1967 Pontiac Lemans #2 - budget build - episode one, introduction

October 5th, 2024:



October 6th, 2024:

Episode one, introduction, here.

Episode two, disassembly and assessment, here.

Episode three, rough body work, here.

Episode four, quarters, here.

Episode five, toe panel and rocker, here.

Episode six, fenders, inner fenders, here.

Episode seven, the doors, found here.

Episode eight, tail light panel, found here.

Episode nine - Hood, trunk, windshield gutter, cowl and firewall, heater box, found here.

Episode ten - Back glass gutter, grill, found here.

Episode eleven - headlight extensions, roof, found here.

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For a solid year, April 2023 to April 2024, I cut and welded and sanded on a derelict 1967 Pontiac Lemans and chronicled it in this blog over 14 episodes. I sold that car 6 months ago and the shop space was empty (first picture, above). I thought I was done with rusty hulks. But for reasons I don't understand, even after swearing off involved and difficult car restoration projects, I bought another. Another, as in another 1967 Pontiac Lemans (second picture, above).

What have I done?

This is the disease, the infection, the affliction, and once caught, one can never be cured of it. I have this disease, yet despite the pitfalls I'm actually glad I have it.

Here is the new acquisition:

Overview

This car showed up on Faceborg marketplace. What caught my eye, beyond the very familiar shape, was this car had a steering wheel. Yes, that was what first drew my attention. Upon further investigation it had an interior. And a dash. And (gasp!), an engine. This was a largely complete car, which was a great improvement over the previous Lemans project, which was little more than a body and a frame.

O, black Lemans, you had me at "hello."

Actually, the car was originally champagne with the gold interior, colors not really in vogue these days. It had a 326 2 bbl, a column-shifted automatic, power steering and manual disc brakes, the latter a surprising find. The only other option shown from the cowl tag is bright trim on the roof gutters.

This is overall a pretty basic car, but I imagine when new it was quite a looker. Sadly, years of neglect has left it looking pretty rough. But once you get past the garish color variations, surface rust, and dents, underneath there's a pretty solid car. At least, that's the way it seems at present. 

That's what I aim to find out, and to fix what I find.

Some prior owner wanted a hot rod, so the seats were replaced with later model high back buckets, air shocks were added to the back, and the power steering was disconnected and plugged. The radio was gone, the grill was gone, and the heater blower motor was gone. He also equipped the car with some wide meats on the back, which necessitated radiusing the wheel openings to make them fit.

Nooooooooo! 

Inventory

So, what did I start with? Here's the list:

• A surprisingly rust free foundation
• A very good frame
• All the front suspension
• A seized 326, probably the original
• An automatic transmission, probably the original powerglide
• A driveshaft
• An intact rear axle and suspension
• A good hood
• An extra trunk lid
• An extra rear bumper
• An extra driver's fender
• An extra core support
• An extra dash pod
• A questionable drivers door
• A skinned (badly) passenger door
• A horrible passenger fender
• Four tail light assemblies (three passenger, one driver)
• A gas tank
• A pair of repairable front inner fenders
• A cut package tray
• A good cowl structure, firewall and dash with a rusty w/s gutter
• All the side glass and window risers
• Both door latch mechanisms
• Inner and outer heater box
• Most of the bright trim
• Seats (fronts are from some other car)
• Power steering and column

What do I need to buy? (assuming I'm going to build the car to completion)

• Grill
• Grill nose piece
• Grill lower panel
• Grill vertical brace
• Driver's inner fender splash shield
• Cooling system
• Glass
• Wheels and tires
• Brakes/shocks
• Wiring
• exhaust
• rubber parts
• Locks
• Heater motor
• Various exterior trim pieces
• A thousand other little parts

What Needs Repair?

• Rear crossmember - Completed 10/24
• Wheelhouse flanges - Completed 10/24
• Quarter lips - Completed 11/24
• Wheel house rust - completed 12/24
• Passenger quarter panel body work - completed 1/25
• Driver quarter panel body work -
• Tail light panel - Completed 12/24
• Driver quarter tail light eyebrow - 
• Both door skins - Completed 1/25
• Doors inner - completed 3/25
• Rockers - Completed 1/25
• Door jambs -  2/25
• Both fenders - Completed 1/25
• Fenders, inner surfaces -
• Radiator core support rust - Completed 11/24
• Core support prep and paint -
• Front window gutter - Completed 2/25
• Front inner fender rust - Completed 11/24
• Inner fender prep and paint -
• Passenger toe panel - Completed 12/24
• Hood skin -  Completed 1/25
• Hood inner - completed 3/25
• Trunk - completed 3/25
• Trunk inner - completed 3/25
• Windshield gutter - Completed 2/25
• Heater Box - Completed 2/25
• Rear window gutter -
• Roof dents - 
• Nose panel dents - completed 3/25

The Plan

What am I going to build? Not a restoration, because it's just a garden variety Lemans. Plus, they made a little over 75,000 of them in 1967, so they are by no means rare. But I do want to retain as much of the original feel as possible since it's really a beautiful style, which means no shaved door handles or mini tubs, no leather interior, no bags, and no billet aluminum pieces. 

At first I thought I would take a different approach from the previous Lemans. That car was solely a rust repair and panel replacement project with no attention given to the non-existent mechanicals. However, this Lemans won't need much panel replacement (fingers crossed). 

Since this car has its running gear, my plan at first was to make the car run and drive. Well, plans have changed, because that seized engine is not savable. I'll cover that in episode two.

After consulting with my wife, the course I'm now taking is to repair the various rust issues. After that, I don't know. Bodywork and paint? Source the mechanicals?

I'm setting a goal of 6 months, April 6 2025. I won't make it...

Rust Repair

Some really key areas are solid on this car: Floorpans, trunk pan, lower cowl areas, rockers, the lower front of the quarters, the firewall, the frame... All good. Though I expected a relative lack of rust, more rust was discovered. 

There's always more. Which is why I didn't make my 6 month goal. 

There's a lot to be done:

• The quarters. Sigh. When the wheel opening lips were rolled they were cut loose from the wheel houses, so those areas need to be reconstructed. Happily, these areas don't appear to be rusty. but I can't have them loose like that, and I can't have debris coming up through the gaps. 

• The lower quarters behind the rear wheels are full of Bondo. So I'm really hoping they are are good enough to repair. I really don't want to replace the entire quarters, having done this on the previous Lemans.

• The lower back areas of both wheel house have some cancer. 

• The doors. After spending hours on them I decided that neither were savable. I bought OEM replacements and fixed their minor issues.

• The rear window gutter. This area had bondo slathered on it. Having chipped some of it away, I can see the damage to the understructure is rather severe. 

• The front window gutter. The glass will need to be removed.

• Taillight panel. There's some rust holes around both taillights. I later discovered that the driver's side quarter panel above the taillight was basically gone, recreated with a thick slathering of bondo.

• The passenger toe panel.

• Both front fenders have rust on the lower area behind the front wheels. Typical. 

• The passenger rocker has some cancer.

Summary

I'm hoping that once I dig in I won't find many surprises. Since I won't need to buy a bunch of expensive replacement panels the total expenditure on the car could be less than what I spent on the previous Lemans. 

As before, I will document the progress of this project in the episodes shown at the top of this page. Thanks for reading.