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1966 Malibu To-Do List for Floors and Trunk, Created Summer 1999.
El-Camino Parts Swap
  1. Buy ‘66 El-Camino. – Done, May 27, 1999 - $2150.00.
  2. Re-assemble Malibu front clip – Done, May 29, 1999.
  3. Remove front clip. – Done, May 29, 1999.
  4. Remove Air Conditioning – Done, May 29, 1999.
  5. Make firewall template for AC unit. – Done, May 29, 1999.
  6. Cut firewall on Malibu to fit AC unit. – Done, May 30, 1999.
  7. Weld plates over El-Camino firewall to close unused ducts – Done, May 30, 1999.
  8. Install heater box from Malibu in El-Camino – Done, May 30, 1999.
  9. Remove dash from El-Camino. – Done, May 30, 1999.
  10. Remove wiring harness from El-Camino. – Done, May 30, 1999. Harness burned!
  11. Paint El-Camino firewall with flat black – Done, May 30, 1999.
  12. Re-install heater hoses on El-Camino. – Done, May 30, 1999.
  13. Remove cooling fan finger guard from El Camino – Done, May 30, 1999.
  14. Install Malibu front clip onto El-Camino – Done, May 30, 1999.
  15. Align and fit front clip – Done, May 31, 1999.
  16. Install battery tray. – Done, May 31, 1999.
  17. Install Malibu bumper on El Camino – Done, May 31, 1999.
  18. Remove interior. – Done, May 31, 1999.
  19. Paint Malibu dashboard red for El-Camino. – Done, May 31, 1999.
  20. Paint interior red .– Done, May 31, 1999.
  21. Identify differences between Malibu and El Camino wiring harnesses – Done, May 30, 1999.
  22. Disassemble wiring harness from Malibu, remove heater wiring. – Done, May 31, 1999.
  23. Disassemble wiring harness from El Camino, remove AC wiring – Done, May 31, 1999.
  24. Re-wrap Malibu wiring harness with AC wiring. – Done, May 31, 1999.
  25. Re-wrap El Camino wiring harness with heater wiring – Done, May 31, 1999.
  26. Fix burned wiring in El Camino wiring harness. – Done, June 3, 1999.
  27. Replace all fuses in Malibu and El Camino fuse blocks. – Done, June 3, 1999.
  28. Fix burned wiring in steering column. – Done, June 3, 1999.
  29. Re-assemble Malibu dashboard for El Camino. – Done, June 5, 1999.
  30. Install dash and wiring harness in El Camino. – Done, June 10, 1999.
  31. Does it start? Do the headlamps work? – Done, June 10, 1999.
  32. Check and fix body wiring if necessary. (Why did the El Camino wiring harness burn up?) – Done, June 10, 1999.
  33. Check brake lights, turn signals, tail lights. – Done, June 10, 1999.
  34. Install red Malibu interior into El Camino.
  35. Paint El Camino white. – Done, June 18, 1999.
  36. Re-install body moldings, tail lights and bumpers.

