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> Project Routy A 1969 Firebird Project by V8TV.com
CPU
post Feb 23 2011, 11:38 PM
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Dateline: Feb 2009

V8 TV's project car - a 1969 Pontiac Firebird named "Routy" - has finally entered the building. It has been patiently waiting in storage in the frozen tundra of Wisconsin, and owner Steve Prouty finally got a break in the weather and hauled it to the V8TV shop. The car is in pretty good shape, we don't anticipate any major panel replacement or real surprises, but we'll see when we get into the project. Here's the intro video with the car, and the other "goodies" Steve brought down from America's Dairyland.





Stay tuned as we add each episode.

Many Thanks to the boys at V8TV.com


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CPU
post Feb 25 2011, 08:32 PM
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Part 2 The Tear Down

Tearing down muclecars to their bare bones can be a big mess. Luckily this phase of the project 1969 Pontiac Firebird named "Routy" went pretty well. Since the car was already mostly disassembled, it came apart fast, and they didn't have to change the name to "Rusty". Now that the car is blown apart and on the Autotwirler rotisserie, it's next stop is the media blaster where the piece-parts and underside will all be stripped of the flaky paint and undercoating residue. Then they'll know the real truth.. if this car is as clean as it claims to be, or if there are any secrets hiding under the primer.




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post Feb 28 2011, 12:51 AM
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Part 3 Body Media Blasted

The moment of truth... project 1969 Pontiac Firebird "Routy" came home from the media blaster. They had the interior, underside, trunk, and firewall of the body tub blasted, along with stacks of smaller parts like the inner fender wells, the radiator core support, and all the bumper brackets. They also had the complete subframe and suspension parts blasted, but that's a different story. This time, they're taking a closer look at the condition of the body. This car had many previous repairs, and they say it's not really fair for them to point out the details of previous work, but they think it's important to illustrate what they found and to make some observations on what they're starting with.



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post Mar 3 2011, 06:57 PM
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Part 4. Update

The 1969 Pontiac Firebird project "Routy" is going through the early phases of its transformation, with many small detail items being checked off the list as they go. In this installment, they fix rusty bodymounts and straighten some slightly damaged supports on the subframe. Then they're repairing rust holes in the radiator core support, inner fenders, and small holes in the body. They uncovered a patch in the fender they didn't like, so they replaced it with new steel using some cool butt-welding panel clamps from Eastwood. A quick spray with Standox SprayMAX 2K Epoxy Primer keeps the part protected until the bodywork phase. This stuff is cool.. it's a Standox 2k epoxy primer in an aerosol can. That means it's got a primer and a catalyst in one container... you break the seal on the can, and the two components mix inside the can. You have to spray it out within about 1 week or it will harden in the can. It's really tough stuff that sprays great over little repair areas like this where you don't want to mix a whole gun full of material. The firewall was welded up in anticipation of a Vintage Air air conditioning unit. The subframe and front sheetmetal parts were sprayed with Eastwood Epoxy Primer and Extreme Ceramic Chassis Black paint for long lasting protection and a factory-like satin appearance. Finally, we installed some Global West Del-A-Lum bushings in the front suspension pieces. Next phase... floor and trunk floor repairs!



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post Mar 6 2011, 07:50 PM
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Part 5 Floor Replacement

Their 1969 Pontiac Firebird project "Routy" was a pretty clean car to start with, but they wanted to improve upon some previous repairs in the floor and trunk floor area. In this installment, They replace the driver's side floor pan with a 1-piece replacement from Classic Industries. There are tips in this video that apply to any musclecar restoration.




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post Mar 9 2011, 03:12 PM
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Part 6 Trunk Floor Replacement

The trunk floor area in their 1969 Pontiac Firebird "Routy" was looking pretty rough, so they elected to use an assortment of repair panels from Classic Industries to replace the rust and previous damage repairs. The process went pretty smoothly, and they were able to butt-weld and plug weld the new pieces in leaving a factory appearance with no evidence they were ever there. A coat of Eastwood Epoxy Primer will help keep them rust free for good.



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post Mar 12 2011, 03:12 PM
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Part 7 Wing Install

Getting the reproduction Trans Am wing ready for install.





Part 8 Masked for primer & the coated in Parayable Standox Polyster

The polyester has been blocked, the seams are sealed, and now it's all masked up and ready for primer!




Here's what the Firebird looks like in Sprayable Standox polyester filler... Like a giant birthday cake iced in white!




Part 9 V8 Water Pump Modification Tip

The Pontiac 400 V8 engine that we're using in our 1969 Firebird project called "Routy" came to us completely as a rebuilt log-block with all new parts inside, but we were charged with the task of doing the final assembly and detail work. This time, we're test-assembling the brackets and parts on the engine, and came across a great tip to help keep your Pontiac V8 engine running cool.



