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1965 Chevrolet Impala SS 6.0 / 6-Speed Build Thread
This 1965 Chevrolet Impala came to us after and restoration was started at a different shop. The car has been in the owner's family since 1970, so we were honored and excited to bring this one back to the road. The recipe calls for a 6.0 LQ9 V8, 6-Speed manual transmission, and updated Ridetech suspension, all while keeping a smoothed-out stock appearance.
http://www.v8tvshow.com/1965_Impala_...0.22.13_09.JPG http://www.v8tvshow.com/1965_Impala_...0.22.13_03.JPG http://www.v8tvshow.com/1965_Impala_...0.22.13_30.JPG This car had seen years of daily driving and occasional racing use, and was showing signs of deterioration. It arrived in our shop having been media blasted and sprayed with a black epoxy primer. At first glance, we noticed some rust around the window frames, in the deck lid, and that the previous repairs were not complete. http://www.v8tvshow.com/1965_Impala_...0.22.13_11.JPG http://www.v8tvshow.com/1965_Impala_....23.13_011.JPG http://www.v8tvshow.com/1965_Impala_....23.13_045.JPG http://www.v8tvshow.com/1965_Impala_....23.13_060.JPG |
After a thorough inventory of the supplied parts, the crew began the metalwork.
The first project was to close the stock antenna whole using a steel insert. The piece was made and fitted to the hole, MIG welded, and ground smooth. We're using an HTP MIG 200 welder for this task. http://www.v8tvshow.com/1965_Impala_....23.13_090.JPG http://www.v8tvshow.com/1965_Impala_...0.25.13_01.JPG http://www.v8tvshow.com/1965_Impala_...0.25.13_05.JPG http://www.v8tvshow.com/1965_Impala_...0.25.13_08.JPG |
Love the 65 Impala's. One of my favorite big cars. :popcorn2: :popcorn2:
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Ohhhh, man. Can't wait to follow this one. Subscribed!
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Love these impalas. Subscribed
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Right on!
This one should be awesome Kevin!
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Next, the crew began the rust repairs around the rear window frame. These window channels held water and rusted all the way through. The rusty metal was cut out with a thin 3M cutting disc on an air grinder. A new channel was fabricated using a shrinker/stretcher, welded in, and ground smooth. Gray primer prevented further rust.
http://www.v8tvshow.com/1965_Impala_...0.25.13_13.JPG http://www.v8tvshow.com/1965_Impala_...0.25.13_18.JPG http://www.v8tvshow.com/1965_Impala_...0.25.13_20.JPG http://www.v8tvshow.com/1965_Impala_...0.25.13_22.JPG http://www.v8tvshow.com/1965_Impala_...0.25.13_24.JPG http://www.v8tvshow.com/1965_Impala_...0.25.13_28.JPG |
Similar repairs were made to the window channel around the windshield in the areas where the metal had rusted thin.
http://www.v8tvshow.com/1965_Impala_...0.28.13_10.JPG http://www.v8tvshow.com/1965_Impala_...0.28.13_12.JPG Next, the rear window filler panel was removed for additional rust repair. http://www.v8tvshow.com/1965_Impala_...0.28.13_14.JPG |
The rearmost edge of the structure had rusted away.
http://www.v8tvshow.com/1965_Impala_...0.29.13_07.JPG A new channel was bent in the Mittler Brothers Box Pan Brake and contoured to the correct shape. http://www.v8tvshow.com/1965_Impala_...0.29.13_09.JPG http://www.v8tvshow.com/1965_Impala_...0.29.13_13.JPG Then it was welded in place with an HTP Quickspot II resistance spot welder. http://www.v8tvshow.com/1965_Impala_...0.29.13_25.JPG |
Next, the middle part of the structure was measured, and a cardboard template was made to assist in fabricating a repair section.
http://www.v8tvshow.com/1965_Impala_...0.29.13_28.JPG http://www.v8tvshow.com/1965_Impala_...0.29.13_35.JPG http://www.v8tvshow.com/1965_Impala_...0.29.13_36.JPG |
The upper portion of the repair section was punched with a dimple die on a Mittler Brothers brothers punch in order to replace the original flared holes. These holes provided strength for the panel.
http://www.v8tvshow.com/1965_Impala_...0.29.13_37.JPG Then, the curved lower section was TIG welded to the upper. Soon, the rusty portions of the structure had been completely replaced. http://www.v8tvshow.com/1965_Impala_...0.30.13_05.JPG |
A contoured lip as added to mimic the shape of the original.
