Danginharl's 1980 Malibu Wagon Project

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Where do I begin? I guess I have to go back almost 4 years to continue on from as purchased condition in the previous couple of posts. The old 267ci was very tired and was due for a date with the scrape yard gods. I pulled the engine and sent it on it's way to the highway in the sky.
With no replacement engine on hand, I focused on the parts I did have. I replaced the rear bumper with a rust free part I had from an El Camino Royal Knight that was just too far gone to save. The replacement is in very good condition as you will see in the pictures once I round them up and get them uploaded.

The next project was to replace the rear axle. Upon inspection of the stock 7.5" open rear end axle, I found the left rear axle seals completely blown out and oil everywhere. It was of no concern though, as I had a nice positraction complete axle from another donor car. This one was a 1980 Grand Prix that I picked up for a $100 and the labor to pull the engine for the previous owner. You will notice a bunch of parts from this GP throughout my build. It was a tired old girl but I saved what I could. The frame of the GP can actually be seen on my driveway in some of the original purchase pictures in the first post. The rear ends were swapped with all factory arms in use for now. A bit of research shows that this axle has a 3.18:1 gear ratio that was a factory option in 1980 and I non-scientifically confirmed that with a count of wheel turns to a single pinion turn. I have yet to pull the cover and confirm this, but maybe some day soon.


Next up, the hunt for a power plant begins...
 
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Sorry guys, I had to delete the last entry to add pictures. Seems some other posts were deleted with it. Anyway, on with the build.

With the rear end installed, it was time to focus on a new power plant. I decided I didn't want to go the typical small block route, so the hunt was on for a 454 big block to fill the void.
The quality of the factory welds and the way they left the frame is astounding.
After a short search in our local classifieds, I came upon a deal I couldn't refuse. A mid 70s 454 complete with 781 oval port heads for $350. What could possibly go wrong.
The block was purchased partially disassembled (this should have been my first red flag). I cleaned it up, did a visual inspection of the rotating assembly and was satisfied that it was good to put back together with new gaskets. It was left 100% stock as purchased and installed in the car.
Hooker 2455HKR headers were fit with some minor tweaks as I could not afford the G-body swap headers. Attached to the headers is a Flowtech 3" universal x-pipe kit and finished off with 3" Flowtech Raptor mufflers dumping in front of the rear axle.
I also build a custom low mount alternator kit and made a bracket to mount the original powere steering pump into the car.
Just before installing the used 454, I came across a set of solid chrome 15" wheels with 235/60R15 rubber for cheap through a friend. A few hours of prep and paint and I had them flat black and looking decent.
 
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So everything posted to date brings us to Fall of 2013. Finances were tight I decided I would hold off until Spring 2014 to register and insure the car so I could actually drive it.

The car was running mostly with open headers to this point, oil pressure was slightly below normal when hot, but not overly concerning. I decided I would button up the exhaust and get the car back together and ready to drive. As luck would have it, my non-existent budget would catch up with me and things went bad. Once the exhaust was in I could hear a knock in the engine. I dropped the oil and my heart broke as I viewed the glistening metal shavings flowing in the oil into the drain pan. I now had a new winter project for 2013/14.

Out came the $350 454 attempt 1 and I completely disassembled the engine and found this.
Rod number 8 was spun and wiped out the crank...Back to square one.
 
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A little discouraged and heartbroken. I started making a new plan to get the wagon on the road for the 2014 season. I did some research, contemplated rebuilding the engine I have, going the small block route and many other options. In the end, I decided I would try my luck again and search for another 454 to drop in. Finances were the biggest concern, so this was going to be my cheapest option. I would just have to be smarter with my purchase.

After another short search, I came across another victim. It was owned by a college kid who lived on a farm and liked mudding trucks, but needed cash in a bad way and decided to sell his trucks engine. The engine was complete from carb to oil pan and turned out it was the exact same casting number block and heads as my previous attempt. The back story was that it came out of a 1980 Suburban and he ran it in his mud truck for a short time. I checked it out and was happy with what I saw, so I paid $500 asking price and hauled it home.
Finances being what they were, I pulled the engine apart to the short bloack again, checked out the internals and was happy with what i saw. New gaskets and a fresh coat of paint and an oil pressure test were done before it was dropped back into the wagon.
Lady luck was on my side for now. The "new" engine was in, running good and had no issues that I could find. Time to cruise!!!

The flat black rims and tires just didn't work for me once I started to drive it a bit more. It needed something better. Traction was also a bit of an issue. Back to the local classifieds I went and sourced a set of Eagle Alloys with usable tires for $500.
The tires on the wheels were 275/60R15 for the back which fit perfect, but the fronts had 255/60R15 rubber and there was no way that was going to fit. I decided to swap a pair of the 235/60R15 tires off my flat black rims and put them on the alloys. They fit good, but I have some rubbing issues with larger bumps, the big block and tired factory springs.
 
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Are you going to stick with the BBC, or are you considering something else?

Keep reading. That was only round 1. I should have the thread up to current day tonight. Round 2 is just above your post. I must of got it in just before your reply.
 
Summer of 2014 was glorious and the wagon was out and about in all of it's glory. My first car show with my own ride was Three Hills Alberta 2014. It is about an hour drive from my place but worth the trip.
Next was the local home town show. Airdrie "Doing it in the Grass" show.
My last show for 2014 was the Springhill RV Show. The weather was cool and turnout was not great, but it was all good for me in the end.
I walked away with the Best of Show 1980s trophy. My first one!.
My daughter and I were super excited as you can see in the picture above.

My euphoria was short lived however. We headed home with our shiny new trophy excited to celebrate. The drive was about 20 minutes through some rolling hills. No big deal. That was until I took a look at my oil pressure gauge during one of the longer downhill runs, 0 psi!!!

I would get back into the gas and the gauge would flick up to 10 psi bounce around a bit and then drop off as soon as I was off the gas. I took it easy the rest of the way home and parked the car until I had time the next weekend to see what I could find.
During the following week I goggled my way into a frenzy, trying to see what could possibly be wrong with my engine. Things like a pick-up tube that had fallen off, to a bad gauge. That weekend I put on a second mechanical gauge to test the cheap and obvious. No dice, pressure was low cold and none existent hot. I pulled a valve cover and ran it to check flow to the top end, very little. I dropped the oil and the ever disappointing shimmer of metal flakes in the oil flow sealed my fate for another fall/winter season of wrenching.
 
I think so. Glad you found a good powerplant. Do you know the width or backspacing on the rims that you have on the car now?

They are 8" rims with I believe 4.5" backspacing, it may have been 4.25". I can't remember. They fit and that was all I needed to know.
 
Thanks very much. I have a set of 15" by 7" rallys for my 1980 Malibu coupe, and a friend of mine is saying that I should install a pair of 275/60s on the rear. I'm thinking that the 7" rims might be a bit too narrow. I'm leaning more towards 255/60s on the rear.
 
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