Kiwibirdmans 1968 Pontiac Firebird Convertible

[Kiwibirdman]

After more than a year of working on the Firebird its about time to start a build thread. @j.e.d. had been asking.

First the back story sharn about this car. I first saw pictures of it in the paper when its was stilling in a car dealers yard in New North Rd in 1986. I remember the car and still have a copy of the advert which I was given when I bought the car. It had been stolen and recovered, minus engine and gearbox and was bashed around with the interior destroyed.

Fast forward 10 years and I had not long got back from a 4 month holiday in Europe and was at a friends place when he said we are going to Whangaparoa to look at Peters Firebird, do you want to come. Peter has to sell it, he has run out of money building a new house and wife is giving him grief about his cars. My mates father was thinking about buying it.

We went up to the house, opened the garage and found a pile of boxes that had a car buried under them. We cleared it off and pushed this car out side. It was red, on rusty HQ holden wheels, ripped roof, no bonnet, noting in the engine bay, not grill, headlights etc, My mates father walked once around the car, scratched his head and said too much work for me. I had a bit of a rummage in the garage and found the seats and boxes of bits. It looked like it was pretty much all there.

We pushed it away and went home. When I got home I found a Pommy Hot Rod magazine that I bough while I was on holiday. In the cars for sale section was a 1968, 350HO Firebird Convertible. Strangely I had been drawn to that car when I bought the magazine. 

A couple of days later I rang Peter and said is the car still for sale and if so how much. The answer was yes and $12k. Sounded fair enough to me so I said it going to take me a couple of weeks to get the money, I need to refinance my mortgage and add a bit more. Bank came to the party and 2 weeks later the car was mine. 

As an aside I got a call about a year later from a reasonable well known Whangaparoa Hot Rodder asking if I owned the car and if so how much did I pay. Yes I own it and paid $12k. This guy, who was known for dicking people around said he offered $15k for the car. I guess I got a good deal and it pays not to stuff people around.

When I collected the car I went up with a car transporter one weekend and go the car, filled with parts, and back the next weekend to get the rest of the parts. Peter had got a lot of good bits out of really well optioned 400HO coupe that got written off. This included a nice black delux interior, power windows, remote mirror. 

The deal included a 350 Pontiac in bits, a 400 Pontiac that needed a rebuild and actually got swapped for a running 350 Pontiac out of another car that was being turned into the written off 400 HO car. There is a yellow firebird out there which isn't quite what it is portrayed as. I also have the original bonnet off that car, but that is another story.

 

[Kiwibirdman]

Firebird sharn part 2. Over the next 5 years I slowly rebuilt the car, having a badly paid job that required me to travel a lot meant that I didn't have the time or money to do the car fast. The final push to get it done was getting married and it was the wedding car.

It got finished in time, 350 Pontiac, not an HO motor but I found a 4 barrel manifold and put an Edelbrock 600cfm carby on it and with a set of headers it went well. It also had a turbo 350 auto with a hi stall converter, a set of SS Cragars and it was pretty cool. Here is a photo from our wedding day.

Over the next few years we used the car off and on. Once the kids were born it didn't get used much when they were small. Also with the autobox, high stall and 3.23 diff it did about 2700 rpm at 100 kph. That is not much for a jap 4 cylinder, its half way to the red line on a Pontiac. It was noise and thirsty and not much fun on a trip.

About 10 years ago we went to see my wifes family in Holland and I drove my brother in-laws left hand drive manual station wagon. This changing gear with the right hand isn't a bad idea, I wonder about the firebird. Not long after we got back I found a Pontiac bell housing and flywheel, then a T5 out of an 1989 TPI Camaro and a friend had an 11 inch GM clutch that he didn't need that would fit. 

The flywheel turned out to be not a Pontiac, I sold it and to this day still don't know what it fitted, possibly big blog Chev or Oldsmobile. I bit the bullet and bought a new fly wheel, hurst shifter and a hydraulic release bearing. The release bearing was a bad idea, i couldn't get enough clearance and I blew the seals out of it twice. Other wise the manual swap was a great success. I had always wanted a manual V8 and in 5th gear it was doing 1850 rpm at 100kph. It will happily go over the harbour bridge at 1250 rpm in 5th. The torgue of a Pontiac is awesome.

 

[Kiwibirdman]

Firebird sharn Part 3, About 4 or so years ago I was going to an oldschool Auckkland meet up and backing out of the garage hit the door post. This pushed in the righthand quarter panel. I new it had bog and there we bubbles coming though. Popping the panel out made most of the bog fall off. Since I already had one car in a million bits the Firbird got parked and ignored for a few years. I robbed the HZ Holden brake calipers of it for the EJ Holden, then the brake master cylinder and finally the front wheels.

