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Sunbird build thread


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#1 neglectedtorana

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Posted 29 April 2014 - 08:20 AM

Hi All,

 

Firstly to all the other forum members that have already posted build threads and info on the forum, thank you! There is a great amount of information on here that makes resto work easier.

 

I have been on the forum for a while taking it in and throwing my 2 cents worth here and there and decided it was time to start my build thread. So here is the history up to present on my build.

 

I am restoring a 1977 Torana Sunbird or Holden Sunbird or just Sunbird depending on what you want to call it.

 

My Dad was a Trading Post Dad, got it every Thursday morning and circled all sorts of things by the time I got to it at the end of the day.

 

He was most disappointed when it went out of print and became online only but before it that happened he bought this car because it was in good nick and he likes to buy stuff. I understand it was a 2 owner car as a young bloke had bought it from his Grandad, had 96000km’s and faded paint, manuals in the glove box and pretty original etc.

 

It was registered and available to be used so I did use it and one day when the oil pressure dropped in the Starfire 4 cylinder and it ceased to turn I spent a weekend swapping in a 308 and Turbo 350.

 

I used it for about 6 months before I got the traveling bug and went overseas in 2000. It then sat in a garage for a few years with another of Dad’s Trading Post purchases, an MG from 1966.

When the garage was no longer available the Sunbird sat in a yard and the grass grew around it until June 2011 when I decided it was time to restore it.

 

Thought I could get it running and have a paint shop touch it up and back on the road for $10,000. Well as many of you will know I was very wrong and it is still in resto mode and the $10,000 mark was passed long ago.

 

The pictures will show the work but at present it sits in a mate’s garage with new paint, front and read screens installed and a new roof lining from Cools Auto Trim. Has a new 9inch diff and needs everything else to be put back in it.

 

I am trying to fit an LS1 and T56. Engine and gearbox were in and out about half a dozen times early on as I tried to work out how to clear the rear cross member near the shifter hole and have enough sump clearance up front. I am still trying to work it out. Did have some trouble with the Tuff mounts allowing enough clearance to the cross member and after talking with Jason from Velocity Auto have just received a new set of arms I am yet to try but hope will make it all fit.

 

I plan on modifying the original loom and buying the HP Tuners software so I can get it running without VATS and tuned to suit the installation. I will probably make the extractors using one of the 4-1 kits from DiFillipo exhausts.

 

I have a short extension housing for the T56 I got from Mal Wood Automotive that also I have not finished fitting but hope it makes all the difference around the rear cross member.

 

Once I have the extension housing fitted to the gearbox and the new Tuff Mounts I am hoping it fits and lines up. I don’t want to have to cut the tunnel and if it means cutting I may go back to the 308 or spend the cash on a TKO600, will wait and see.

 

Wheels will be Walkinshaw 5 spoke, brakes will be VN or later, interior will be fairly standard looking with material inserts in the chamois vinyl, paint is original Aquarius

 

Pictures below should show the work sequence. Hope you all enjoy and thanks for the help so far as I have learnt a lot without having to do it.

 

Progress from here will be a little slow as I am working overseas for the next few months but hope to get into it later in the year and be driving it before Christmas (although I did originally think the whole project would only take me 6 months).

 

Cheers, Tom

 

Guess it was more than long grass

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Cut the grass

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Rats had made a nest under the brake booster

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Spiders had made babies inside

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In the shed ready for the resto

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#2 neglectedtorana

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Posted 29 April 2014 - 08:32 AM

Started stripping it to get it blasted

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Then all of a sudden it looked like this

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One of the 1st attempts

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Plenty of room here

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#3 Shiney005

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Posted 29 April 2014 - 08:48 AM

Looks like it was a great body to start with. What model are these? Is it an LX Sunbird?



#4 neglectedtorana

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Posted 29 April 2014 - 08:50 AM

And now it looks like this

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Yes it is an LX Sunbird

The i.d. tag says LX Torana so guess it is the Sunbird model of the LX



#5 purrlx

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Posted 29 April 2014 - 11:50 AM

Not 100% sure but I thought the sunbird LX was the 4 cylinder model???



#6 Shiney005

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Posted 29 April 2014 - 11:53 AM

8UG69???

#7 _LS1 Taxi_

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Posted 29 April 2014 - 12:06 PM

Wow!
I had an lx sunchook same colour and trim combo. Mine had the opal 4 banger in it.
Your car brings back some memories!

#8 _LS1 Hatch_

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Posted 29 April 2014 - 12:13 PM

Nice to see another LS powered car coming together :)

And that sure is tall grass! ha ha..


On the trans, I used a camaro box in mine, and did need to raise the tunnel along with some other trimming and plating here and there. Along with making my own crossmember of course too. Quite happy how it all came out in the end though and as you'll see...plenty of fun to drive!

#9 _mick74lh_

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Posted 29 April 2014 - 01:28 PM

Awe cool. I love how you've stuck with the original colour too. Be sure to share plenty of photos of the rest of the build.