[img]http://www.v8tvshow.com/1965_Impala_SK/slides/1965_Impala_SK_10.30.13_17.JPG[img] http://www.v8tvshow.com/1965_Impala_...0.30.13_25.JPG http://www.v8tvshow.com/1965_Impala_...0.30.13_46.JPG Once the piece was welded in place, it was cleaned with a wire wheel and 3M rowlock abrasive discs, and then sprayed it with primer. http://www.v8tvshow.com/1965_Impala_...1.12.13_02.JPG A new filler panel was obtained from Classic Industries, and welded in place over the lower structure to complete the repair. http://www.v8tvshow.com/1965_Impala_...1.12.13_01.JPG http://www.v8tvshow.com/1965_Impala_...1.12.13_05.JPG http://www.v8tvshow.com/1965_Impala_...1.12.13_06.JPG The tail pan section was rusty and damaged, so the crew removed the original panel by drilling out all the spot welds holding it in place. http://www.v8tvshow.com/1965_Impala_...1.12.13_07.JPG http://www.v8tvshow.com/1965_Impala_....23.13_073.JPG |
Note the support rod welded in to keep the decklid opening the correct size.
http://www.v8tvshow.com/1965_Impala_...1.12.13_08.JPG A new panel was obtained from Classic Industries, and it was fitted and welded in place. Note the fitting of the deck lid and tell light packets in this process to ensure all the panels fit properly before welding. http://www.v8tvshow.com/1965_Impala_...1.13.13_03.JPG http://www.v8tvshow.com/1965_Impala_...1.13.13_02.JPG http://www.v8tvshow.com/1965_Impala_...1.15.13_20.JPG |
The dash steel at the base of the windshield had rusted through, so we replaced the steel after fabricating some new pieces in-shop. The challenge here is that this is 3 layers of steel welded together, so they had to be replaced in the same manner.
http://www.v8tvshow.com/1965_Impala_...1.14.13_03.JPG http://www.v8tvshow.com/1965_Impala_...1.14.13_05.JPG http://www.v8tvshow.com/1965_Impala_...1.14.13_06.JPG http://www.v8tvshow.com/1965_Impala_...1.15.13_01.JPG http://www.v8tvshow.com/1965_Impala_...1.15.13_05.JPG http://www.v8tvshow.com/1965_Impala_...1.15.13_24.JPG http://www.v8tvshow.com/1965_Impala_...1.15.13_31.JPG http://www.v8tvshow.com/1965_Impala_...1.15.13_33.JPG http://www.v8tvshow.com/1965_Impala_...1.19.13_01.JPG http://www.v8tvshow.com/1965_Impala_...1.19.13_03.JPG http://www.v8tvshow.com/1965_Impala_...1.20.13_01.JPG http://www.v8tvshow.com/1965_Impala_...1.20.13_03.JPG |
A close-out panel was made and welded in to smooth the firewall.
http://www.v8tvshow.com/1965_Impala_...1.26.13_02.JPG The rear package tray was damaged, so new panels were cut to size and welded in place. http://www.v8tvshow.com/1965_Impala_...0.22.13_01.JPG http://www.v8tvshow.com/1965_Impala_...1.26.13_09.JPG The panel was strengthened by adding ribs with a Mittler Brothers bead roller. They were held in place with some Eastwood panel clamps. http://www.v8tvshow.com/1965_Impala_...1.27.13_04.JPG After welding, the panels were ground flush to complete the repair. http://www.v8tvshow.com/1965_Impala_...1.27.13_15.JPG http://www.v8tvshow.com/1965_Impala_...2.02.13_18.JPG |
The rear passenger floor was riddled with rust pinholes, so a replacement piece was ordered from Classic Industries.
http://www.v8tvshow.com/1965_Impala_...2.02.13_22.JPG http://www.v8tvshow.com/1965_Impala_...2.02.13_25.JPG The perimeter of the panel was punched for plug welds, and then sprayed with weld-through primer. http://www.v8tvshow.com/1965_Impala_...2.03.13_01.JPG http://www.v8tvshow.com/1965_Impala_...2.04.13_05.JPG The welds were ground smooth to complete the install. http://www.v8tvshow.com/1965_Impala_...2.04.13_09.JPG |
Great job.............................
Ken |
Show us more!! Surely there's more to this since the first post in March!
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Nice work Kevin. I love to see fab work.
