1977 Chevelle Malibu Classic Progress Photo's aka Mali
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G3GM :: Media :: G3 Project Pictures
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1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Tue Jul 26, 2011 7:29 pm
I picked up Mali last November up in NH. Found her on craigslist after hunting for over 2 years on every type of internet site available for classic cars. I new she was the one because she was solid, about 97% complete and most importantly, we could afford her! This project has been not only a reconnect with classic cars (that I've always loved) but restoring a car, to me, is the best therapy money can buy. Everyone needs a hobby to escape the day to day grind and old Mali has given me a chance to step out of my comfort zone and take on a different challenge. I will be posting progress pics here in the future for various things but I wanted to start with one of the first major challenges: Removal of 2 vinyl tops and the subsequent repair and restoration of the roof and surrounding body areas. All in all, I was pretty lucky there was no real "cancer" eating away at her. Another year out in the elements and it might have been a different story. Those studs are all ground down. She will not be getting a new vinyl roof covering.
Here you can see the 30+ year old adhesive residue and the two tops. Look close cause the old "saddle" colored one looks like the adhesive!
It's funny that the cleanest part of the roof was the center-line where the original top was stitched in the middle and where no adhesive was used!
The "After"...1st coat was today...will wet sand and put on another coat of primer (Maybe 2 depending on how the wet sanding goes).
Here you can see the 30+ year old adhesive residue and the two tops. Look close cause the old "saddle" colored one looks like the adhesive!
It's funny that the cleanest part of the roof was the center-line where the original top was stitched in the middle and where no adhesive was used!
The "After"...1st coat was today...will wet sand and put on another coat of primer (Maybe 2 depending on how the wet sanding goes).
Last edited by 77mali on Wed Jul 27, 2011 6:41 pm; edited 3 times in total (Reason for editing : added pic)
77mali- Donating Member
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by JB2wheeler Tue Jul 26, 2011 8:42 pm
Keep up the good work. JB
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by Limey SE Tue Jul 26, 2011 8:58 pm
very nice buddy looks good so far, are you two toning it ??
___________________________________________
1977 Chevelle SE x2
One Mild original
one Wild NON original
Anthony
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Tue Jul 26, 2011 9:50 pm
Thanks guys. Not sure of scheme yet...still pondering. Moving right back into the interior now which is another story. I spent the winter doing this to the interior did a boat load of other "little-stuff" too...
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by HDHugger Tue Jul 26, 2011 10:57 pm
Looks a lot like my interior during periods of the past 2 summers. I am still hoping to have time to get mine together and drive it some before the snow flies!
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by orange Juiced Tue Jul 26, 2011 11:26 pm
Looking good, keep it up
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by Fishgrinder Thu Jul 28, 2011 2:45 pm
Great log, can't wait to see the progress!
Just a question: Why would you wet sand the primer if you're putting one more coat? I would just do 220 or 320 on a longblock.
Just a question: Why would you wet sand the primer if you're putting one more coat? I would just do 220 or 320 on a longblock.
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Thu Jul 28, 2011 7:40 pm
Fishgrinder wrote:Great log, can't wait to see the progress!
Just a question: Why would you wet sand the primer if you're putting one more coat? I would just do 220 or 320 on a longblock.
At this point 320 is too rough and would take off too much of the primer...there are some small imperfections still that will need wet sanding to blend into the first coat but they are small and can be done with 500/600 grit. This 1st coat was basically protect all the work from the elements too as the car is not in a garage....a blankie...tarp & weatherproof cover on it...LOL.
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by Fishgrinder Fri Jul 29, 2011 3:58 am
Ah, then I see 
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Sat Aug 13, 2011 8:22 pm
More body work today using Por15 (with marine clean and metal ready prep) on lower rear pass fender. Took all day to follow all steps and I'm very impressed w/ the Por15. Marine clean must be diluted w/ water...I made the mistake of misting it on the fender and ran for the hose! In the end no harm done thank goodness. The Por 15 is not very camera friendly you can see reflections in it when it hardens and I got the regular black, not semi gloss. After experimenting today, I'm a believer in these products they work great and the coating is as hard as a rock.
Here you can see the original Light Buckskin color :-)
Here you can see the original Light Buckskin color :-)
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by Limey SE Sat Aug 13, 2011 8:28 pm
good progress Buddy the non stop ran for 3 days has me dead in water
___________________________________________
1977 Chevelle SE x2
One Mild original
one Wild NON original
Anthony
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by JiMi_DRiX Sat Aug 13, 2011 10:54 pm
Nice work! Have you seen this for the firewall? I'm curious about getting one, but I'm not sure yet. How hard was it to remove everything like you did from the firewall? I'm mostly concerned about the air boxes, they look like the most work.
