's really good. He's done a couple early 50s Studebaker pickups that are top notch.
 
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