'66 Le Mans...keeping the Pontiac Spirit alive

[PBarkley]

Well I figured I had done enough rambling in my intro thread, so here's a build thread to keep it all contained, haha.

As I said in my intro, my father and I had kicked around the idea of getting a project car to build together. Having already cut my automotive teeth in the import world (turbo/swapped Nissans, specifically) I wanted the challenge of a complete restoration.

Finding this '66 was by complete chance. Feb2013 I decided on a whim to see what they were going for on eBay, and lo and behold, there was one located in Acworth, GA. I called the owner, and arranged a time to inspect the car.

This is how it sat for the last 10 years:
http://img.photobucket.com/albums/v601/AFSil80/2_zps1e175091.jpg

Having spent a few years up north courtesy of the USAF, I crawled under the car to check for rust and I was pleased to see that it was minimal. The missing rear windshield and the metal in that area is the worst spot on the entire car...and it's going to be an easy fix. So I paid the man half of the money since I wasn't able to transport the car that day, he removed the eBay ad and I came back in 2 weeks to pick up the car, paid in full.

http://img.photobucket.com/albums/v601/AFSil80/IMAG0681_zps7568d76c.jpg

http://img.photobucket.com/albums/v601/AFSil80/IMAG0683_zps5fe500bf.jpg

The 240SX in the above picture has been my labor of love since 2004...and once I got started on my new project, I quickly lost interest in the car and sold it the following July.

Step one...remove the engine/trans. My hoist is showing it's age, and didn't want to pull both out at the same time. And yes, I know the torque converter is supposed to come off with the trans. Late night crunch, and it slipped my mind.
http://img.photobucket.com/albums/v601/AFSil80/IMAG0804_zpsf0651082.jpg

Within a few days, had the forward bodywork off the car, preparing to strip the frame and coat it.
http://img.photobucket.com/albums/v601/AFSil80/IMAG0824_zps87e564ee.jpg

http://img.photobucket.com/albums/v601/AFSil80/IMAG0830_zps1b2deb7c.jpg

Hard at it. I'm still young enough to pull transmissions out with the car on jackstands, so I have figured I might as well get in there with the wire wheel and get everything cleaned out.
http://img.photobucket.com/albums/v601/AFSil80/IMAG0007_zps8b687243.jpg

Everything coated from the firewall forward...
http://img.photobucket.com/albums/v601/AFSil80/IMAG0840_zpsfbebc1c9.jpg

BMR 2" drop springs w/ fresh Bilsteins ordered around Thanksgiving...prompt shipping, and I am definitely going to order more parts through them when the time comes.
http://img.photobucket.com/albums/v601/AFSil80/IMAG1031_zps7155d3f3.jpg

NOTE...all but ONE body mount came out without issue. I only had one mount that we had to cut the bolt. I consider myself EXTREMELY fortunate thus far with the car...we have not encountered any serious rust.
http://img.photobucket.com/albums/v601/AFSil80/IMAG1065_zps2654631e.jpg

Late night with the best friend...
http://img.photobucket.com/albums/v601/AFSil80/IMAG1066_zps9f6077cc.jpg

End result the next morning...
http://img.photobucket.com/albums/v601/AFSil80/IMAG1071_zpsf7f2ba4a.jpg

New fuel tank, sending unit and straps courtesy of Original Parts Group, Earl's lines and fittings (-6 feed) via the Summit store...that is only an hour from where the car is kept. ;)
http://img.photobucket.com/albums/v601/AFSil80/IMAG1182_zps012ad359.jpg
Since this car was a factory original A/C car, it came with a fuel return setup that we decided to keep in place.

New polyurethane bushings, just need to box the arms now.
http://img.photobucket.com/albums/v601/AFSil80/IMAG1239_zps9aa654d5.jpg

And that's basically where we are at right now...awaiting a few more pieces to arrive for the rear end, and I have yet to decide on what differential I'm going to toss in there. Once I have the rear end guts back in place, I can install the rear disc brakes and fab the new hardlines. Since I live in Savannah and the car stays at my parent's house in Central GA, I don't get to work on it as often as I'd like. However, once I have wrapped up this house purchase, the car will be relocating to Savannah so I can make some real progress.

Thanks for checking out the car, and I will make it a point to keep this thread updated regularly.

[Spiffav8]

Great build Peter! Looking forward to watching the progress.