Floor Pans / Interior

  1. Remove front clip. – Done, May 16, 1999
  2. Remove doors. – Done, May 16, 1999
  3. Paint floor braces with RM BLACK EPOXY PRIMER. – Done, May 16, 1999
  4. Remove dashboard – Done, May 21, 1999.
  5. Remove heater box – Done, May 21, 1999.
  6. Sandblast under dash on LH side, uncover all spot welds – Done, May 22, 1999.
  7. Paint floor all pans, both sides, with RM BLACK EPOXY PRIMER. – Done, June 18, 1999.
  8. Remove all convertible top and interior hardware from windshield.
  9. Remove all accessories from firewall.
  10. Remove windshield.
  11. Sandblast under dash on RH side, uncover all spot welds
  12. Sandblast firewall.
  13. Sandblast remaining interior areas (tunnel, rear seat area, etc…)
  14. Sandblast RH rocker panel to uncover all spot welds.
  15. Sandblast windshield area, windshield posts, and top of dash.
  16. Clean out windshield weep holes, and fill any rusted areas with body filler.
  17. Sandblast cowl area, incl. under grille.
  18. Sandblast or strip any remaining visible interior panels.
  19. Prime firewall, under dash, rear seat area, and tunnel with RM Black Epoxy Primer.
  20. Prime cowl, windshield area, pillars, top of dash, and other visible interior panels with RM White Epoxy Primer.
  21. Paint top of dash, pillars, other visible interior panels, and firewall with SW Black Catalyzed Acrylic Enamel.
  22. Replace RH and LH firewall floor pan sections.
  23. Remove LH rocker panel.
  24. Remove LH pinch rail.
  25. Fabricate LH and RH pinch rails, paint with RM BLACK EPOXY PRIMER epoxy primer.
  26. Install LH pinch rail.
  27. Install middle floor brace, weld to LH pinch rail.
  28. Install LH rear floor pan, weld to tunnel and floor brace.
  29. Install front floor brace, weld to LH pinch rail.
  30. Install LH front floor pan, weld to tunnel and floor brace.
  31. Remove RH rocker panel.
  32. Remove RH pinch rail.
  33. Install RH pinch rail.
  34. Weld floor braces to RH pinch rail.
  35. Install RH front floor pan, weld to tunnel and floor brace.
  36. Install RH rear floor pan, weld to tunnel and floor brace.
  37. Paint rocker panels with RM White Epoxy Primer.
  38. Install LH rocker panel.
  39. Install RH rocker panel.
  40. Grind all welds and re-weld if necessary.
  41. Paint all welds with RM BLACK EPOXY PRIMER.
  42. Paint floor pans with SW Black Catalyzed Acrylic Enamel.
  43. Seal all seams with black RTV. (Can I paint over RTV?)
  44. Install under dash soundproofing.
  45. Install heater box and gaskets.
  46. Install floor soundproofing.
  47. Install floor jute.
  48. Install new carpet and sill plates.
  49. Install dashboard
  50. Install windshield.
  51. Paint rocker panels white (temporary!).

 Trunk

  1. Paint all trunk pan sections and supports.
  2. Remove fuel tank
  3. Install LH body brace to trunk pan with Cleko pins, and check alignment.
  4. Weld LH body brace to trunk pan.
  5. Remove LH trunk pan.
  6. Weld new fuel tank support to LH trunk pan using original pan as a reference.
  7. Remove rust/paint from any areas hidden by the LH trunk pan.
  8. Paint with RM BLACK EPOXY PRIMER.
  9. Install LH trunk pan.
  10. Install LH trunk body mounts.
  11. Install RH body brace to trunk pan with Cleko pins, and check alignment.
  12. Weld RH body brace to trunk pan.
  13. Remove RH trunk pan.
  14. Weld new fuel tank support to RH trunk pan using original pan as a reference.
  15. Remove rust/paint from any areas hidden by the RH trunk pan.
  16. Paint with RM BLACK EPOXY PRIMER.
  17. Install RH trunk pan.
  18. Install RH trunk body mounts.
  19. Replace middle trunk pan section.
  20. Grind all welds and re-weld if necessary.
  21. Paint all welds with RM BLACK EPOXY PRIMER.
  22. Seal all seams with black RTV. (Can I paint over RTV?)
  23. Paint the trunk with trunk splatter paint.
  24. Install new trunk mat.

 Things that can be done asynchronously:

