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 Post Posted: Sun Jan 15, 2012 9:55 am 
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Very Nice Todd, and this Bue is coming along VERY NICELY! =D> \:D/ =; Great job.
Cool also to get some press where it is due. =D> =D> =D>

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 Post Posted: Thu Jan 19, 2012 8:56 pm 
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http://i676.photobucket.com/albums/vv124/10secBu/assembly67.jpg

So do they look any different? lol

Just got the front shocks back from Afco where they were revalved. They were originally BNC shocks, but had the rebound side updated to the Big Gun package. Needed more control as the rebound was maxed out and the car was still 18"+ on the bars (with 2 3/4" of extension travel).

Hoping this tweak will ultimately allow me to take the bars off for good. We'll see come spring.

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 Post Posted: Thu Jan 19, 2012 9:09 pm 
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Oh yea, I got started building a jig of the stock core support. It's almost done with two more holes to locate. Once that's done I'll be able to start fabricating the brackets & bending tubes for the new chromoly tube core support.

BTW, the original core support (swiss cheesed) weighed 23 lbs on the digital scales. My calculations show the tubular version should weigh around 8 lbs.

Will take some pics over the weekend and give a weight on the new tube version once it's done. Hope to make decent progress on the fabrication Sunday.

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 Post Posted: Sat Jan 21, 2012 12:44 pm 
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Momentous occasion here today.

After 14 months of rebuild time, the Malibu is back on it's feet once again!

http://i676.photobucket.com/albums/vv124/10secBu/assembly68.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly69.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly70.jpg

Back to the shop tomorrow to work more on the tubular core support.

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 Post Posted: Sat Jan 21, 2012 4:49 pm 
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An other step closer. =D> =D> =D> =D> Beautiful.

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 Post Posted: Sun Jan 22, 2012 5:02 pm 
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I worked today and got most of the tubular core support fabricated. I still need to mock up the fenders, hood & header panel to verify everything still fits as it should.

I also need to fabricate a bracket to hold the Star vacuum pump intake/exhaust tank. I'll also need to decide if I need to make a bracket for the coolant overflow canister as well.

Original core support, swiss cheesed down to 23 lbs.

http://i676.photobucket.com/albums/vv124/10secBu/assembly74.jpg

New chromoly tubular core support, 6 lbs.

http://i676.photobucket.com/albums/vv124/10secBu/assembly71.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly72.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly73.jpg

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 Post Posted: Sun Jan 22, 2012 9:43 pm 
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Mocked up the front end this evening. Fit seems good, little more flex than I'd like so I'll be watching that as I bolt the fenders down tight and if needed, I'll need to come up with some sort of bracing. I also plan to make come stand off's to provide bolt locations for some of the header panel bolt locations so I'm not relying on the end bolts under the turn lenses.

http://i676.photobucket.com/albums/vv124/10secBu/assembly75.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly76.jpg

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 Post Posted: Tue Jan 24, 2012 8:53 am 
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Todd,

Is that one of them there Sniper intakes??? :-k

John

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 Post Posted: Tue Jan 24, 2012 9:54 am 
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Elkyman wrote:
Todd,

Is that one of them there Sniper intakes??? :-k

John

No, it's the Brodix Head Hunter 2017.

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 Post Posted: Wed Jan 25, 2012 7:22 am 
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Last evening I got the core support flex corrected with some diagonal gusset tubes as well as a bracket to hold the vacuum pump canister.

Next up is some stand-offs to help hold the stock fiberglass header panel. Once that's done, off to chrome I suppose.

http://i676.photobucket.com/albums/vv124/10secBu/assembly77.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly78.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly79.jpg

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 Post Posted: Thu Jan 26, 2012 8:58 am 
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Todd that radiator support area looks killer and very user friendly now vs. the old stock one! =D> Great work as always.

I nominate Todd's car for Car of the Month for Feb. =; \:D/

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 Post Posted: Sat Jan 28, 2012 6:48 pm 
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Quite a frustrating day in the garage. I got the collectors/mufflers/turn downs mocked up and was ready to weld them together. Man, what a PITA. I've done alot of Tig welding the last couple years and these had me ready to throw them across the shop. Anyways, their done and I'll leave it at that. It's a good thing they will get recoated. ;)

http://i676.photobucket.com/albums/vv124/10secBu/assembly84.jpg

Next on the To-Do list was to make some mounts to secure the header panel to the core support. Went a little better, but still a meticulous time consuming process.

http://i676.photobucket.com/albums/vv124/10secBu/assembly80.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly81.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly82.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly83.jpg

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 Post Posted: Wed Feb 01, 2012 9:57 am 
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10secBu wrote:
Tried to have a productive weekend working on the car last evening and this afternoon. I wound up spending that time doing some rewire work on the power & ground cables.

Some of the professionals that saw the pics suggested I install a dedicated ground cable front to back in the car to attach all the ground circuits as the chromoly tubing & stock metal is not a sufficient ground plane.

Anyway, turned out to be quite a bit of work and was difficult to make the grounds look neat with as many connections there wound up being. Turned out alright I guess, but this case, form must follow function, so a properly grounded electrical system was more important than neatness.

The car previously had 1/0 power cable which I removed and replaced with 2 gauge cable and ran an identical size 2 gauge for the ground front to back.

In the passenger kick panel area I installed a pass-thru stud to allow me to ground the engine block & cylinder heads to the main ground cable. The block was tough to figure out since the diaper completely covers the block to the bottom of the heads. Passing from the frame to the block with the cable took some head scratching.

I also made up a harness leading up front to power the fan, head lights, parking lights and their respective ground circuits. I terminated that harness at the front of the frame rails with a 5 pin round Delphi weatherpak connector. I'll finish the rest of that once the tubular core support is built and I can install the front clip for the last time.

Other than the forward harness, the only other electrical components that need completing is connecting a couple data logger sensors to the engine.

Next project will be making a jig so I can then build the tubular chromoly core support.

http://i676.photobucket.com/albums/vv124/10secBu/assembly65.jpg

http://i676.photobucket.com/albums/vv124/10secBu/assembly66.jpg


On the ground cable pic is it going thru the firewall and then to the block and frame?
and did you ground everything to the ground lug in the interior

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 Post Posted: Sun Feb 05, 2012 12:47 pm 
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Worked this morning in the garage correcting an issue that came up.

The seat covers came this week, so I installed them, sat in the car and put my helmet on. The headroom was not what I was looking for. It was a bit tight and once I put padding on the upper bars it was gonna get worse. Also, the seat position vs steering wheel location and gauge display location had the top of the steering wheel blocking my view of the top half of the tach. This bothered me from day one, but everything was pretty much mounted where it needed to go.

Well, this morning I decided to lower the seats by cutting down the seat brackets. A couple hours worth of work allowed me to drop the seats 1" which is about all I could get out of them.

Everything back in place and the headroom is much improved, and gauge display visibility is noticeably improved as well. Not perfect, but better and I think I can live with it now.

Will have to take the seat brackets for blasting and then have them powder coated again.

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 Post Posted: Sun Feb 05, 2012 6:35 pm 
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Thought I would share this one pic quick to show how the interior colors will work out.

http://i676.photobucket.com/albums/vv124/10secBu/assembly85.jpg

Rear plastic interior panels will be reinstalled and are black. Carpet will be black as well as the 5 point harness. The window net is silver as it was the only color webbing they had in stock when I was doing the fabrication phase. The door panels will be carbon fiber and the dash will be painted black.

Just trying to have a little contrast in the interior as it was all black prior.

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