Danginharl's 1980 Malibu Wagon Project

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A little frustrated and upset with what was going on, I made a decision to get serious with the car and make it right. I pulled the engine and and began trying to diagnose my low oil pressure issues.
Each part cleaned and inspected. I measured the rods and main caps, all within specs. Bearings were worn, but not excessively. The crankshaft look great, but once on the mic it was a different story. The main journals were measuring up to .060" under sized for a total clearance of almost .100". Well there's your problem!
After making some calls and doing some research, I elected to purchase a new crankshaft for the awesome price of just over $300 through a local performance parts supplier.
I saved my $ and was able to round up a few more goodies to breath some life into this tired engine.
The list included a new high volume oil pump, 7 quart oil pan with matching pick-up, high flow fuel pump, new valve covers and air cleaner housing, new bearings, a Summit version of the Edelbrock camshaft and of course new gaskets. I was also able to pickup an Edelbrock water pump as a local swap meet to finish it all off.
Back together and ready to drop back into the car I made a discovery that I want you all to pay attention too. This is the flexplate I had been running on my BBC since day one of the first build, it came with the first engine.
IT DOES NOT HAVE A COUNTER WEIGHT! OOPS!
I researched and sourced a used flexplate and confirmed I had the correct damper on the front.
Running the wrong flexplate will cause premature crankshaft & bearing wear. It also cause a slight annoying vibration. Sounds familiar and is the reason I am on round 3 of 454 builds. I wont be doing that again!
The heart of the beast was once again up and running. Smooth as silk, sounding mean and with tons of oil pressure!
 
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If you thought that was a lot of work, you are right. But I also did a ton of other serious upgrades while waiting for engine parts.
The fun all started with gutting the interior.
I had the GP dash, seats and console from the old donor car that I got the differential from. Here is a test fit.
While that was all happening I took the opportunity to put down some sound proofing and heat protection. That floor looks pretty mint for it's age!
I also took the time to install a sound system. It is a Bluetooth deck, new speakers all around, 5 channel amp and 2 x 8" subs custom mounted in the rear storage compartments.
With that complete, it was time to put it all back together. I decided that the GP dash was not in good enough condition to use when I had a near mint Malibu dash. The end result was a Malibu dash with a GP console that included a custom mounted B&M Megashifter.
I also finished it off with a new Grant steering wheel.
Not wanting anymore external gauges, I custom mounted my tach into the dash panel and installed LED lighting. My mechanical temp gauge was also mounted into the lower left, but I do not have pictures of it.
With all of that complete, it was nearly time to cruise again for 2015!
 
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2015 became another great year of cruising and car shows. I drove the car more in the Summer of 2015 then I had since I bought the car. I drove it to work and just because I could!
The first show was the new High School 1/2 a block from my house.
Then I once again tried to make it to the Three Hills show for 2015. This however was not meant to be. The lower radiator hose let go about 30 minutes from home. Turns out the hose was not quiet on straight and had the slightest of rubs causing a failure point.
This did, however, create some great photo ops while waiting for my wife in the open prairies.
My wife delivered some fluids and a new hose and I headed back home. Unfortunately the situation of the day brought to light another oversight. As i pulled into the driveway after making it home from the blown hose, my radiator proceeded to let go. Upon further investigation, it appeared to be a major air lock issue and I could not for the life of me figure out why. The following weekend I did a hose by hose inspection of the cooling system and came across a gruesome discovery. When I had pulled the engine for the rebuild, I had inserted some clear plastic plugs into the heater core piping. One of those plugs was never removed. BINGO. Man do I feel stupid. My friends to this day still ask me why i would admit to such a thing.
After sourcing a radiator from another G-body freak like me, I was up and running. This time with a transmission cooler as well. I also failed to mention that during the winter build session, I had installed a stage 2 B&M shift kit into my TH350 transmission. It shifts much nicer and with the B&M shifter it is a lot of fun to bang through the gears.
Next show was a 2.5 hour road trip south to Lethbridge on a 28'C day. This was a long hot drive, but the car performed like a champ.
Airdire show was next.
Then the Springhill RV show. No awards for me. I lost out the 80s trophy to another G body, so it's all good.
 
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Phew! That's a lot of updates!!!


The car ran great for the remainder of 2016. I still have a list of things that I need to get done and I will update this thread as I do them. For the first year since I bought the car, I have done NOTHING to it this winter. It is ready for 2016 as it sits. I did notice that it burned a little oil on long highway runs with continued high rpm. That is my bad for not doing a hone and rings with the "rebuild" but finances just wouldn't allow it again. It doesn't smoke or smell of burnt oil yet, so I plan to drive it.

What does 2016 bring with it? Time will tell. Here is a list of things i plan to explore and hopefully do in the future.

LS engine? Twin turbo? Single turbo? (I have 2 x 5.3L engines on stands in the garage)
4 speed transmission
Working A/C
Additional LED lights (turn signals and possibly tail lights)
Smaller front tires that won't rub, new rubber for the rear
1" lowering springs front and rear (also in my possession)
Install large front sway bar (got it)
Install rear sway bar (got it)
Install complete poly bushing kit (on the shelf)
Recover bucket seats and paint plastic backs
Paint sub woofer mount plates

I'm sure there is more, but you get the idea. They are never done. The next "rebuild" will be a full frame off.

Thanks for reading, I hope you all enjoyed the ride.

Your thoughts and comments are appreciated!

Matt
 
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Thanks for sharing Matt, I enjoyed reading that with my morning coffee. Great that you shared with us your failures as well as successes, not a common thing these days, lol.
 
Wow, yeah, a lot of updates. Thanks for sharing with us, especially all the photos. After all of the trials you've had with the BBC, and finally getting it all sorted out, I'd be reluctant to change now. I'd work on some of the other items you listed (A/C, 4 speed, and some of the interior work). Just my $0.02. Thanks again.
 
Matt,
It looks like you decided to keep the car after all...that's good! If I recall, you had it up for sale not too long ago.

I'm glad you were able to get your big block back to good health again. Your floors are some of the cleanest that I've seen. Most have some traces of rust..
 
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Lots of detail, thanks for the effort! Your interior is in fantastic shape. Most of us are not so lucky. I must admit I like the Malibu dash better (not just because it was cleaner). Nice score on the 454 - even if you had some unfortunate lessons along the way. Not everybody can claim credit for a bearings-out rebuild in their garage. I suggest you put your wagon in for GBOTM. I need to do a similar marathon upload and finally post a build thread...
 
Thanks for the comments guys.

I have put my name in for the GBOTM. Vote for me! lol

One detail I forgot to mention was that I sold the original 454 for $350 as a core for rebuild, so on that front I was only out my time and the cost of the gasket kit.

I did have the wagon up for sale this past fall. As you can see in my signature I also have a 81 Malibu 2 door that is a full frame off build. I was thinking of selling the wagon to fund the new build, however, I came to the conclusion that I would be upset with myself for selling the wagon knowing what I had into it and the condition it is in.
 
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Matt
Thanks for taking the time to upload and post all those pics and updates for us. It takes a long time and a bit of effort I know, but we all appreciate it.
I thought I knew most of the back story on your wagon, but I picked up a few new things I wasn't aware of in reading thru your thread.
🙂
The wagon's coming along nicely, and if I can add my $.002, I'd say keep the big block in there too and save the LS engines for the coupe build. Glad to see you're in the running for GBOTM, you've got my vote my friend!
Nice job, keep up the great work.
Donovan
 
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