BUILD THREAD Malibu T-Top Conversion

SupremeSpeed

SupremeSpeed

G-Body Guru
Sep 29, 2016
510
93
GA
I've always had a soft spot for the Malibus, and growing up in the 80s, thought t-tops were the coolest thing someone could have on a car. Our neighbor had a t-top cutlass, and I was always a little jealous our 'Bu didn't even have that option. Fast forwarding some years, I started building my current Malibu project and at some point got the bright idea to graft on a t-top roof and live out that childhood dream.

Before cutting up the car, I did some research and learned while the bottom 90% of the A pillars are the same between, the B pillars are completely different and that there are two different B pillar designs on the t-top cars. When it's done, I want the car to look completely stock, so I knew that I would have to do some custom fab work to make it all fit. The donor roof came from a 1986 Monte Carlo.

This picture shows my clean, 1979 tub, braced and ready to go under the knife.
View attachment 73936

I started by cutting the A pillars roughly half way down and took a sawzall to the entire roof right in front of the B pillar. No turning back now!!
View attachment 73937

Next, I cut the front face off the B pillar, leaving the quarter window frame intact. I also cut the inner roof structure back to fit the cross brace on the t-top roof and notched the remaining roof skin to reach the inner structure to weld it together.
View attachment 73938

At this point, I was able to test fit the donor roof section into place. I was starting to feel better, like I might actually be able to pull this off.
View attachment 73939
I tacked the A pillars into place and went to town fully welding the donor B pillar to what was left in the Malibu. I measured 100 times for each weld to ensure the roof was square and that all dimensions were correct to the templates I created before I cut the roof off the Monte. The bracing lined up almost exactly between the two, and the biggest challenge was matching up the inner structure of the B pillars. The factory Malibu pillar ends about an inch further back than the Monte, meaning the Monte B pillar is more upright than the Malibu. The seatbelt mount was put in the correct position for a Monte to allow less customization required on interior parts. The picture below shows the inside after welded, along with my garage pal. He's now old enough to understand what tools are what (and how to get beer out of the fridge) so he makes a great gofer, and loves to spend time in the garage.
View attachment 73941

I was going to weld the two halves of the A pillars together, but could not for the life of me get either one of them straight, using the windshield and side trim as a guide. I decided to spring for new A pillars, and found that the front header panel was reproduced as well. Mine didn't have any holes, but did look a little crusty even after being dipped. I drilled out what felt like 200 spot welds, most of which in the header, to remove the components and welded the new ones in. I was amazed how much seam sealer was used to cover questionable welds at the base of the A pillars. The header had a spot weld every inch or so, and the base of the A pillar had maybe a half dozen total holding it to the firewall, some of which popped off without drilling out. I put in some extra welds both on the outside and inside for good measure. For aftermarket parts, I was actually impressed with the fit. Only the A pillars needed the fender hole oblonged to align properly, and that may be because they aren't actually meant for the car. View attachment 73942
View attachment 73943

View attachment 73944
With the structural work done, I changed focus to working on the frame. The tub will be going in to be acid dipped this winter, and when it returns, I will have the cosmetic work completed. I will pay someone to do that, as it's above my abilities and available time. The bottom of the B pillar skin will need to come in about 1/4" to match the character line found on the Malibu. The steel around the quarter window will be finished, removing the drip rail and closing off clean to the window. The roof transition is different between the two, so I will use the sharp crease found on the t-top roof all the way to the C pillar.

In all, the conversion isn't too difficult. The key, as with most in-depth projects is to take your time and wear out the tape measure before welding things together. It's always easier than taking it back apart and redoing it!!
That's some great detailed work. I'm definitely following this build. I've always had a soft spot for Malibus to. This is a great project and I look forward to seeing more of this build!
 
Last edited:
  • Like
Reactions: superbon54
superbon54

superbon54

Master Mechanic
Apr 15, 2014
366
93
Thanks guys!!

Funny story on the bolt... the bellhousing fastener kit had some extras in it. When I was mating the engine to the trans, a time where I wish I had 3 or 4 hands, I dropped one of the bolts. I picked up an extra within reach and kept working. Afterwards I looked and looked and looked and couldn’t find it. I almost convinced myself that it somehow fell into the bell housing and that I needed to separate the engine from the trans just to check. I took that pic from the front and I’ll be dammed, there it is!

It’s like the easiest way to find a lost tool - stop looking.
 
  • Like
Reactions: Rktpwrd
ssn696

ssn696

Older Than My 1980 Malibus
Supporting Member
Jul 19, 2009
4,238
113
New Mexico
It’s like the easiest way to find a lost tool - stop looking.
This relates to my earliest brush with probability and statistics. When I was 9 I invented the 'Lego inverse probability theorem'. [Named later when I had a bigger vocabulary.] If I needed a particular part to finish a project, the harder I looked, the less likely I'd find one. Give up, move on, and I'd find like four of them quickly. Hinges were the one part that comes to mind...
 