  1. Sandblast and paint armrests with RM BLACK EPOXY PRIMER.
  2. Replace felt on armrests, recover.
  3. Front Clip

a) Inner Fenders

o        Remove from front clip.
o        Strip old paint and primer.
o        Apply rust converter to rusted areas.
o        Prime with RM Black Epoxy Primer.
o        Paint with SW Black Catalyzed Acrylic Enamel
b) Fenders
o        Remove from front clip.
o        Strip old paint and primer.
o        Sandblast rusted areas of fender and mig-weld new sheet metal.
o        Prime inside with RM Black Epoxy Primer.
o        Prime outside with RM Gray Epoxy Primer.
o        Paint back side of fender with Black Catalyzed Acrylic Enamel.
o        Repair dings and dents, apply primer.
o        Paint inside visible portions of fender with Maroon Catalyzed Acrylic Enamel.
c) Hood
o        Strip old paint and primer.
o        Prime underside with RM Black Epoxy Primer.
o        Prime top side with RM Gray Epoxy Primer.
o        Repair dings and dents, apply primer.
o        Paint underside of hood with Black Catalyzed Acrylic Enamel.
o        Paint underside visible portions of hood with Maroon Catalyzed Acrylic Enamel.
d) Radiator Support
o        Strip old paint and primer.
o        Prime with RM Black Epoxy Primer.
o        Repair dings and dents, apply primer.
o        Paint with Black Catalyzed Acrylic Enamel.
e) Valence panel 
o        Strip old paint and primer.
o        Prime back with RM Black Epoxy Primer.
o        Prime front with RM Gray Epoxy Primer.
o        Straighten panel, apply primer.
  1. Rebuild door hinges.
    • Remove Door Hinges – Done, May 16, 1999.
    • Disassemble, clean, primer upper door hinges – Done, May 16, 1999.
    • Install new bushings and pins.
    • Disassemble, clean, primer lower door hinges.
    • Fix lower hinge detent mechanism. (Find new spring)
    • Obtain new attaching bolts.
  1. Paint fuel tank straps with RM BLACK EPOXY PRIMER.
  2. Restore dashboard
    • Disassemble dashboard -
    • Strip and prime dash with RM black epoxy primer.
    • Paint dash with SW Black catalyzed acrylic enamel.
    • Clean all dash components, ie: speedo, gauges, etc… - Done, May 25, 1999.
    • Roll odometer back to 0 miles. – Done, May 25, 1999.
    • Clean electronic contacts and check lights.
    • Re-assemble dashboard and wiring harness.
  1. Air Conditioning
    • Strip and prime under dash component.
    • Strip and prime firewall component.
    • Rebuild A/C Unit.
    • Paint both components with SW Black Catalyzed Acrylic Enamel.
    • Clean, inspect, and lubricate heater control cables, flaps, etc…
    • Fabricate/Locate new gaskets.

Other Plans (Long-Term)

  1. Re-skin doors.                      ($ 280.00)
  2. Install new SS Hood.                           ($ 300.00)
  3. Install new fenders.                             ($ 600.00)
  4. Sandblast and prime the cowl
  5. New Radiator Support                         ($ 140.00)
  6. Paint the car red.                  ???
  7. Install new weatherstripping.             ($ 800.00)
  8. Install new black interior.    ($1400.00)
  9. New grille and moldings.    ($ 400.00)
  10. New Front Bumper.
  11. New Rear Bumper.
  12. New rear moldings.
  13. New

Parts Ordered as of 5/6/1999            ($650.00)

  1. Fisher Body Manual. – RECEIVED.
  2. Factory Assembly Manual. – RECEIVED.
  3. Floor pan kit. – RECEIVED
  4. Front and middle floor braces. – RECEIVED.
  5. Rocker Panels. – RECEIVED.
  6. Door-hinge pins, bushings, and detent repair kit. – RECEIVED.
  7. Wiring diagram. – RECEIVED.

To be Ordered (floors):

  1. RM BLACK EPOXY PRIMER epoxy primer.
  2. Floor soundproofing insulation.
  3. Floor jute.
  4. New carpet.

 To be Ordered (trunk):          ($560.00)

  1. Trunk mat kit.                                        ($ 70.00)
  2. 7-piece Trunk pan/support kit.          *              ($ 300.00)
  3. Fuel Tank.             *                                              ($ 180.00)
  4. Fuel tank anti-squeak gaskets.                          $ 10.00)

 Diary (that I was able to keep up for a couple of days)

 May 5 to May 13, 1999:

    • Removed interior.
    • Sandblasted and primered battery tray.
    • Drilled out spot welds on RH rocker panel.
    • Cut middle floor brace and part of the floor pans.

Sunday, May 16, 1999:

    • Removed front clip and doors.
    • Disassembled and sandblasted RH and LH upper door hinges.
    • Removed lower door hinges.
    • Primered upper door hinges.
    • Cut out a cross section of the rocker panel, pinch rail, and stiffener.
    • Fixed LH lower door hinge detent roller.

 Monday, May 17, 1999:

    • Remove front inner fenders.
    • Strip inner fenders.

 Tuesday, May 18, 1999:

    • Continue stripping inner fenders.
    • Apply rust converter to inner fenders.

 Thursday May 20, 1999:

    • Primered inner fenders, touched up floor braces.

 Friday May 21, 1999:

    • Removed dashboard.
    • Removed heater box.

 Saturday, May 22, 1999:

    • Sandblasted under RH dash area, RH portion of tunnel.

Sunday, May 23, 1999:

    • Disassembled dashboard.
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