:captain:

[Rick D]

Great build Peter! Llove the 66 Lemans!, what are the rest of the plans?

[PBarkley]

At this point, I still need to purchase the Kore3 C5 brake kit for the front, and the BMR sway bars. I did buy the factory GTO/Chevelle SS rear chassis braces that tie the upper and lower trailing arm attachment points together, and those are currently installed. Outside of that, I did the 85-88 Monte Carlo steering box, replaced all the suspension hardware (which was severely worn out) with Grade 8 nuts and bolts, and replaced all of the steering components, even the pitman arm. Basically the only remaining OEM parts on the front of the car are the control arms.

As for the engine/trans, it was originally an automatic and I plan to keep it that way since this is going to be a car that my dad will be driving more often than I do. We're keeping it Pontiac powered, and will likely back it up with a 700R4 trans. I have a cherry 400 block from a '73 Le Mans in addition to the original 326 and 2 speed auto that came with the car, and for now the plan is to build the 400 with forged pistons/rods and a roller cam. Still undecided on heads at this time. However, I will be putting nitrous (100-150 shot) to it, mostly just for kicks. I have no intentions of making the track a regular venue for this car. Just a fun street rod that can light up the tires if desired, but mostly aiming for driveability and reliability.

The garage was a bit of a mess in this picture, so excuse me for that haha. Here's the 400 block fresh from the machine shop after being magnafluxed and hot tanked, the 326 is on the tire.
http://img.photobucket.com/albums/v601/AFSil80/20140813_150755_zps42ccffc7.jpg

And here's one of my dad helping move and hold the rear end in position while I crawled under and got the bolts in place...
http://img.photobucket.com/albums/v601/AFSil80/IMAG1242_zpsc8a56163.jpg

My goal is to have the rest of the aforementioned chassis work done by spring.

[67goatman455]

lookin good! from what a chevelle friend told me, the BOP 10 bolts are about as strong as a chevy 12 bolt, so you might consider hanging onto it and tossing a limited slip differential in!

[PBarkley]

Right on! As for now I plan on retaining the stock housing and axles (until they fail), but I am probably going to go with an Auburn LSD, haven't decided what gear ratio just yet. Factory final drive is something like a 3.23 on these cars with the 2 speed, but if I'm stepping up to a 700R4 that could change things for what gearing the rear end requires.

I had a few more parts show up today and I'm itchin' to get up there and put some work in...but the house hunt comes first. :goofy:

[PBarkley]

Not a majorly huge update, but it appears that we (my wife and I, that is) are going to be homeowners soon...which prompted me to get the car back on the ground ASAP! I tossed the rear axles back in without the diff (gotta love the BOP axles...just bolt them to the brake assemblies and they're secure). I gotta have it ready to move since we close in less than 3 weeks!

If anyone reading this ever frequents Roebling Road Raceway outside of Savannah, GA...you better lemme know if you're in town! I'm going to be living very close to the track! :woot:

Also, snatched this up from a close friend...
http://img.photobucket.com/albums/v601/AFSil80/IMG_20141013_222248_zpsa638c365.jpg

Brand new, never been installed...and for a third of the regular price.

[PBarkley]

Well, I've been busy...but not exactly with the car.

Finally bought a home! The car hasn't moved down here with me yet, but in due time...gotta get a handle on the yard and other things first.

http://img.photobucket.com/albums/v601/AFSil80/20141109_140351_zps11907df8.jpg

Now for the cool part...I have a constant source of motivation:

http://img.photobucket.com/albums/v601/AFSil80/SatelliteShot_zpse1697bdf.jpg

Yes...this is a screenshot of Google Earth as it overlooks Roebling Road Raceway. However, my house is also in this same screenshot. If you think the UPS guy showing up at your house is exciting, you have no idea how it feels when you're in the garage as you hear a Daytona Prototype banging through the gears during a private test day on the other side of the treeline.

Best of all, my wife actually thinks its cool.

[77LT]

Welcome to Savannah, GA, I live here as well. I know a guy that lives adjacent track as well and has a super cool 1950 Studebaker Champion street rod. You know the one with bullet nose. Enjoy the Pontiac and the warm weather! :D
Todd

[PBarkley]

^ I appreciate it! I'd be interested to see the Studebaker!

