'68 GTO resto... Mad Max meets Pro-Tour - Page 2 - Pontiac GTO Forum
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post #11 of 118 (permalink) Old 05-11-2018, 10:12 AM Thread Starter
 
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The old cliche... If I knew then, when I first built this engine, what I know now I would certainly have stroked it. I couldn't agree more about bang for your buck. That will have to wait until the next complete engine overhaul. My problem with the cam was a few things. One, I never checked the piston clearance. I thought... well they built this engine with all of these parts and didn't have an issue... why should I...

So I built an awesome first engine. It idled terribly and always shot a 3' flame out of the carb... I had timing issues not to mention, I built a dyno engine. It was not street friendly at all. Wide open it was bad a$$ but that's about it. Little did I know what the timing culprit was... So fast forward from 2004 to 2016 when i bought a house and decided to finally rip into her and start figuring out how bad they rust was. It wasn't too bad come to find out but I still don't know why i tore into her so deeply knowing well enough that my wife at the time wouldn't let me buy a body bushing kit let alone pay to remediate the rust or fix what i found in the engine....

We'll start with the engine...

So I had a nagging oil leak in the oil pan and the rear main so I had to pull the engine to get to them. I also had a small coolant leak around the timing chain cover so i begrudgingly pulled that off, fortunately I pulled it that is... I was running an Edelbrock timing gear set, loved it but not worth the price. The second i pulled the cover the bold securing the gear to the cam fell to the ground and so did my stomach...
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Last edited by curtis.smith68; 05-12-2018 at 10:00 PM.
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post #12 of 118 (permalink) Old 05-11-2018, 11:53 AM Thread Starter
 
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Turns out by inspecting the markings on the bolt head... somehow I installed a metric bolt. Sure it torqued up but obviously it was cross threaded and worked itself out. If I had been using a normal timing chain my engine would have been trashed... Those large pins on the idler gears were actually making contact with the inside of the cover and holding everything in place, the fuel pump cam was too. The large gear key way slot was beaten open pretty good so that slop was where my inconsistent timing issues were coming from. Knowing i had to replace the cam now as the inside was polished smooth where that bolt was banging around, I went ahead and pulled the heads... The discoveries kept coming...

Every piston looked like the attached.

The exhaust valve was making contact but not much. The pistons are aluminum and quite soft. It was only the sharp edge of the valve relief they were hitting and after pulling the valves and inspecting them, they turned out to be perfect and true. I was so damn lucky... I went ahead and cleaned the pistons up by gently hitting them with a carbide bit. Dishing them slightly on the exhaust side.

Since I knew this car wasn't going anywhere for a long time, because of a lack of being able to spend... I went full bore and ripped her apart....



That one with the front end completely torn apart is what she looked like when I moved out... Not even a rolling chase... So the house was being sold and I had to act fast to get her rolling again. I said screw it and did what I want for once. I had enough saved up to get her to Stage 2 as Stage 3 suspension was only a pipe dream so I pulled the trigger on upgraded brakes as this is what the original ones looked like...
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Last edited by curtis.smith68; 05-12-2018 at 10:09 PM.
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post #13 of 118 (permalink) Old 05-11-2018, 11:55 AM Thread Starter
 
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ugly...

I went with an awesome Willwood setup and a Stage 2 suspension kit from BMR and a beefy steering linkage kit from Proforged Steering Rebuild Kit..... I also didn't have time or space to do a full frame off so i cleaned up the front half and re painted...

Degreased, wire brushed and metal etched...

[IMG]02D0AE89-850D-43B6-B665-F4A2B79384F5 by paradox_69_666, on Flickr[/IMG]

Primed with Rustoleum's rusty metal red oxide primer

[IMG]0F032EAE-5298-4A38-B26E-F0A1008C23B5 by paradox_69_666, on Flickr[/IMG]

Painted with the help of my boy. We have a great connection and he loves helping on this project. I don't push him so it never seems like a chore to him. I always let him and encourage him to help as much or as little as he wants

[IMG]970BAD8E-A70A-4EE5-8FFC-0904ED011E88 by paradox_69_666, on Flickr[/IMG]

The finished product...