When the Holden was getting close to finished I started ordering bits. From classic industries  I got 2 new back guards, both sides had been flared out to clear big tires, a boot spoiler and a bunch of other bits like the proper remote mirror and new badge for the centre of the bumper.

I wrote a list of all the things that needed to be fixed, clutch mechanism- get rid of the hydraulic release bearing, better brakes, new front seats-the original drives seat was bent and they were like sitting wooden park benches, fix the rust and paint.

Summit racing supplied an external hydraulic slave cylinder, clutch fork and release bearing. In another order I bought a kit to fit C5 corvette discs and calipers. This was from Classic Performance and was based on a new cast stub axle. I like the idea of using factory parts so that pad etc will always be available. 

Even though Corvettes run 17 inch wheels I had to get 18 inch to clear the calipers. Not what I wanted but I'm happy with the result.

 

 

[Kiwibirdman]

Here is the place to discuss

 

[Kiwibirdman]

Writing this up has caused me to think about how much has been done so far. I had the gearbox rebuilt. Ever since it went in the change from 4 to 3 would not go without double clutching. Up changes were fine and down changes for all other gears were good as well. 

I took it to a guy in Puke that @cletusrecommended. He asked what was wrong and explained and said otherwise box was quiet and changed well. He said that while it was apart might as well do all the synchros and bearings. When I picked it up he said that it was amazing that any down shifts worked and all the bearings has lost their preload. Amazing that it did as well as it did.

While that was out I made a bracket for an external slave cylinder, universal from Rock auto but designed for a jeep, and refitted the original clutch fork came with bell housing. The pedal now has proper travel and is jap car light. It still needs the final adjusting/massaging once I can drive the car. It is light enough for the wife to use OK. Not sure that is a great idea. Also never took any photos, sorry.

The next major job was fitting the new back guards. I had been watching a body man from New Foundland in Canada call Fitzee on YouTube. He did some videos on swapping panels and has a system called Cut and Butt. This inspired me to have a crack, working on the theory that the guards weren't expensive and if it all turned to crap I could buy another one. It was also a good excuse to buy a Mig.

Here are a couple of phots of the bad guard

H

Here it is with the guard cut off. Amazing how little rust there was, I was worried what I was going to find.

And the final product

Here is the other side finished

I did the drivers side first. The first cut into the guard took a out of doing, mainly the thought of cutting up a really expensive car. I did remind myself that I have had it for 25 years and it only owes me a about $25k. Once the fit cut was done it was all on. I took my time and it worked out pretty good. For anyone who wants to do something similar here is the link.

 

 

[Kiwibirdman]

Overdue for an update. The car is at the painters, they have hocked into it and making good progress. I had done a lot of the prep work but it needs finishing off by some one competent. Both doors had the front and rear corners replaced. There were old patches that were failing, mainly due to not painting under the repairs. I also replaced the bottom of both guards and then had them blasted. Found more rust, surprise.....

I pulled the engine and gearbox out the night before it went to the painter, I can get some other stuff sorted, like cleaning it and fitting the EFI. Photos to come.

[Kiwibirdman]

Here are some photos of the paint job

.

I brought it home today. The guards and bonnet are still at the paint shop, I'll collect them once the chassis rails are painted and engine in.

Quote from oldest son, Even though it is the same colour it looks completely different.

Also went via the certifier to get a baseline toe test on the front suspension, 34mm of change through the full motion. Just have to make it better than that with the CPP C% corvette brake kit. I have some factory style raised tie rod ends that should do the trick.

[Kiwibirdman]

Quick update. I have been bolting stuff on to the car, engine is painted and in, EFI manifold is on. The corvette brakes are back on, with the new tie rod ends the bump steer is much better. As the suspension drops it doesn't go cross eyed any more. I'm sure it does move a bit but nothing like stock.

The plan has been to clear the piles of parts up from being spread round the house and put them back on the car. I have been procrastinating about bolting the front guards on. Basically I'm scared of scratching the paint, first gen F-bodies must have the inner guard bolted to the guard and then the whole lot put on the car. Need to find my big boy pants and just get on with it.

When I was going through the EFI stuff I opened up the box for the regulator and found a fitting missing. This is the only thing let to get to finish off the fuel system and get it running. Not looking good for getting another one before the end of the month. 

I promise a better update and photos soon.

[Kiwibirdman]

I lied Very long time, no posting. Car is more or less together, runs and drives and has had a the first run through with the cert check.