[PBarkley]

I almost feel bad crawling back here to do an update since it's been so long...once spring semester rolled around, it's been non-stop for me between yardwork, married life, school, work, and the car.

I honestly forgot where I left off, so I'll try to pick back up at a reasonable spot.

Finally got around to trimming the inner fenders on the car so the 275's fit, I'm sure it'll have to get a little more taken off since the rear end may have some lateral sway, but I'll cross that bridge when I get to it. For now, I just wanted to get the tires clear.
http://img.photobucket.com/albums/v601/AFSil80/20150331_211052_zpswjufupgj.jpg

This pic really makes me rethink having 17's all the way around...kinda leaning towards 18's out back with a taller tire, but I'll wait until the engine is in the car with the front fenders on before I make my final judgement.
http://img.photobucket.com/albums/v601/AFSil80/20150331_232120_zpsabdf0e3j.jpg

Ordered a bulk amount of loom clamps from Del City. I doubt I'll use them all in this build, but I still want them for the next car, regardless of what it is.
http://img.photobucket.com/albums/v601/AFSil80/20150408_213556_zpsqgnzyazb.jpg

Terminal stack-up similar to how we assemble them in the aerospace industry...
http://img.photobucket.com/albums/v601/AFSil80/20150409_092633_zpsfnb2y2wm.jpg

Fuel feed(-6AN) and return (-4AN), more on that in the next pic...
http://img.photobucket.com/albums/v601/AFSil80/20150409_102404_zpsm0zehz0u.jpg

Nicely tucked into the frame rail, third clamp is for the brake line. For now, I'm going with a -6AN feed since I'm rebuilding the 326 to go back into it. When I finish the 400, I'll probably be stepping up to a -10AN feed, and at that point I'll go hardline on the fuel feed which will be an almost identical outside diameter to the stainless braided line. Fuel return will likely stay at -4AN.
http://img.photobucket.com/albums/v601/AFSil80/20150409_164639_zpspocryepr.jpg

Striking a pose before the engine teardown began...and to give y'all a sense of how small of a garage I'm building this thing in, haha.
http://img.photobucket.com/albums/v601/AFSil80/20150305_162832_zpsf7gt996r.jpg

The only real victim of the 326 teardown...front timing cover. Corroded from the inside-out, took a 5 lb sledgehammer to get it off since the bolt was spinning, but corroded to the housing. If I could've gotten the crank out, I would've just spun the entire timing cover off, but that wasn't gonna happen, so I had to get violent on it.
http://img.photobucket.com/albums/v601/AFSil80/20150308_232000_zpsizolwqdr.jpg

I took all of the engine parts to Simon's Balancing & Machine in Charleston, SC. My Uncle Pete trusted them with all of his engine work before I was even born, so they were the ones who got my business, and will continue to. Boss Dawg inspecting everything on it's return from machining...
http://img.photobucket.com/albums/v601/AFSil80/20150603_185856_zpso79azjii.jpg

Turns out the 326 had already been rebuilt once 0.040" over, and it unfortunately had some inconsistencies and I had to step it up to 0.060". At this point, CID is 336 and it has a nearly square bore x stroke. 3.750 stroke and 3.800 bore.
http://img.photobucket.com/albums/v601/AFSil80/20150603_185917_zpsj9ag2dlc.jpg

Connecting rods were inspected and deemed worthy of being re-used, fresh OEM spec slugs and pins with ARP rod bolts.
http://img.photobucket.com/albums/v601/AFSil80/20150603_190424_zpszkqdc3he.jpg

Luckily the crank came out not needing any major work. Polishing on the main journals and the rod journals had to be ground to 0.030" under.
http://img.photobucket.com/albums/v601/AFSil80/20150603_190826_zpssndwdyjh.jpg

Went through and checked all my clearances, everything came out to an acceptable spec. Rod journals were a little tighter than I'd like them to be for a street engine, but the mains were spot on. But, she turns smooth and consistently which is the important thing. Boss Dawg making sure I'm working hard...
http://img.photobucket.com/albums/v601/AFSil80/20150806_143336_zps5hzgg7jl.jpg

Rotating assembly complete with camshaft and timing set installed...
http://img.photobucket.com/albums/v601/AFSil80/20150810_144926_zpsencfkgms.jpg

Speaking of the camshaft...I probably went a little more aggressive than I should have, but since it's a 326 it was never going to be fast so it might as well at least sound like it goes fast, haha.
http://img.photobucket.com/albums/v601/AFSil80/20150505_171544_zpsplyiyhcw.jpg

Continued in the next post...