[IMG]CE92327F-7A76-4F07-8F89-31552BC612D4 by paradox_69_666, on Flickr[/IMG]

[IMG]6CFC05E8-4CE8-4628-9709-982A244E15FD by paradox_69_666, on Flickr[/IMG]

Huge difference in the steering components. They are freakin amazing!

[IMG]628015E2-FB43-423B-8012-77F610B2304E by paradox_69_666, on Flickr[/IMG]

[IMG]C167CAD0-E5BA-4582-B930-AB2F3772EBF0 by paradox_69_666, on Flickr[/IMG]

Last edited by curtis.smith68; 05-11-2018 at 12:11 PM.
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post #14 of 118 (permalink) Old 05-11-2018, 11:56 AM Thread Starter
 
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The brakes and my 2" drop spindles by CPP and the stage 2 BMR suspension package with Bilstein shocks and 1" lowering springs... I may have a ride height issue but we'll see. Everything went together very nicely. I have an issue with the bump stop fr the upper A-arm as it doesn't make contact with anything.... I'll have to address this once the care comes back from the body shop...

[IMG]52F617F3-37B0-475F-A00C-041E824A5932 by paradox_69_666, on Flickr[/IMG]

[IMG]813CA9FF-3DF1-41A6-9B5E-4A5EC99B9549 by paradox_69_666, on Flickr[/IMG]

[IMG]77E690B5-D5C4-4EBD-B4F7-9CA01307975A by paradox_69_666, on Flickr[/IMG]

[IMG]9C62869D-E164-4BB8-A149-E22E7E5DE3C3 by paradox_69_666, on Flickr[/IMG]

Ignore the Christmas colors on the engine... LOL!!!

The sway bar is an absolute beast!!

[IMG]0113E9B4-A91C-45F1-BEB5-6BF01FEE5ADA by paradox_69_666, on Flickr[/IMG]

This is one of many piles of parts awaiting the arrival of the car. Complete wire harness, radiator and fans, Wilwood MC and on and on.... I also have the rear of the suspension to install from that kit....

[IMG]B9C13665-FF9C-4DDD-B94A-C6FF74606E4E by paradox_69_666, on Flickr[/IMG]

There are many things that will need to wait... First I still need a carb, I'm thinking a 750 Quick Fuel with Annular secondaries.... I also need wheels and tires so between those three I'm looking at another $1700-1900... I want to rebuild the rear end and install disks in the rear as well but I can at least get her running for now as I don't want the engine to sit another year without running. The last time i opened it there was surface rust on the cylinder walls... I also would like to be able to listen to music but luxuries like that will have to wait for sure!!

Stay tuned.... more to come on where the body stands now.... I'm going to the shop tomorrow to deliver the rear window I took out and to take pictures. They are taking care of the last rust spot and will be shooting primer today maybe... I don't want it to sit primed for too long either so I will need to get it ready for final paint which will be a satin black. Not a flat matte black but one that has just a touch of shine also all of the trim will be blacked out including the rear bumper... this is an example of what I'm after...

[IMG]inspiration by paradox_69_666, on Flickr[/IMG]

[IMG]perfect if they were hoosiers by paradox_69_666, on Flickr[/IMG]

I also just picked up a set of valve covers from Butler Performance and let me tell you..... WOW!!!!! They are beautiful and worth every penny... Also I installed their billet valley pan. I'm not sure on it's seal but we'll see.....

[IMG]covers by paradox_69_666, on Flickr[/IMG]

More on the engine specs and components later.....

OPGI has had the steering box I want on back order since March and it looks like I won't get until July.... Ugh...

Last edited by curtis.smith68; 05-14-2018 at 10:13 AM.
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post #15 of 118 (permalink) Old 05-11-2018, 11:57 AM Thread Starter
 
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aaaaaannnnddddd..... It looks like Photobucket doesn't like to play for free so I will be editing those posts as soon as I find a site that will allow 3rd party hosting for free... I'm not paying them $400/year to do that
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post #16 of 118 (permalink) Old 05-14-2018, 10:31 AM Thread Starter
 
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So the green is gone on the engine... It would have looked awesome but with the red suspension it looked way too much like Christmas.....