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Subscribed. :thumbsup:
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Kevin,
You guys are doing a wonderful job! What color is the owner wanting? See you soon. Dan |
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The transmission tunnel had been expanded to accommodate the Viper-spec T-56 6-Speed manual transmission, but the work was not as clean as the owner wanted to see, so we removed it to fab up a new one. More on this later.
http://www.v8tvshow.com/1965_Impala_...2.05.13_02.JPG http://www.v8tvshow.com/1965_Impala_...2.05.13_04.JPG http://www.v8tvshow.com/1965_Impala_...2.09.13_10.JPG There were also some “dots” that needed to be connected in the driver side rear wheelhouse, as new sheetmetal was installed but the wheelhouse to floor to quarter connections were not made. We normally would have elected to remove and replace the trunk floor and wheel tubs, but the owner challenged us to make the existing pieces work. http://www.v8tvshow.com/1965_Impala_...2.09.13_01.JPG http://www.v8tvshow.com/1965_Impala_...2.10.13_06.JPG http://www.v8tvshow.com/1965_Impala_...2.10.13_07.JPG http://www.v8tvshow.com/1965_Impala_...1.20.14_03.JPG http://www.v8tvshow.com/1965_Impala_...1.20.14_01.JPG |
Anxious to see more!
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Subscribed.
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The owner wanted the 6.0 LQ9 engine to sit as low as possible in the chassis, and he had a Cadillac oil pan in mind, so we notched the cross member to make it happen.
http://www.v8tvshow.com/1965_Impala_...2.10.13_15.JPG http://www.v8tvshow.com/1965_Impala_...2.12.13_05.JPG http://www.v8tvshow.com/1965_Impala_...2.13.13_01.JPG The doors had been butchered with speaker holes, so repair panels we made and welded in. http://www.v8tvshow.com/1965_Impala_...2.12.13_11.JPG http://www.v8tvshow.com/1965_Impala_...2.12.13_09.JPG http://www.v8tvshow.com/1965_Impala_...2.12.13_24.JPG Under the car, this home-brew control arm support is going to be removed. The concept is solid, that is to reinforce the control arm mount for better traction and control, but the execution is below what is desired for this car. http://www.v8tvshow.com/1965_Impala_...2.17.13_09.JPG The crew then lifted the body off the frame to be able to work on both sides of the floor on the rotisserie. There were still a ton of little holes to fill, and they wanted to get a good look at the repairs previously made to the bottom of the Impala’s body structure. http://www.v8tvshow.com/1965_Impala_...2.18.13_07.JPG http://www.v8tvshow.com/1965_Impala_...2.18.13_18.JPG http://www.v8tvshow.com/1965_Impala_...2.18.13_20.JPG … and on the spit. http://www.v8tvshow.com/1965_Impala_...2.18.13_44.JPG |
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Thanks for the updates; can't wait to see more! '65 has recently become my favorite year Impala (at least until '95-'96). |
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More to come on this car! Thanks! |
A previous shop welded supports to the floor to make the transmission crossmember. This isn't a good idea, as the engine and transmission are bolted to the frame, which moves independently of the body, albeit slightly. Also, the floor of the car was never intended to support a transmission, much less a manual behind a high horsepower V8. We removed it in favor of a traditional frame-mounted crossmember.
http://www.v8tvshow.com/1965_Impala_...2.18.13_48.JPG http://www.v8tvshow.com/1965_Impala_...2.18.13_46.JPG New fuel tank supports were installed, as these were neglected when a previous shop installed the floor pans. We also finished welding and grinding all the floor welds. http://www.v8tvshow.com/1965_Impala_...1.02.14_11.JPG http://www.v8tvshow.com/1965_Impala_...1.03.14_01.JPG |
That Shoddy workmanship just makes a guy Crazy !!!!..........Sheesh.....If they are going to take the time to fix some issues......Do it correctly !!!Great job Kev............
Ken |
http://www.v8tvshow.com/1965_Impala_...1.03.14_08.JPG
Meanwhile, the crew was preparing to trial fit the Ridetech Street challenge suspension system on the Impala’s frame. http://www.v8tvshow.com/1965_Impala_...1.09.14_05.JPG This kit consists of tubular upper and lower control arms, specific rate coil springs and coil over shock assemblies, and an oversized front sway bar. We were also installing an upgraded quick ratio steering box. http://www.v8tvshow.com/1965_Impala_...1.09.14_02.JPG http://www.v8tvshow.com/1965_Impala_...1.09.14_19.JPG The original front suspension design used a straight lower control arm and a radius rod bolted to it. The Ridetech design is a vast improvement, using an “A” shaped tubular lower arm with an articulating end in the forward mount rather than a rubber bushing. http://www.v8tvshow.com/1965_Impala_...1.09.14_14.JPG http://www.v8tvshow.com/1965_Impala_...1.11.14_02.JPG http://www.v8tvshow.com/1965_Impala_...1.11.14_04.JPG http://www.v8tvshow.com/1965_Impala_...1.11.14_05.JPG |
You almost need an extra tall rotisserie for that big boy! That suspension kit should make a big difference in the ride and handling.