[PBarkley]

Ditched the 8.5:1 comp #92 heads and went with some #46 62cc heads that my friend had leftover from his Poncho build that never took off. From my understanding, these should raise compression to 10.0:1. The only downside to these heads are the pressed in rocker studs...I've got a set of threaded studs on standby, but I'm honestly not sure if I'm gonna need them right now. I plan on keeping the factory rocker ratio.
http://img.photobucket.com/albums/v601/AFSil80/20150812_123247_zpssmiishfp.jpg

Dual valvesprings, fresh parts all around.
http://img.photobucket.com/albums/v601/AFSil80/20150812_123225_zpsa0unhxfs.jpg

So for now, the short block will be the original 326, and the top end and front of the engine will be updated to factory '69+ 400 standards. I'll be using an OEM 400/455 4 barrel manifold with a 750cfm Quadrajet. I'm saving the Edelbrock manifold for the 400 build later on.

Which brings us to the transmission...originally planned on going with a 700R4, but I had a co-worker basically give me a Pontiac TH350 from a Firebird. Turns out it was in fantastic shape, but as with everything else on this car, I wanted to go through it to make sure it was going to be safe to operate.

Mid-teardown...
http://img.photobucket.com/albums/v601/AFSil80/20150519_193648_zpssvku8yq0.jpg

http://img.photobucket.com/albums/v601/AFSil80/20150519_213417_zps8gv4tshg.jpg

And awhile later, after everything was completely cleaned, fresh frictions and shift kit installed, all reassembled and ready to go (aside from paint, haha.)
http://img.photobucket.com/albums/v601/AFSil80/20150708_212924_zpstzro3duh.jpg

*WHEW* I think that brings me up to speed on updating this thread...like I said in the last post, once we moved in it was non-stop around here. I've basically been watching the UPS guy drop off boxes and then they get moved to the garage and sit until I had a block of time to knock it all out. But, having the parts at the machine shop while I was in school was a great move on my part, and when the spring and summer semesters were over, I had about a month to put EVERYTHING together, and I somehow made it happen. Unfortunately, fall semester starts on Monday so I'm sure it'll be awhile before I get to work on it again. :underchair:

[WSSix]

Looking good, Peter. Good luck with the car and the coming semester.

[PBarkley]

Looking good, Peter. Good luck with the car and the coming semester.

Thanks, Trey. I'm definitely gonna be busy, but it'll just mean more parts hoarding in the meantime, haha.

[Justin@EntropyRad]

Will be watching where it goes..is that an S13 in your avatar?

[PBarkley]

Will be watching where it goes..is that an S13 in your avatar?

Yup...my old 240SX.

http://img.photobucket.com/albums/v601/AFSil80/BecauseRaceCar.jpg

'91 model, swapped in a CA18 that had a Forced Performance 20G hybrid turbo and some headwork. She wasn't the most polished 240 out there, but she was very well rounded. I still miss it at times...it was good for harassing most of the Mustangs and Camaros I came across on the street, haha.

Also, I might be shooting you a PM around the time I get the engine back in the LeMans. I think I saw you posting somewhere on YB.com and I checked out y'all's website, and I'm definitely gonna need a new radiator for the car.

[PBarkley]

Another quick update during my Thanksgiving break...finals are next week, and then I've got plenty of work to catch up on with the car.

Had to chase out several holes for the ARP head studs, but they went in smoothly and everything is torqued down with fresh Cometic MLS gaskets. Also got the timing cover, water pump and backing plate installed, and went ahead and threw on the fuel pump and harmonic balancer.

http://img.photobucket.com/albums/v601/AFSil80/20151015_192135_zpsqsb1xv9e.jpg

http://img.photobucket.com/albums/v601/AFSil80/20151015_224251_zpsmhhnw6b1.jpg

http://img.photobucket.com/albums/v601/AFSil80/20151124_194934_zpsogfcsq2s.jpg

Also picked up the headers, ended up going with Doug's full length ceramics.

http://img.photobucket.com/albums/v601/AFSil80/20151014_200024_zps6rjtpmgq.jpg

Rockers arrived the day before Thanksgiving, had my pushrod checker waiting on standby and verified the lengths for the new pushrods immediately. I'm still waiting on my guy to finish with the carb rebuild, and I've also gotta source the hardware to install the oil pump and the windage tray before I can throw the pan back on. The goal is to get the engine broken in on the engine dyno, mated to the transmission and in the car before I go back school on 15Jan.