I didn't want to completely tare the block apart again just to paint so I went ahead and masked off the heads best I could because the method I chose to use is dangerous with respect to the aluminum heads. I bought two cans of Easy-Off oven cleaner and went to town. First I tried it out on an inconspicuous spot in the rear of the engine that would be covered by the bell-housing. Since the engine is cold steel i needed to let the stuff soak for a couple hours covered so it didn't dry out too quickly. This stuff worked like a champ!
You really need to be extra careful using it but if you are, it is worth the effort. The old coating came right off and this stuff will draw out all the grease and oil from the pores of the cast block. I also used an aircraft paint stripper on the timing cover as I didn't want to use this stuff on that cover as it's cast aluminum...

These are some of the pictures during the stripping process... I'll upload more of the bare block tomorrow night. I also applied te first of three steps of the KBS engine coating system. I used a diluted solution of KBS Clean and let that soak for about 20 min before rinsing off. Tomorrow I will be applying the KBS Rust Blocker which is a metal etch and rust converter to prime the surfaces for the final KBS engine seal coating, black...

After one application of the oven cleaner...

[IMG]09E3A358-5368-4D5A-A5A5-D60362A3ED4F by paradox_69_666, on Flickr[/IMG]

The process...

[IMG]IMG-2448 by paradox_69_666, on Flickr[/IMG]

[IMG]IMG-2449 by paradox_69_666, on Flickr[/IMG]

[IMG]IMG-2450 by paradox_69_666, on Flickr[/IMG]

[IMG]IMG-2451 by paradox_69_666, on Flickr[/IMG]

[IMG]IMG-2452 by paradox_69_666, on Flickr[/IMG]

Stay tuned.... The body is coming back from the shop later this week! Glass is going back in now!!!
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post #17 of 118 (permalink) Old 05-15-2018, 06:31 AM Thread Starter
 
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Let’s rewind to the body......

There’s nothing like trying to do a full restoration around a divorce and moving twice... so I assembled the front suspension and mounted the engine to make moving the car into storage easier. While living in an apartment and the car was in a self storage unit, wadded up in there nicely, I began my search for a shop. Maybe I could’ve found one more cost effective, maybe I could’ve found one closer to home.... I am in the Syracuse area and I know there are many shops around here. Word of mouth is huge for this part and I don’t know anyone around here.

I’m originally from California and since I moved around so damn much within NY over the past few years I’ve never had the chance to really get to know many car guys to reference a good shop. I relied on google. I found a few shops here and there until I stumbled upon B&B Automotive in Newark Valley. It’s about two hours from me and in the middle of nowhere.

I met the owner at my storage unit and got an estimate. The usuals were shot whith my baby. Trunk filler panel, 2/3 of the lower trunk pan, package tray was a little rough but salvageable, a couple rough spots on the fender dog legs, a couple rough spots around the rear wheel wells and richer panel areas and annoyingly the roof....

Since my budget isn’t limitless and I want to drive this thing again in my lifetime I decided to only take care of the rott. There are a couple other cosmetic issues but that can wait. The quarters took a hit at some point and they were hammered out but are still bumpy so those could be changed. I’d like to box in the frame but that can wait too. The floors, cowle, firewall and everything else is in excellent shape. The roof was trashed because it was a vinyl top and had gotten really bad inder it. The previous owner wirewheeled it as best he could given there wasn’t anything left in some spots back in ‘99, before the reproduction roof was being made. The he applied a DIY rhino liner to it. Looked cool but it made things so much worse. It absorbed moisture and was horrible getting off....

So B&B Automotive took my car in early December and couldn’t start working on it until mid April. She’s coming home this week!!! First the took some of the rhino liner off the roof to evaluate its condition. There were holes as bid as my fist.

[IMG]Untitled by paradox_69_666, on Flickr[/IMG]

[IMG]Untitled by paradox_69_666, on Flickr[/IMG]

[IMG]Untitled by paradox_69_666, on Flickr[/IMG]

[IMG]B4AB2223-7663-4382-A430-059CE5B44DC3 by paradox_69_666, on Flickr[/IMG]

So a new roof was in order.