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The rear suspension consists of tubular control arms with adjustable upper control arms, and a stronger panhard bar with improved bushings.
http://www.v8tvshow.com/1965_Impala_...1.09.14_22.JPG http://www.v8tvshow.com/1965_Impala_...1.09.14_20.JPG This frame had some old-school hot rod tricks, like these control arm support brackets that were stick-welded in. We removed them and reinforced the frame to appear more original. http://www.v8tvshow.com/1965_Impala_...2.17.13_09.JPG We disassembled the rear axle assembly and media blasted the housing. http://www.v8tvshow.com/1965_Impala_...1.17.14_11.JPG After epoxy and Imron enamel in satin black paint were applied, a new gearset was installed along with bearings and seals to make this 12 bolt rear axle like new again. http://www.v8tvshow.com/1965_Impala_...1.22.14_04.JPG http://www.v8tvshow.com/1965_Impala_...1.23.14_04.JPG http://www.v8tvshow.com/1965_Impala_...1.23.14_12.JPG Here, the yellow paint illustrates the proper gear mesh contact pattern ensuring quiet operation. http://www.v8tvshow.com/1965_Impala_...1.23.14_15.JPG |
Make sure you put the steel bushings in the lower control arm bushings where the Camber adjusting screw goes thru the cross member.....easy to miss....ask me how I know........If you need some let me know as I have an extra set.........Also....when you finish the car and get the front end aligned....We had to put a lot of pressure on the front strut rod to get some caster in the front........Because the strut rods are solid mounted in the spherical bushing in the front.......the lower arm pulled forward on the bushings and the control arms were now rubbing against the inside of the cross member.........so we ended up shimming the control arm to get the Caster without the pressure on the arms...............Just Say'in !!!!
Ken |
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The front suspension parts bolted to the frame. These are obviously not torqued to spec for driving, but in place to mock-up the build.
http://www.v8tvshow.com/1965_Impala_...1.11.14_10.JPG Quick-ratio steering gear. http://www.v8tvshow.com/1965_Impala_...1.13.14_20.JPG The body was placed back on the frame, and the whole rig was supported on jackstands. It was time to finish fitting the 6.0 LS and T56 transmission in the car. http://www.v8tvshow.com/1965_Impala_...1.17.14_09.JPG The transmission tunnel would need completion, but there’s only one way to know if something really fits, and that is to put it together and measure. http://www.v8tvshow.com/1965_Impala_...1.17.14_16.JPG http://www.v8tvshow.com/1965_Impala_...1.17.14_26.JPG |
The floor opening was increased for the transmission and Quicktime bellhousing.
http://www.v8tvshow.com/1965_Impala_...1.21.14_02.JPG A loose cardboard mock-up was made to get an idea of the shape of the tunnel. This car will be running a stock 1965 Impala console, so a mounting surface was required for that as well. http://www.v8tvshow.com/1965_Impala_...1.22.14_05.JPG The new tunnel was made and welded in place. http://www.v8tvshow.com/1965_Impala_...1.23.14_06.JPG A few ribs were added to strengthen the firewall at the tunnel. http://www.v8tvshow.com/1965_Impala_...1.24.14_07.JPG Now we had plenty of clearance for the transmission. http://www.v8tvshow.com/1965_Impala_...1.24.14_12.JPG |
Next, the new transmission tunnel was fit to the original SS floor console.
https://lh3.googleusercontent.com/-l...2.03.14_20.JPG https://lh3.googleusercontent.com/-J...2.04.14_01.JPG After the new console mounting brackets were made and installed, a considerable gap existed between the side of the console and the transmission tunnel, so a new base was made out of fiberglass to fill the void. https://lh3.googleusercontent.com/-8...2.04.14_03.JPG https://lh3.googleusercontent.com/-i...2.04.14_05.JPG Wire framing was used to form the shape. https://lh3.googleusercontent.com/-L...2.04.14_07.JPG Fiberglass matting and resin was used to make the structure. https://lh3.googleusercontent.com/-k...2.04.14_09.JPG With the seats in place, and the new base sanded and primed, the gap is now filled. https://lh3.googleusercontent.com/-l...2.05.14_09.JPG This will be covered with carpet when finished. |
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Did you run viper to ls bellhousing and turn input down, or convert front plate and input to LS? Also, what are your plans for speed sensor? Thanks |
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