I hope everyone had an enjoyable Thanksgiving, and I hope the space under y'all's Christmas trees is overflowing with new parts, haha.

[Panteracer]

Peter,
Good to see another Pontiac with a Poncho motor

Bob

[Gscherer78ta]

Did you check those chambers for Volume? The info I have and the chambers I measured on my #46 heads says they are 73cc chambers and when I checked them I got 72cc. Mine had press in rockers as well which I drilled and taped for screw in and I enlarged the exhaust valve to 1.77 on my 400 build.

[PBarkley]

Did you check those chambers for Volume? The info I have and the chambers I measured on my #46 heads says they are 73cc chambers and when I checked them I got 72cc. Mine had press in rockers as well which I drilled and taped for screw in and I enlarged the exhaust valve to 1.77 on my 400 build.

I didn't do any sort of fluid measurement like you suggested...I went by the chart on Wallace Racing, my date code indicated that they came off a 1969 400, and it didn't give a chamber volume. It simply said 10.0 CR, and my valve size matches what the chart indicated. Leap of faith in hindsight, but all sources I had recommended using the charts from Wallace.

[PBarkley]

Peter,
Good to see another Pontiac with a Poncho motor

Bob

Sorry I missed this the other day, haha.

I've caught flak from a number of people saying "just go LSx blah blah blah" but I think that would kinda ruin the point of the car.

Hell, I'll go with an IAII block before I go LS in this car. :G-Dub:

[PBarkley]

Digging this thread back up, as it has proven to be a valuable way to track the history on this build haha.

So...2015 was my last update, and here we are in 2022. I left the Savannah area in 2016 and returned to the Atlanta area and this project slowed to a crawl until I was able to buy our current house in 2017. While I'm no longer adjacent to a fantastic race track, I do have a dedicated workspace for the car as the house has a basement with a drive-in garage in addition to our upstairs garage! It has proven to be a nice adjustment over the previous cramped garage, but ultimately I will still want to have a standalone building for the shop.

Anyway! Updates!

- The car runs and drives!
- I've nearly completed an entire re-wire of the car (not a hard task, but was absolutely necessary as the original wiring was desperately needing replaced)
- Rear end is factory posi trac unit with 3.55 gears
- Front and rear windshield pans have been replaced
- VintageAir setup nearly complete, I just need to charge the A/C system. Heater system has already been leak checked and pressurized up to operating temp
- Still need to buy BMR sway bars :lol:

Hoping to have the last few mechanical kinks worked out in the next few weeks and then I will be taking the car down to my parents in Central GA in anticipation of getting it painted, and then begins the fun task of putting the interior back together!

[camcojb]

Thanks for the update. Post some pics when you have time. :thumbsup:

[ScotI]

Thanks for the update. Post some pics when you have time. :thumbsup:

x2. Get some updated pics posted when you get the chance.

[WSSix]

It's fantastic that you're still making progress. Good luck with it.

[PBarkley]

Digging back into this thread...I had previously crossed my fingers about the press-in studs for the rockers.

Yeah. That didn't pan out.

I ended up pulling the heads back off, and Tommy Goza was kind enough to pull the press-fit studs, cut threads into the heads and installed new ARP threaded rocker studs. After that, I ended up modifying a set of factory pushrod guides to work with the setup and the engine no longer throws rockers or lifts rocker studs! Imagine that!

I have to go back and dig up pictures and get them hosted on photbucket, but here's a pic from awhile ago of the important parts, haha.

https://hosting.photobucket.com/images/v601/AFSil80/received_696564670824492.jpeg

[WSSix]

Goza built the bottom end of my 383 LT1. He did good work for me as far as I'm concerned. Glad you found him and his guys.

[PBarkley]

Goza built the bottom end of my 383 LT1. He did good work for me as far as I'm concerned. Glad you found him and his guys.

Agreed. He has a wealth of knowledge and there aren't many like him left so it was a no brainer. It's hard to find those guys that have the knowledge AND are fair on pricing!