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post Mar 18 2011, 11:22 PM
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Part 10 Suspension Install

They reassembled their restored front suspension with some new tricks to make our 1969 Pontiac Firebird "Routy" drive and handle better. First they replaced all the stock worn-out control arm bushings with some new Global West Del-A-Lum bushings for minimal deflection and smooth articulation. Then they replaced all the loose steering components with new parts from Classic Industries, including a new steering box, tie rod ends, center link, ball joints, idler arm, and pittman arm. Once they could put the wheels back on, they rolled the subframe under the body, aligned it, and bolted it up. Out back, they added some Del-A-Lum bushings to the Detroit Speed & Engineering 3" drop leaf springs and put the rear axle assembly back in the car. Classic Industries had more hard-to-find nuts and clips for the front leaf spring mounts. Now they can hang all the sheetmetal back on the car and start the panel alignment!





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post Mar 18 2011, 11:23 PM
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Part 11 Sheetmetal Install

After the subframe was re-attached to their 1969 Pontiac Firebird "Routy," the reassembly began. First up was the sheetmetal, namely the doors, fenders, core support, and the reproduction steel Trans Am hood. They had to do a few tricks to make them all line up correctly, but it wasn't too bad of a project. Here's how the process went.





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post Mar 21 2011, 02:26 PM
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Part 12 Painted DuPont Hot Hues Red

After completing all the bodywork on their 1969 Pontiac Firebird, they disassembled the body to paint the tub with DuPont Hot Hues Red Hot Meltdown 2-stage urethane. After the red had flashed, the crew masked off the jambs and sprayed them with DuPont Clear. Then the fenders, doors, hood, and other parts were shot red, and the jambs and backsides cleared. It looks good in red!



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post Mar 21 2011, 02:30 PM
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Part 13 Currie Rear Axle & Baer Brake Install

They're building this car to have awesome drivability, and they wanted to use components that could stand up to some occasional punishment. It's no secret that the Currie 9+ rear axle systems are up to the challenge. They already had the Boyd's Junk Yard Dog wheels and Nitto 555 tires, so they worked backwards and fit the rear axle to the car and wheels. In this case, they used a custom narrowed Currie housing loaded with a Nodular iron center section, 3.25:1 gears, a Detroit Truetrac differential, and 31 spline Currie axles. The Truetrac is a nice piece because it offers smooth, quiet operation, and locks automatically when needed. Once it was painted and installed, they added a Baer Track 13" rear disc brake kit. In front, they again used a Baer Track kit with 13" rotors and dual piston calipers for awesome stopping power. An Eastwood powder coated CPP master cylinder and stainless brake lines from Classic Industries round out the system.




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post Mar 21 2011, 02:32 PM
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Part 14 Climate Control and Sound Deadener

They wanted their 1969 Firebird to be fun to drive, and that ment keeping the interior free from unwanted noise, and climate controlled. This time, they're installing Hushmat sound deadoner and heat insulation in the cabin, then adding a Vintage Air A/C system to keep the occupants cool. Some reproduction 1969 Trans-Am style gauges and dash pieces from Classic Industries as well as a Flaming River tilt steering column complete the job.




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post Apr 28 2011, 03:49 PM
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Part 15 Engine Install and First Start


The time came to install the rebuilt 1973 Pontiac 400 into our '69 Firebird. It's running a rebuilt bottom end, roller rockers, #16 Pontiac iron heads, a Professional Products intake manifold, MSD ignition, h Holley carb, Royal Purple break-in oil & filter, and Eastwood coated long-branch exhaust manifolds leading to MagnaFlow exhaust. Also shown is the Vintage Air compressor and accessories from Classic Industries.






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post Apr 28 2011, 03:52 PM
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Part 16 Flush Glass and Final Paint Spray


In this video, we final install the classic auto glass innovations flush glass and prep our 1969 Pontiac Firebird "Routy" with 3M wetsand paper, tape, and mask paper and bring it to the booth for final application of DuPont Hot Hues Red Hot Meltdown color. Part 1 of 3.








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post Apr 28 2011, 03:59 PM
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Part 17 Final Paint Spray Video #2


The paint sprayout continues with our 1969 Pontiac Firebird project "Routy." This time, we're spraying DuPont Hot Hues Red Hot Meltdown color and intercoat clear in preparation for the painted stripe treatment next. We're spraying with the 3M PPS system to minimize cleanup time and solvents, and to help measure the mixture accurately. Eastwood Pour-It lids also make things easy, and SAS Safety gear keeps everyone in top shape. Once the color was applied, a 3M Sun Gun was used to check the coverage. Part 2 of the paint application series.







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post Apr 28 2011, 04:01 PM
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Part 18 Final Paint Spray Video #3


The final video covering the paint process on our 1969 Pontiac Firebird project "Routy." This time, we're laying out the stripe design and spraying the DuPont silver and Gun Metal stripes. Later, we do the initial wetsanding with the 3M Trizact system, including the new 3M Denibbing gun. Lastly, we polish the car using 3M products. Next is the final assembly and installation of Holley's Avenger EFI system.







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