Finalizing the Malibu to GTO Frame conversion

The freshly cleaned gas tank was polished, its straps given a fresh coat of paint. The newly checked float, ensuring optimal range, was carefully installed into place, followed by the meticulous installation of the tank itself.

It’s time to trim and narrow the front frame rails. The Malibu’s rails are wider and a tad longer compared to those of the GTO.

The car was raised on jack stands and carefully leveled before work commenced on the rail ends. I used the center line for rail alignment and referenced the alignment holes in the frame, situated between the suspension and the cowl. I have diagrams for both the Malibu and GTO, providing factory measurements for precision.

I made step-cuts around the steering box to reinforce the frame for when the box is reattached to the rail.

A bit of adjustment here and there to align the angles correctly for its intended placement. Relief cuts were employed to facilitate the movement of the metal into position.

This offers a clearer comparison between the two frame ends. The first side is beginning to fit into position.

After aligning everything using the laser level and measuring alignment holes, the interior of both the rail and the piece were painted prior to installation.

The front rail on the driver’s side is finished, now moving on to the passenger side.

The identical method was employed on the passenger side, with constant measurement checks during fitting. The stack of old Malibu frame pieces that were trimmed to ensure proper fit. A plasma cutter proved indispensable for this task.

Taking shape.

With all the welds completed and the rail painted, it’s time to see if the front end will fit properly now.

All the weathered parts were reinstalled onto the car to identify all necessary hardware and ensure proper alignment with the body. It’s likely been a while since it resembled a car. The front and rear frames are now completed, transforming it into a GTO frame with accurate numbers!

Some welding was still needed to complete the lip of the trunk, rear seat mounts, and install the bucket seat mounts inside the car.

The rear seat still retains its tag underneath and appears to be in excellent condition overall. There was a spring that required some maintenance.

The rear seat was fitted into place, and the bucket seat mounts were positioned roughly where they should be. However, there are issues with the power seat, and the sliding bracket will need replacement to accommodate the brackets being fit on the floor.

The front end was disassembled again, and the areas where the upgraded tubular A-arms made contact were marked on the wheel wells. The components removed were cleaned in the parts washer before being placed in the blast cabinet.

The bumper brackets, lower headlight valance, and the edges of the wheel wells were repaired, with slight reshaping where necessary.

Some of the painted small parts

The radiator support, front bumper, and wheel wells underwent a thorough cleaning process, including pressure washing, degreasing, sanding, and painting. Additionally, the front bumper was polished before its interior was painted.

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