Firewall Insulation OPGI
Firewall Insulation OPGI
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Sun Aug 14, 2011 9:04 am
I Have seen that online but too late for me, the fire wall is done on mine. I reused the brown pad, it came off very easy and was in good shape. Had a lot of rust but during the winter I sanded , primed and then painted. Used rustoleum products..wish I'd known about the Por 15 then. My kick panel insulation was gone but S&S classics have some decent replacements (not exactly the same but very good).
The heater box and or A/C box (can't remember if one or both) bolt to both inside the car and in the engine, it;s a pain on the neck but if you're careful not a big deal. I will say that my pass side inner fender is off the car and that will make it easier to access some of the bolts. Here is a pic w. the stuff off.
My heater box was in good shape the A/C box in the engine compartment needed work though. I took that out and used the green Bondo w/ the short fibers to patch it and then used Duplicolor for plastic in black, came out good. I did remove the small amount of rust scale on both this box and the Heater box door.
Using my drop light to heat the bondo...was a cold day in the workshop.
The end result. Heater motor hidden, sorry. Gotta have some secrets! Used red High Temp RTV Silicone to seal the two pieces & around the blower motor also.
The heater box and or A/C box (can't remember if one or both) bolt to both inside the car and in the engine, it;s a pain on the neck but if you're careful not a big deal. I will say that my pass side inner fender is off the car and that will make it easier to access some of the bolts. Here is a pic w. the stuff off.
My heater box was in good shape the A/C box in the engine compartment needed work though. I took that out and used the green Bondo w/ the short fibers to patch it and then used Duplicolor for plastic in black, came out good. I did remove the small amount of rust scale on both this box and the Heater box door.
Using my drop light to heat the bondo...was a cold day in the workshop.
The end result. Heater motor hidden, sorry. Gotta have some secrets! Used red High Temp RTV Silicone to seal the two pieces & around the blower motor also.
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Sat Aug 27, 2011 4:19 pm
Today was good! Got the Old Girl running. Turns out...new starter, batt cables, a little Seafoam in the tank, starter fluid, oil change w/ 1 substitute quart of Mystery Oil and the (almost totally) reinstalled column. Still may have to shim starter..thought I heard it spinning when I let off the key BUT..1st try and she cranked right over. I could not believe it as she's been sitting since last November. Now the fun starts...must rebuild carb & reinstall the right exhaust manifold, get an air cleaner and breather, reinstall the master cylinder & bleed the brakes, new pads ups front, Transmission gasket, rear bumper reinstall.....wait there's more but that's good for now LOL. Still don't know the casting number on the engine but on drivers side says 5.7L. Casting on right side cylinder head indicates swirl polish heads from a 305. Must replace those but good for now.
Hopefully by spring she'll be @ the inspection station.
Will post some pics when the weather gets better! 
Hopefully by spring she'll be @ the inspection station.
Will post some pics when the weather gets better!
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by abajc3 Sun Aug 28, 2011 4:54 am
nice, keep up the good work! the engine is probably a newer block, i have a couple of `99 vortec 350s and they also have a 5.7 stamped there. havent seen this on any of the other blocks i have, and they are all older.
its very possible that you have a roller cam too. as for the heads i`d recommend a set of used vortecs, shouldnt be too expensive and best bang for the buck IMO
its very possible that you have a roller cam too. as for the heads i`d recommend a set of used vortecs, shouldnt be too expensive and best bang for the buck IMO
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Mon Aug 29, 2011 8:32 pm
Well, the Lord giveth & the Lord taketh-away...Started her up this am no problem. Brought up to temp...no issues. Later on in the day she didn't turn over. Don't know if this is fuel issue, as carb is pretty shot. There was a bit of a rough idle and a backfire or two when running. Noticed when putting the exhaust manifold back on this PM that there was an oily residue on the #6 port. The rest were only "sooty" Maybe a ring there? Anyway, She's put back together and waiting for the bench seat to go back in temporarily and rest of the work on the column so I can hopefully drive it. What stinks is all I wanted to do was move her to a new spot. ARRGH! 
Anyone else go through something similar?
Anyone else go through something similar?
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by texan01 Mon Aug 29, 2011 10:48 pm
I'm going through that with my DD 95 Explorer. Here lately it's been the project car and the 77 has been the DD. Good thing it's dead reliable!
