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PostPosted: Fri Nov 10, 2017 8:37 pm 
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Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4241
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
It looks rusty, and it is, but there's still plenty of thickness to this metal. This is the upper portion of the inner rocker, most of the rust is from the outer rocker that is spot welded to the top of it. But the spot weld drill hole tells me that the metal is mostly salvageable:
Image

Wire wheel, sanding wheel, and cutoff wheel to remove the metal that was too thin to be of use, then POR-15 what's left before riveting and welding in the new inner and outer rocker:
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And all done on the passenger side:
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Now I can start putting things back together. Starting with the cargo lamp switch, that broke when I tried to remove it:
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_________________
I don't know how much boost it takes to blow the tires off. But I know how much I'm going to use!
Image

Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, racecar! Build thread
'97 Chevy Camaro - 3800, T5, T-tops, my DD
'05 Cadillac STS - V8, AWD, her DD
'89 Buick LeSabre Limited - winter DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 project
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim


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PostPosted: Sun Nov 12, 2017 10:59 pm 
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Certified Bonneville Nut
Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4241
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
Sound deadening stage 1:
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Used the sound deadener stuff to seal off the 4x10 box area on both sides:
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Dash speakers also got the sound deadener treatment:
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The next layer goes in. The entire interior is covered with this stuff:
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And yet another layer:
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And, finally, the new MLV and jute backed carpet is in! I had to trim it, still need to put the holes for the seatbelts and the seat tracks, etc.... Not happy with the lack of the 4x4 shifter hole in this carpet, that was supposed to have it. There were a few other area's that needed trimming, but I guess, at the end of the day, this carpet fit better afer trimming than the original did, and is far higher quality.
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The latest kick in the nuts: The 4x10 speakers don't fit the original brackets. If I had known that the speakers wouldn't fit, I would have gone with something better than a 4x10. But, I'm stuck with these Kenwood speakers and having to make a custom bracket from MDF to mount them to. But, not a huge problem.

I ended up snipping the tweeter wires off all 4 speakers, and all set to wire up directly to the monsoon amp. So all 8 channels on the amp will be in use.

_________________
I don't know how much boost it takes to blow the tires off. But I know how much I'm going to use!
Image

Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, racecar! Build thread
'97 Chevy Camaro - 3800, T5, T-tops, my DD
'05 Cadillac STS - V8, AWD, her DD
'89 Buick LeSabre Limited - winter DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 project
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim


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 Profile  
 
PostPosted: Tue Nov 14, 2017 11:54 pm 
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Certified Bonneville Nut
Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4241
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
Worked on the dashboard tonight.

Got the dash sanded and trimmed down after the repairs:
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A layer of spacer foam to give the dash a soft feel
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And all wrapped!
Image

I still need to trim out the holes and put all the trimmings back on it, but otherwise it's all done

_________________
I don't know how much boost it takes to blow the tires off. But I know how much I'm going to use!
Image

Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, racecar! Build thread
'97 Chevy Camaro - 3800, T5, T-tops, my DD
'05 Cadillac STS - V8, AWD, her DD
'89 Buick LeSabre Limited - winter DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 project
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim


Top
 Profile  
 
PostPosted: Thu Nov 16, 2017 11:34 am 
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Certified Bonneville Nut
Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4241
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
More interior goodies!
Image

Working on the headliner next; had to do some minor repairs to the baseboard before I attempt to re-cover it. While I'm waiting on the fiberglass resin to harden (man, does that stuff stink!), I've got my work cut out for me to attempt to restore some other parts:
Image

Image

I do need to add the wiring harness for the mirror yet, and could probably finish wiring in the amp and head unit. Or grab the seat tracks from the parts car, or pop out the exhaust gaskets to find which one is leaking, or bleed the brakes again. We'll see what I feel like doing next!

_________________
I don't know how much boost it takes to blow the tires off. But I know how much I'm going to use!
Image

Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, racecar! Build thread
'97 Chevy Camaro - 3800, T5, T-tops, my DD
'05 Cadillac STS - V8, AWD, her DD
'89 Buick LeSabre Limited - winter DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 project
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim


Top
 Profile  
 
PostPosted: Fri Nov 17, 2017 12:22 am 
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Certified Bonneville Nut
Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4241
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
Got some more stuff done tonight. The headliner repairs are done, just needs to be covered, once the stinky fiberglass resin sets up. Finished wiring up the 'courtesy' lamps that will be the LED strips under the seats, finished the wiring for the speaker LEDs that you don't know about yet, wired in the head unit, and made templates for the amp mount and speaker mounts. Got the wiring harness for the autodim/compass mirror done, and the stereo Bluetooth mic hardwired in.

_________________
I don't know how much boost it takes to blow the tires off. But I know how much I'm going to use!
Image

Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, racecar! Build thread
'97 Chevy Camaro - 3800, T5, T-tops, my DD
'05 Cadillac STS - V8, AWD, her DD
'89 Buick LeSabre Limited - winter DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 project
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim


Top
 Profile  
 
PostPosted: Mon Nov 20, 2017 11:26 am 
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Certified Bonneville Nut
Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4241
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
Well, I had a busy weekend. It seems like I didn't make as much progress as I wanted, but then again there was a lot to do..