The rear window ledge was really bad along the bottom and half way up the sides.....

[IMG]DDE18BDC-4671-4FEC-99EF-9ED1C370159E by paradox_69_666, on Flickr[/IMG]

[IMG]2B0C32D1-CC2A-4050-A1DB-E618EE309CCD by paradox_69_666, on Flickr[/IMG]

[IMG]DD8E79B6-3DFF-4822-9054-A97BEBBDD064 by paradox_69_666, on Flickr[/IMG]

[IMG]14E118FA-CDB2-4947-8ACC-29C12D9F762B by paradox_69_666, on Flickr[/IMG]

I also thought the package tray would need to be replaced but it will be covered and only had a few holes. Nothing a little rust inhibitor wouldn’t handle.

[IMG]7F5A559D-5691-4837-B079-D1C173D2052D by paradox_69_666, on Flickr[/IMG]

[IMG]72A1748D-4AA3-4569-9332-C879FAAAC7B2 by paradox_69_666, on Flickr[/IMG]

Stay tuned.... tare down continues to the roof next.

Last edited by curtis.smith68; 05-15-2018 at 08:53 AM.
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post #18 of 118 (permalink) Old 05-15-2018, 09:09 AM Thread Starter
 
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The roof came off and the structure under was in great shape. There was only mild surface rust but it was superficial and not structural at all.

[IMG]7F87776F-2D9A-4DC4-8EEC-EACC79E378A4 by paradox_69_666, on Flickr[/IMG]

[IMG]49883F56-A8B4-4A81-9ED6-D29BF8E1A8C6 by paradox_69_666, on Flickr[/IMG]

[IMG]B56F9882-B447-46D1-9C87-5925DB1941AA by paradox_69_666, on Flickr[/IMG]

[IMG]1D1DE2B9-D8EA-425F-9486-FFC501E51124 by paradox_69_666, on Flickr[/IMG]

The then 2/3 of the lower trunk pan came out and the rear window to trunk filler panel cam out...

[IMG]CDDA6155-3224-49F3-9B31-581D7A4E1A89 by paradox_69_666, on Flickr[/IMG]

The roof went in only a couple days after they took it off... They cleaned up the structure and epoxied it before the roof went back in...

[IMG]2F24D95D-022A-4B61-A2A4-2A158142AFC9 by paradox_69_666, on Flickr[/IMG]

[IMG]866842C5-9F9F-441C-A7C8-2FEA3812DEA4 by paradox_69_666, on Flickr[/IMG]

[IMG]887C3E95-540E-4344-895D-7253C2D5C662 by paradox_69_666, on Flickr[/IMG]

Shortly after that the filler panel went in and the trunk panels too... The trunk pictures will come later as I don't have them yet... then they assembled the fenders and bumper, which they mounted incorrectly at first but have since fixed and they epoxy primed the whole thing... and the glass went in yesterday. New windshield up front as they broke the original taking it out for the roof...

[IMG]34D19728-382C-45DA-9FA3-C284D366CDCB by paradox_69_666, on Flickr[/IMG]

[IMG]primed by paradox_69_666, on Flickr[/IMG]
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post #19 of 118 (permalink) Old 05-15-2018, 09:11 AM Thread Starter
 
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[IMG]Untitled by paradox_69_666, on Flickr[/IMG]

[IMG]Untitled by paradox_69_666, on Flickr[/IMG]

I'm waiting on word for delivery and also asked them to fill in that gaping hole for the antenna mount.

Much more to come... We're basically all caught up to date at a high level. Later on I'll go deeper into the component specifics in the engine, suspension and others...
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post #20 of 118 (permalink) Old 05-15-2018, 08:57 PM
 
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Ah, all the "usual"rot spots. So glad reproduction parts are available! Looks like they are doing so great work.

A few more matte black cars. The first pic is from a T-shirt company. I like it in that I was thinking it might be cool to go with a shiny black on the lower portions and a matte black on the upper portion separated by a brite thin custom strip, ala lime green outer layer, lemon yellow inner layer, & white center - sorta like the Judge colors.
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