It was a big fight getting the panels to line up. Jack the car up and the door gaps shift all over the place. The the drivers side has come up pretty good, the passenger side not so much. The right hand guard has been hit a couple of times and even had lead in it as part of a very old repair. Reality by the time I bought the patch panel and had the guard blasted, it was most of the price of a replacement. 

The cert check came back with a list of stuff that is mainly easy, Some of the stuff is wheel studs are too shot by one turn of engagement, lock washers on the rear spring shackles and tighten up the engine mount bolts.

Also in the list is move the exhaust so that it clears the driveshaft on full droop (only been like that for 25 years), Crush tubes on the spacer for the belly plate and lock nuts on the drive shaft U Bolts. 

The EFI is awesome. Once I sorted the timing out, I completely fucked that up first time round, it fired instantly and idled perfectly. It might be my imagination but it sounds quieter than before. The in tank pump is noisier than expected, this might be because I don't have carpet and sound deadening in yet.

The last major challenge is the clutch, It is a hydraulic master cylinder, to an external slave and doesn't want to disengage properly. I am wondering if I need a bigger master to get more fluid to the slave. There also might be some air in the system, I have to take the slave off to bleed because the bleed nipple ended up on the bottom. 

All of it is fixable with the right application of time and money. It is still meant to be finished by Americarna, even though we probably wont take it down.  

 

 

[Kiwibirdman]

Here is a photo or 2 and a bit more of an update. I'm really happy with the way the car sits. Getting rid of the cast iron intake and putting on an alloy one has raised the front about 20mm. This is well hidden by the wider wheels. Front are 18x8 and rear are 18x9.5. Originally I wanted 17 inch wheels for a bit more sidewall, but they wouldn't go over the brakes. I am a bit worried how I will get on with the shit state of the roads.

 

The EFI is not really obvious at first glance, just the end of the fuel rails and the regulator on the side of the motor. The reg is temporary until the proper one comes from the US. It is an Edelbrock that goes onto the fuel rail in the same style as most factory EFI. One of the things I had to fix was no shroud on the fan. I have mounted an electric fan in front of the radiator, not done in this photo. It will be controlled by the computer.

[Kiwibirdman]

Took it for the recheck by the certifier. Couple of minor things that got missed the first time, missing lock washers and a sway bar that didn't get bolted back down properly. Wont take long to fix. Then all it needs is a dry day for the road/brake test and we should be away.

I took it out on Sunday night to bed the brakes in, and much driving like a lunatic couldn't get them to fade so the test should be fine.

I will be great to have it done and driving legally, only been 6 years since the last WOF

[Kiwibirdman]

One step forward and 2 steps back. The car passed the brake test but locks the back wheels up at the end. It doesn't have a proportioning valve so putting in an adjustable one will sort this out. 

The big issue is that the BMW seats I put in have failed because I trimmed the mounting legs, which is a big no no. It this point I'm going to put the original seats back in and later on get them made a bit more comfortable. Luckily I'm only in this for less than a $100 and 20 hours of my spare time.

Also have to fix the leak out of the drivers side rocker cover, it runs down on to the exhaust and smells evil. Normally a 10 minute job but there is almost no space between the brake booster and the cover. I have been procrastinating because it looks like a prick of a job.

 

[Kiwibirdman]

Certification is done. The oil leak ended up being the wires going to the alternator getting caught under the corner of the rocker cover. Rookie mistake. Original seats back in and Willwood proportioning valve installed.

I also fixed the interior lights that have never worked. A couple of LED bulbs then made rubber spacers to go on the front edge of both doors to hit the switches. 

Still a list of stuff to finish off. Align the front panels and get the bonnet to fit properly, strip paint and fit the lower stone tray, add sound deadening under the back seat. Nothing important, just stuff to keep me out of trouble.

Booked for a WOF next week. Dangerously close to having everything legal. 

Future plans, drive it.... lots

[Kiwibirdman]

On the first go for the WOF it failed on the LH outer headlamp low beam barely working, indicators flashing too slow and LH rear brake only 40% of RH

Headlight was pull the plug off and push it back on, now works. I swapped the flasher units between the indicators and the hazard lights (2 flashers on these) and then the brakes. I adjusted and rebleed with a fair amount of air coming out, should be good. Went back for the recheck, lights, indicators all good brakes still the same. I had a spare drum which I chucked on and gave it another bleed. Nothing but fluid for the first couple of pumps then this monster air bubble. Got back to the mechanic about 5 mins before closing on friday. Chucked it on the machine and good enough for a pass. 

I did the rego on line and when we came back on Saturday from a week away there was a nice new rego sticker. Sunday afternoon youngest son and I took it for its first legal drive in over 6 years. At 80mph on the northern motorway all was good, lots of wind noise with the windows down and the roof up. 