Those trim pieces that had shattered took several layers of epoxy to fix them; good thing I was planning to wrap them from the beginning:
Image

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Crazy what 33 years will do to the color of the interior on a car:
Image

After a bunch of work, I got the headliner and most of the trim installed (it was difficult to get a good picture, the camera flash messes with the colors):
Image

Then once I got the amp wired up I moved on to the seats. The plan is to make a frame that I can bolt the seat tracks to. I wasn't about to tear up the original bench tracks to fit, and I'd need to get another set anyway. So I ended up cutting the tracks off their mounting brackets that came with the seats. Unfortunately, my grand plans to put the powered seat tracks in did not pan out, they were simply too tall.
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I'm still debating if I should just weld the hacked up tracks directly to the frame I made. It would certainly make things a bit easier.

Other things I got done: Replaced the floppy hinge pins and bushings, re-hung the doors (will have to see how the drivers door lines up to the fender), finished wiring up the stereo and amp, re-installed the bottom of the dash, painted the kick panels as it doesn't make sense to wrap something that's going to be in contact with dirty shoes..

So next on the agenda is trying to find the matching seatbelt set from the GMT400. It looks like they will be a very close fit, if not 100% bolt on. The seat belts from the truck are a complete mess and not worth the hassle of trying to clean them up and the losing prospect of dyeing them to match; when GM already made a color matched set I can pull from a donor.

I bought 3 yards of the fabric to cover the interior, and I ran out before I could even get to the doors. I don't know how I could have done that, seems like when I measured it out before 3 should have done it. But it's not that expensive that I'm going to worry about it. I had to order more, so the door panels are coming off and staying off for a little while.

_________________
I don't know how much boost it takes to blow the tires off. But I know how much I'm going to use!
Image

Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, racecar! Build thread
'97 Chevy Camaro - 3800, T5, T-tops, my DD
'05 Cadillac STS - V8, AWD, her DD
'89 Buick LeSabre Limited - winter DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 project
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim


Top
 Profile  
 
PostPosted: Tue Nov 21, 2017 10:45 am 
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Certified Bonneville Nut
Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4241
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
Don't you just love it when you have a good set of drill bits?
Image

Taking the lazy way out, tacked the tracks directly to the frame:
Image

Image

The final test fitting:
Image

I never noticed it before now, but the one drivers side seat track is messed up. It's sloppy and the sliding lever doesn't release the mechanism that locks it in place. I'm going to have to fix that, hoping to find a good one in the junkyard later today when I go back for the blue seat belts that match the seats.

_________________
I don't know how much boost it takes to blow the tires off. But I know how much I'm going to use!
Image

Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, racecar! Build thread
'97 Chevy Camaro - 3800, T5, T-tops, my DD
'05 Cadillac STS - V8, AWD, her DD
'89 Buick LeSabre Limited - winter DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 project
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim


Top
 Profile  
 
PostPosted: Tue Nov 21, 2017 1:18 pm 
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Certified Bonneville Nut
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Joined: Wed May 13, 2009 10:45 pm
Posts: 5280
Location: CHICAGO
Year and Trim: 2006 Cadillac STS-V, 2004 Pontiac GTO
This is turning out awesome.

_________________
Image

Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2015 Chrysler Town & Country Limited Platinum: Mommy's NEW RGC
2007 Chrysler Town & Country Limited: Daddy's beater affectionately called the Rolling Garbage Can or "RGC" for short
2009 Chevrolet Impala SS: LS4 V8, Victory Red
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck


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PostPosted: Wed Nov 22, 2017 10:51 am 
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Certified Bonneville Nut
Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4241
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
So I figured out why the seat track was feeling sloppy:
Image

Image

Image


There's a three roller carriage inside the seat track. The primary roller that takes your weight, and two side rollers that hold the assembly tightly together. It would seem as if this seat saw a lot of action letting somebody into the back; the stamped steel flange that the side rollers ride on was bent up. I fixed it as best as I could, it's tight now, maybe a little too tight, but I don't expect that to be a problem.

I finished welding the seat tracks to the frame last night, but forgot to get a photo.

_________________
I don't know how much boost it takes to blow the tires off. But I know how much I'm going to use!
Image

Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, racecar! Build thread
'97 Chevy Camaro - 3800, T5, T-tops, my DD
'05 Cadillac STS - V8, AWD, her DD
'89 Buick LeSabre Limited - winter DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 project
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim


Top
 Profile  
 
PostPosted: Wed Nov 22, 2017 12:18 pm 
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Posts like a Northstar
Posts like a Northstar
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Joined: Thu May 22, 2008 11:38 pm
Posts: 1785
Location: Lincoln Park, Mi
Year and Trim: 2004 GTO
I would imagine that the seats wouldn’t even need to be moved. Even with my height deficiency I can reach the pedals with the seat all the way back.

_________________
Image
-Ryan
2004 GTO....LS1, 6MT
96 SSEi...September 2010 COTM........GONE
04 GTP comp G.... December 2015 COTM........GONE
2001 Volkswagen Passat, 1.8T 5MT......winter beater

yourgrandma wrote:
Hi.


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