#10 _AD_75_

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Posted 29 April 2014 - 03:14 PM

Sunbird only came in LX series didnt it? body looks like it came up okay after a blast. :)



#11 neglectedtorana

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Posted 29 April 2014 - 03:21 PM

It was originally the 4 cylinder 1.9L with floor shift auto

Same cross member as the rest so was easy to go to 308 

 

I was not sure about the colour as I really like Barbados green and the Brock blue from the 85 VK but once I made 

the decision to go with the original colour never looked back.

It looks more green in the flesh, can't get it to come out right on camera

 

Hardest part is being away for work and not being able to do anything for the next few months



#12 BIG KEV

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Posted 29 April 2014 - 05:19 PM

That looks cool ...well done

#13 neglectedtorana

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Posted 30 April 2014 - 10:43 AM

Not sure if the Sunbird was LX only.

Trimmer and diff shop thought it was a UC being a Sunbird but it definitely is an LX.

 

Can't remember the engine code and won't be able to access it for a few months

 

Glad the colour and LS1 are appreciated by others, thanks



#14 Redslur

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Posted 30 April 2014 - 07:37 PM

Just for your info, the LX and UC Torana used the Sundird option, it was the 4 cylinder variant.  LH's 4 cylinder version was the Torana 1900.  Hope that clear things up :-)

 

Nice car by the way.  Love Aquarius....



#15 _Lazarus_

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Posted 30 April 2014 - 08:45 PM

Bloody hippies...............

 

 



#16 neglectedtorana

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Posted 06 December 2014 - 09:31 PM

Time for an update

 

Put the pinch weld on around the door frames and 2 of the door rubbers, need to drill some more holes in the other 2 doors as looks like they were welded up in the rust repair process

 

I bought a shorter gearbox extension housing from Mal Wood and have fitted it to the T56 and put the engine and gearbox in again. Got some new Tuff mounts from Velocity as the ones I was originally sent were different lengths.

 

Had to disassemble the gearbox completely to change the shift rail for the shorter extension housing. Might get my reassembly checked and have it shimmed by a professional.

 

The shifter ends up in a better spot and the cross member behind the gearbox will not need modifying however the tunnel will still need to be raised, can't get the gearbox high enough to fit the rear mount without it hitting the tunnel.

 

I didn't want to cut the tunnel and am yet to decide if I will. Weighing up best options. Looks like it is the only way if I am to continue with the LS1 and T56 and I think I am past the point where I want to put the 308 back in.

 

 

 

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#17 Statler

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Posted 06 December 2014 - 09:44 PM

lol. You can't stop now!.



#18 neglectedtorana

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Posted 09 December 2014 - 04:08 PM

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Some more progress, better buy a MIG



#19 _LS1 Hatch_

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Posted 11 December 2014 - 01:59 AM

Nice progress so far, and the floor will come together ok once you get the welder going !

#20 Jay#2

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Posted 11 December 2014 - 05:34 AM

That shorter gearbox housing really makes it a good job, should be easy enough to form the trans tunnel around that.

#21 _LS1 Hatch_

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Posted 11 December 2014 - 06:22 AM

It looks similar to the factory F body setup? Here is the one in mine. (Out of a 2000 Camaro) Might be a little shorter still actually.. Street & Performance over here was selling a couple different style rear housings as well from memory..

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#22 neglectedtorana

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Posted 11 December 2014 - 09:11 AM

You're right it will come together easy once I have a welder

 

Although I was trying to not cut the tunnel it does make it easier and it will be easy enough to get it back together. Spoke to the engineer and he said any welding on the new tunnel has to have at least a 15mm overlap and I was worried it would be difficult to make a nice neat butt weld so that is some relief

 

With the short extension housing I did not have to cut the cross member behind the gearbox so although it requires cutting the tunnel not cutting that cross member makes it easier on my skills.

 

Picture of the extension shows a bit better how much shorter it is

 

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#23 neglectedtorana

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Posted 31 December 2014 - 03:12 PM

Did some more tinkering, have fitted door locks, inside door mechanisms, front windows and winders with new bailey channel etc and toyed with the idea of using the VZ dash from the donor vehicle.

 

Had to cut some plastic of the dash housing but might end a realistic option with some more work.

 

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#24 Bigfella237

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Posted 31 December 2014 - 11:38 PM

Nice dash conversion Tom but I predict many hours of fun learning about GMLAN single-wire CANbus modules in your future!

 

Everything in that cluster is computer controlled over a "Controller Area Network" (CAN) that runs through the whole car, the instruments don't connect to the engine and transmission as with older cars but are instead 'told' what to display by the ECU and BCM. Same goes for the backlighting, warning lights, high beam/indicator telltales and the DIC (the little LCD screen).

 

I'm not saying it can't be done, but it's gonna get mighty technical... maybe you know all this already? At least it sounds like you have a complete functioning donor car (or at least one that was) which is a huge head start, a lot of these CANbus modules are keyed to the vehicle's VIN as well so make sure you record every detail from the donor vehicle in case you ever need to replace anything later.

 

I'm following with interest as I've thought about transplanting a later model dash myself.



#25 neglectedtorana

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Posted 02 January 2015 - 11:45 AM

Thanks for the info Andrew,

 

 

I know it won't be straight forward but am hopeful.

I have the entire loom from the car and both the original ECU and BCM

 

Hoping that like turning of VATS there may be options for which displays can be used, some time in the future I will plug it all in and see what I can work out






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