The EFI helps for a nice drive, good brakes,clutch is light enough. Already for some summer miles./

Big day in my life, every vehicle I have is legal. Still plenty to finish off and other toys to play with.

[Kiwibirdman]

I finally took the car back to the painters for the final buffing. Happy would be a major understatement.

I have never had such a nice looking car before, I have to admit driving it around after picking it up freaked me out, far too nice.

Last night I put the badges on, which changed the way it looked again. I still have the wheel arch trims to go on. I don't think it was a bad thing to leave it for 15 months to let the paint go good and hard.

Many thanks go to Dan the painter at Trevor Hanson Collision Repairs who did the paint and final buffing.

Off to Americarna at the end of February. Still have a few things to sort out, need a boot around the gearlever, exhaust is hitting somewhere in the back.......always something to do. Big sound system to drown out the noisy EFI pump.

Also the starter decided to not work when it was hot. I got stuck at a burger place in East Tamaki on Christmas eve. Lucky manual so could bump start OK. Went home and ordered a reco one from Rock Auto. Turned up 4 January and cost $190 sitting in my garage.

Anyone want a works when its cold Pontiac starter, big and heavy enough to be a mooring for a good sized launch, free to a good (or bad) home.

[Kiwibirdman]

Not sure where this year went. Didn't get to take this to Americarna. I thought the alternator had died. Turns out it was the battery. This happened the night before we were due to leave. Ended up taking the Silverado instead.

I took the car for a WOF last week, passed with a warning thatvthe brake lights would sometimes stay on. Turns out tge switched needed adjusting. 

The car did a massive 365 miles between WOF checks. 

Been working on making it better. The noise from the fuel pump was annoying. I dropped the fuel tank out and covered the top of it with sound deading. This has stopped a lot of the noise transfer into the car. So that was a win. 

Also played around with the clutch slave cylinder. It was very close to one of the header pipes and I was worried about it getting cooked. I had made a heat shield, which seamed to make things worse. I have moved the slave so now ther is 20 mm gap to the closest pipe. Hopefully this will be ok.

Also fitted the wheel arch trims, i wasn't sure that I liked them. They are on now and will stay.

As usual I forgot to take photos. 

[Kiwibirdman]

Here is a photo from the other day.

It is amazing how the wheel arch trims change the look of the car.

I had been playing around with the EFI, it was still pretty much at the default settings. 

The Edelbrock user interface is really easy to use. I leaned up the cruise AFR and gave the engine some more advance, especially the vacuum advance. 

Driving on the motorway I had my sone in the passenger seat watching the real time display. (this is sitting in the garage with the engine off)

It took about 5 kms driving to learn the new AFR which the target had gone from something like 13.8 to 14.6. I was really impressed.

Sitting on about 70 mph on the motorway north of Albany it was on 9% throttle. 

The other thing I found was the throttle was only opening to where the secondaries on the throttle body just cracked. A 5 minute bend on the accelerator pedal and throttle goes to 100%. Not that a mild 350 Pontiac needs 1000 cfm, it did need more than the guestimated 400 cfm it was getting to.

On Sunday went for a drive out to Hunua to see @sheepers and collect a Holden workshop manual. The car is a joy to drive and even gets reasonable fuel economy.

Its only going to take 35000 miles for the fuel savings to pay for the EFI conversion. Considering its taken me 28 years to do 17000 miles I better drive this thing a lot more. 

From a its so much better perspective the EFI is an absolute win and worth every last cent.

[Kiwibirdman]

Over the long weekend I took the Firebird to Napier with a bunch of other American car owners. My son took our 1990 Corvette.

The Firebird did really well. In the nearly 29 years I have had it this is the longest trip it has ever done, total was about 1200 km over the 4 days we were away. Over the time the stuff settled down, the brakes feel better, more to do with all the crap being burnt off the rear brake shoes than anything else and the gearbox is shifting much better.

I have a list of things that need looking at, clutch needs slight adjustment, brake light switch keeps working loose and leaving the brake lights on, the drives seat is bent (always been like that) and gets uncomfortable and the 2 really annoying things, an oil leak on to the headers an both tail pipes hitting the diff and the back springs. 

I worked out the cars does somewhere between 12 and 13 litres per 100, the corvette looks like it does 9. I'm pretty happy with the economy, even with EFI its still a 60 year old design with pretty low compression. 

Just as an aside, the Corvette used to do about 10/100 before a set of headers and a full twin exhaust. The increase in torque was very noticeable, I certainly didn't expect the economy to get better as well. There is probably more in it, I know my son was giving it the Welly every chance he could.