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Specializing in the 3g CSM
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PostPosted: Thu Aug 15, 2013 2:50 am 
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The happy administrator
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Joined: Tue Apr 20, 2004 3:20 pm
Posts: 5583
Location: Wisconsin
I decided to fix the annoying no-valve-cover-clearance issue on my '78 Cutlass while the motor was out. The heater box sticks out just far enough to make it near impossible to take off the passenger side valve cover, back spark plug, and don't even think about taking out pushrods, when a big block (455) is swapped into it. Swapping to a non-a/c box moves the blower motor into the same place so this was my only choice.

Things I used:

Dremel with a cutoff wheel
Few rags
12"x18" piece of "Mechanic's Mesh" (1/4" square wire mesh)
Wire snips
Zip ties
Drill/bit
Shop Vac (to suck up the fiberglass dust while cutting/drilling)
Resin and giant sheets of fiberglass

First I cut out the old A/C core in the heater box and drilled holes around the perimeter.

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Then I formed the mesh and started zip tying.

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Then the fiberglass dust that escaped the vacuum got the best of my arm.

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I closed up the hole as much as possible with the zipties, keeping the locking part inside the box but eventually the hole got too small.

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So I used a couple buttonhead screws I had in the bin.

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Then the first layer of fiberglass went on. Pretty simple, cut your giant sheets into manageable pieces, mix your resin, brush a little onto the wire first to keep the sheets in place, then lay the glass, and brush on enough resin to saturate the glass.

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I did 3 layers and let it dry for a couple days. It's rock solid and almost as thick as the original box. A quick coat of satin black and she's ready to go.

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Then I got a bug up my ass about my engine bay, cleaned it and painted it.

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_________________
Had a:
1991 Eagle Summit ES Hatchback - 4g15 12v 5spd
1991 Dodge Colt -4g15 12v 4spd
Have a:
1978 Oldsmobile Cutlass - 468BBO TH350
Round 3:
1990 Dodge Colt-4G63T 5spd


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PostPosted: Sun Aug 25, 2013 10:02 pm 
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Some call me a god

Joined: Thu May 05, 2005 2:31 am
Posts: 1789
Location: Commerce City, Co
We want more pictures of the car.

_________________
1985 Mitsubishi Cordia
Build in progress


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PostPosted: Mon Aug 26, 2013 3:55 am 
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The happy administrator
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Joined: Tue Apr 20, 2004 3:20 pm
Posts: 5583
Location: Wisconsin
I'll take some more pics and throw up a build thread.

Found halo's on the bay, I love em. Seems to get a hate/love reaction.

Image

Image

_________________
Had a:
1991 Eagle Summit ES Hatchback - 4g15 12v 5spd
1991 Dodge Colt -4g15 12v 4spd
Have a:
1978 Oldsmobile Cutlass - 468BBO TH350
Round 3:
1990 Dodge Colt-4G63T 5spd


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PostPosted: Mon Sep 02, 2013 8:30 am 
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The Silent Administrator
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Joined: Wed Dec 24, 2003 3:32 pm
Posts: 9514
Location: Ottawa, ON, Canada
Tron was made around that time frame right?? :D

Looks great, and so much more practical to work on, as you say.


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