Steve’s 2-year TAM Rebuild, part 2 – Back On the Road!

This is my final post covering the rebuild and startup of TAM, our 1969 Pontiac Firebird Trans Am convertible. Go here if you missed the disassembly of the car. This post won’t be wordy, but it will be picturey (is that a word?). Several of the shots were taken by my wonderful and talented photographer wife 🙂

As I concluded the last post, TAM had been moved into her new home. After hauling all of my parts, tools and equipment down there it was time to start the rebuild part of the project. Once I tore down the engine and took the major components and many new parts to the engine builder I started on the other systems:

Hi-ho, hi-ho, it’s off to the machine shop I go!
I installed all new front suspension and disc brakes front and rear
I used Leed Brakes for the booster, proportioning valve and disc brake components all around
Prepping the tranny for rebuild
A few weeks later the rebuilt transmission was hanging by a thread (well, actually baling wire)
Port-matching the intake manifold to the heads for maximum airflow. This is part of the blueprinting process, which entails meeting or exceeding manufacturer’s tolerances on engine assemblies. TAM’s engine exceeds in several areas 🙂
Testing the power top after replacing the 50+ year-old hydraulic system
My lovely assistant helped with installing the rear seat after the hydraulic work was completed
I installed a fuel cell in the trunk and moved the battery there for better weight distribution – and because it looks cool 😉
I love this image of TAM resting in her shop after a long day of work
After 7 months I finally got my completed long block back, and once I painted and assembled the rest of the engine it was ready to go back into TAM. It is a full roller cam/lifter/rocker arm valvetrain engine – bored, balanced and blueprinted
Works for me!

Dave helped tremendously with installing the engine and exhaust systems:

Another exciting day at the office…
With the exhaust system completed, we ran the main power and fuel lines forward to the engine bay

At this point Dave and Sue left for the summer on an extended RV adventure (lucky devils), so once I determined that I was going to re-wire the entire car I started on that project:

Lord have mercy, this is going to be a big job!
Above is the complete-car Painless Wiring System. I often called it the “Pain in the Ass Wiring System”, but it is an excellent kit. If you take on this job, be sure to get the higher-end kit that has all of the wires labeled. Wiring the entire car without the labels would have been impossible for me
This is the wiring to the fuses and relays for the fans and electric water pump

I should mention that I decided to install Electronic Fuel Injection (EFI) rather than a more expensive and finicky supercharged engine. However, integrating the EFI system turned out to be quite complex. After getting the lighting and most of the engine wired successfully, I was in over my head with the dashboard and some of the other computer components.

Because of the brutal summer we had in 2023 (over 125º in the uninsulated shop on many days) and just being burnt out, I put the project on hold for several months. I was about to hire an automotive electrician to help me finish the job when Dave returned from his trip and I learned that he’s an excellent electrician!

Dave assesses the situation
Figuring out which color and number wire goes where, how and why

The huge wiring project finally completed, we moved to the details of mating old technology with new. Dave fabricated a custom bracket for the throttle and transmission kickdown cables. He designed and shaped it, then I did the finish work. It came out gorgeous, if I may say so:

How cool is that!

Since then we’ve fired TAM up and fine-tuned the EFI, brakes and suspension systems. Here’s a video of the initial startup captured by Mona Liza:

She’s running and she’s running good!

We replaced the front end and hood in a few hours and installed a hood tachometer. TAM is now a (estimated) 425 horsepower fuel-injected street machine, and my dreams have been fulfilled!

One of my favorite engine compartment pics
TAM with her top up, which won’t happen very often
The center console had a bunch of holes drilled in it by a previous owner, so I had to either replace the entire console or somehow make it look nice. Dave came up with a solution – fabricate an aluminum plate to cover it. He made it, then I painted it and added a Trams Am body emblem. I’m very happy with the result!

We will soon upgrade the rear differential gears from the current 3.90 ratio to 3.55. That will make TAM better suited for long distance driving with this engine. It will be the last major change we’ll make to her (and my bank account).

Quite a difference under the hood…

Mona Liza made excellent smoothies to keep us energized while we worked

Here’s a short video of a little fun we had after completing such a major project…

Go Tam, go!


13 thoughts on “Steve’s 2-year TAM Rebuild, part 2 – Back On the Road!

    1. Aside from being impressed with the length of time you’ve been at this project and the result, my thoughts are:

      I haven’t seen a timing light in years…

      and

      I thought that re-wiring a single fuse on our CR-V to support being towed was hard.

      That light blue you used for the block is a favorite of mine ever since I saw Kawasaki use something similar on their Z-1R in 1978.

      No tickets!!! 😆

    1. My next project is paying for this project 🙂 But seriously, this is my last major rebuild. I might buy another car to tinker with, but my days of heavy lifting are over.

  1. I had a similar year Pontiac, rust everywhere. The tail pipe was rusty on the show room floor. This looks so much better than new.

  2. Brilliant! I have sent your post to my brother who continues to renovate various muscle cars. He will love it!

    Currently writing this in my RV as I watch the snow in Bryce Canyon!

  3. Well, look what you did! It must’ve felt thoroughly rewarding to fire her up. The best part, in my humble opinion, is the helper you have — not only a very knowledgeable fella, but someone you actually enjoy spending time with and don’t just need for assistance. Two rare treasures in this post!

  4. Two great posts Steve. I’ve only heard (in great detail) about each section of this restoration so it’s really cool for me to see pictures (mighty professional pictures, I might add) of the progression.  Super job!

  5. Wow, what a project!! All of those wires would have done me in, LOL. I probably would have created a bomb. So glad you had Dave to help you and of course, your lovely assistant ML to do the filming and supply smoothies to keep you guys fueled up. How cool to realize another dream! Have fun cruising in that beauty!

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