Last edited:
Thread starter Similar threads Forum Replies Date
S Back Glass: 1978 Malibu A-Body Coupe (Non-Landau, Non-Vinyl Top) Body / Trim / Paint / Glass 2
Davenz 82 Malibu Wagon in New Zealand G-Body Build Threads 23
Warren Connecting 1980 Malibu Engine Wire Harness Electrical / Ignition / Starting 2
C ISO a 1978-1981 Malibu 2 door G-Body Cars for Sale / Trade 1
Davenz Cheers For The Add - Just bought an 82 Malibu Wagon in Nz New Users 21
Lane S 430 CI Buick in a '78 Malibu sedan Engine / Swaps / Driveability 5
T Malibu interior New Users 7
R 1978 Malibu Coupe, Vernon,Ct 06066 G-Body Cars for Sale / Trade 0
P Need help decoding a 1981 Malibu body tag General Discussion 1
Warren Looking for 80 Malibu Landau Exterior Pillar Emblem Body / Trim / Paint / Glass 11
michmalibuman WANTED Malibu 9C1 speedo Wanted 18
JAMCAR223 Oh Noooo... Poor Malibu General Discussion 9
H 9C1 Malibu New Users 4
Warren New to GBODY Forum (1980 Chevy Malibu Classic 2 Dr Coupe v8) New Users 8
G 1980 Malibu classic landau chev SB 267 vacuum routing General Discussion 13
Grant Smith 1979 Malibu 6.0 T56 Magnum G-Body LS Swap 47
MariaMalibu Malibu Classic 1979 G-Body Build Threads 10
R Has Anyone Seen This Malibu??? General Discussion 0
08Malibu Malibu Tail light filler color Body / Trim / Paint / Glass 8
55Belairman 81 Malibu bumpers G-Body Parts For Sale / Trade 0
55Belairman 1981 Malibu parts for sale G-Body Parts For Sale / Trade 0
butch2427 my new project, 1981 Malibu 9C1 New Users 16
Michael Bennett 80 Malibu Springs and Ride Height Wheels / Tires / Brakes 8
WanaBa442 '80 Malibu in Blue - Faysbook listing G-Body Cars for Sale / Trade 3
08Malibu MALIBU 81 Malibu sweep cluster , Navy G-Body Parts For Sale / Trade 1
R 1983 Malibu 9C1 New Users 5
M Buzzer chevy malibu 1979 Electrical / Ignition / Starting 4
442kid 1980's MONTE CARLO SS MALIBU EL CAMINO 200R4 SHIFTER CABLE & LINKAGE G-Body Parts For Sale / Trade 6
O 78 Malibu brake parts G-Body Parts For Sale / Trade 5
dickeymoore 1979 Malibu Landau G-Body Cars for Sale / Trade 0
39F Malibu hood on regal? Eh why not Body / Trim / Paint / Glass 8
Boglog 1980 Malibu Wagon resurrection G-Body Build Threads 37
D 1979 Malibu 9C1 2 Door G-Body Cars for Sale / Trade 4
83GWAGON 81' Malibu Factory v8 Transmission / Rear End / Driveline 20
Michael Bennett 15x8 Weld Draglites with 275/60/15 for '80 Malibu- 3.5 or 4.5" backspacing???? Wheels / Tires / Brakes 8
Reddzedd Malibu Wagon trunk gate? Body / Trim / Paint / Glass 5
blackbuck350 81 malibu wagon rear window weather seal General Discussion 19
D 81 malibu turbo 350 shift linkage Transmission / Rear End / Driveline 2
MalibuDavyou5 Malibu Starter Help. Electrical / Ignition / Starting 16
08Malibu MALIBU Monte SS cluster in Malibu Electrical / Ignition / Starting 9
83GWAGON MALIBU What's going on G-Body peeps? I recently bought an 83' Malibu CL Wagon. New Users 57
8 81 Malibu A/C system rebiuld Cooling / Heating / AC 3
Bruce Compton 1978 MALIBU G-Body Cars for Sale / Trade 2
B Malibu exhaust crossmember Exhaust 23
B Lowering the back of a Malibu Frame / Chassis / Suspension / Steering 20
gnvair Another odd ball 4 speed Malibu for sale (not mine) Chevrolet Monte Carlo / SS / Malibu 20
08Malibu Malibu Rocker Moldings-North Jersey G-Body Parts For Sale / Trade 3
08Malibu 81 Malibu project restarting G-Body Build Threads 49
Regalman08 FOR SALE More parts added 1981 Malibu classic 2door parts G-Body Parts For Sale / Trade 12
Ihlaan-J-Nova My Malibu Project New Users 4
Similar threads


















































Please support GBodyForum Sponsors

Classic Truck ConsolesDixie Restoration DepotMike's MontesP-S-TSouthside Machine PerformanceUMI Performance

contact[email protected]for info on becoming a sponsor