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Tue Sep 06, 2011 7:15 pm
Well since last time I've made the decision to disassemble the engine and have the lower end components evaluated locally. I think it's a head gasket at best and possibly in addition a bad set of rings on two cylinders on the even side of the block. We'll go from there & hopefully will have it up to them in a couple of weeks. Thus far the entire front assembly minus the bumper is off the car. Radiator, radiator/condenser housing, fan, alternator, pulleys, belts, water pump, carb..etc...now cataloging all the pics for reassembly. Oh what fun. Here she is without her "teeth". Most parts are still worth restoring too which is good!
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by pila Tue Sep 06, 2011 10:13 pm
Looks like you have a lot of clean-up to do on your engine installation. How many miles on the engine ?
Maybe the cylinder bores will accept a ridge ream, a honing, & new rings. Problem there is, cleaning the ring grooves on the pistons etc. Pain in the butt...
Got a ball-park figure on how much you can spend on the engine?
Maybe the cylinder bores will accept a ridge ream, a honing, & new rings. Problem there is, cleaning the ring grooves on the pistons etc. Pain in the butt...
Got a ball-park figure on how much you can spend on the engine?
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Tue Sep 06, 2011 10:20 pm
Have a great shop up here to do all that. If needed will have them rebuild & balance the bottom end. With all that needs to be done to get her on the road...my time is at a premium. Would rather have it blueprinted & done up right. No idea how many miles on the engine, the body has 134k but engine is not the original 305.
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Thu Sep 08, 2011 4:49 pm
So I spoke to my engine shop & they did confirm that the heads are from a 305 but block is a 350 5.7 L. Going to swap heads for some 23 degree Vortec & will have to get new intake too as the old one will no longer work. Have not pulled the heads yet but will look at the cylinder walls once I do that to be sure there is no issues w/ the pistons & rings. I sent him this pic and he said by looking at it it was probably a low mileage engine that I should reuse w/ the better heads. Should make from 320-340 HP. Not to shabby for just cruising LOL just gotta remove all the grime & rust from the thing sitting. Wish me luck though!
Edit- sent him this pic....prior to covering the oil galleries...
Edit- sent him this pic....prior to covering the oil galleries...
Last edited by 77mali on Sun Sep 25, 2011 7:25 am; edited 1 time in total
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by Fishgrinder Thu Sep 08, 2011 5:26 pm
The galleries do look clean! To late to turn around now Mali, keep up the good work 
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Mon Sep 12, 2011 7:59 am
Fishgrinder wrote:The galleries do look clean! To late to turn around now Mali, keep up the good work
Yes they are, very. I owe my wife a can of Easy-Off oven cleaner...used it to clean out the bottom & cross over in the Air intake manifold. Worked good...the manifold was a little cleaner than the ports you see in the Heads in the previous pics. Good riddance to those! There is some carbon build up as well on the tops of the Pistons but nothing a little Seafoam won't cure. No grooves or rust inside there aside from the very top on some near where the gaskets were. I think once everything is back on, that will clear up as well. she also needs a reverse flush on the cooling chambers...I was not surprised to see a very "gunky" coolant slurry when I was pumping it out near the bolt holes...pretty gross.
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Mon Sep 19, 2011 4:16 pm
Finally got the engine casting # from the back of the block clean and legible. #14093638...circa 1987-1995. The research shows that this casting corresponds with assemblies that were either 2 or 4 bolt mains and came w/ either a flat tappet or roller cam. Mine are flat tap, so I'm assuming that it's a 2 bolt main. These engines went in everything from Camaro's & Blazer's to Pick-ups, so just your run of the mill block I suppose. I may pull the pan to check just for giggles after the new heads & intake go on, hopefully this weekend. Not sure after all if I'm going to rebuild the Q jet or get may end up going w/ a new or factory reconditioned Edelbrock Carb. The heads are a fairly new design by RHS & are aftermarket Vortec heads that mate w/ Edelbrock Vortec Performer intakes (not sure of this part #). I hope this turns out good as this set up will set me back some on the many other things that need to be done before road worthiness.
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Re: 1977 Chevelle Malibu Classic Progress Photo's aka Mali
by 77mali Tue Sep 20, 2011 9:14 pm
pila wrote:Looks like you have a lot of clean-up to do on your engine installation. How many miles on the engine ?
Maybe the cylinder bores will accept a ridge ream, a honing, & new rings. Problem there is, cleaning the ring grooves on the pistons etc. Pain in the butt...
Got a ball-park figure on how much you can spend on the engine?
Heads/Intake/Gaskets approx 1K. (better than a total rebuild I suppose or crate motor).
Reusing the rocker covers too...clean up & paint to save some $$.
Not perfect but will do for now.
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