1966 Nova Gasser Build

By Ron Ceridono – Images by Dennis Overholser

The name Dennis Overholser is familiar to many automotive enthusiasts. He’s one of the founders of Painless Performance Products, which introduced wiring harnesses in 1991. Overholser is also an avid hands-on builder, and his latest project is typical of the unique hot rods he creates. This time around it’s a 1966 Chevy II Nova Wagon gasser build for the street.

Builder power washing grease and grime off a white 1966 Chevy II wagon project car secured on an open flatbed car trailer.
A real barn find, this four-door Nova wagon had been sitting for three decades. The first step in its transformation was a thorough cleaning.

Back in October 2019, Andrew Erichsen and Overholser went to Manhattan, Kansas, to get a Nova wagon that had been in a barn for around 30 years. The engine, transmission, fenders, and many other parts were missing. What it did have was four doors, two more than Overholser wanted.

Back in the heart of Texas, the wagon’s transformation began with help from Tom Denny. The stock front suspension was removed and replaced by a straight-axle gasser assembly from Speedway Motors. The new subframe came complete with axle, springs, steering gear, shocks, and brakes.

Overhead view of a black tubular gasser front subframe bolted to the cowl with leaf springs, mock-up engine block, and steering box in place.
The Speedway Motors front subframe was bolted in place, then the engine and trans assembly was mocked up to check clearances at the firewall.

To power the wagon, Overholser chose a GM 6.0L LQ9 from an Escalade. While the bottom-end remains stock, the engine was treated to head work, a complete Comp Cams valvetrain and was topped with an electronic stack injection system from Inglese. Backing the engine is a GM 4L80E transmission that connects to a Lincoln Versailles rear axle with disc brakes.

With the chassis work taken care of, Overholser turned his attention to making a major modification, turning the four-door wagon into a two-door. Larry Sparks and his son, Cameron, took care of the metalwork by removing the original doors, the B-pillar, and patching the roof section where the original B-pillar attached. New two-door sedan doors from Classic 2 Current Fabrication were installed with replacement two-door–style B-pillars from AMD (they also supplied the glass). What remained of the rear door openings were filled with a combination of the cut-down original doors and AMD patch panels that matched the contour of the new front doors. The final body modification was the installation of new right side rocker panel.

Detailed engine bay shot showing polished fenderwell headers routing around the steering shaft and chassis tubes next to an orange LS block with Inglese injection.
Nothing says old-school gasser like fenderwell headers. The exhaust system will run outside the frame stiffeners and exit in front of the rear wheels.

To be a proper straight-axle, nose-high gasser, fenderwell headers are practically mandatory. As none were readily available for this application, Doug’s Headers was called on to build a custom, one-off set. To complete the gasser look, the wagon rolls on Rocket 15×6 10-spoke wheels with Americus 165/80R15 tires up front. In the rear 15×8 U.S. wheels wear M&H Racemaster 245/55R15 “cheater slicks” that are DOT certified and street legal. Overholser added the “pie stripes” to the wheels—the old-school way to watch for tire spin when launching from a standing start.

With patience, persistence, and considerable effort, what was once a forlorn, four-door station wagon sitting in a Kansas barn has been transformed into a tribute to gassers of a bygone era.

It now has everything a proper gasser should have: a big engine poking out of the hood, fenderwell headers, ladder bars, and the right stance—and too few doors.

Check out this story in our digital edition here.

Engine hoist and chain rigging lifting the removed stock front clip and suspension assembly away from the front firewall of a 1966 Chevy II wagon.
The chassis update began by removing the entire stock front suspension assembly. It attached to the firewall with seven bolts on each side.

 

Bare front firewall and unibody frame horns of a 1966 Chevy II supported by orange jack stands during front suspension teardown.
With the front suspension and sheet metal out of the way, the firewall was cleaned and prepped for paint.

 

Close-up of the front solid tube axle, multi-leaf spring pack, shock absorber, and engine mount bracket on the custom fabricated gasser chassis.
As the engine mounts were adjustable front to back, it was easy to get the firewall clearance needed. The original transmission mount was modified to accept the overdrive automatic.

 

Wide garage view of the 1966 Chevy II Nova wagon rolling chassis with newly installed straight front axle, diagonal strut bars, and narrow steel wheels.
With the location of the engine mounts verified, the subframe-to-firewall supports were added.

 

Set of custom stainless steel fenderwell headers clamped in a steel alignment jig fixture on a metal welding workbench.
Doug’s Headers made a pair of jigs to fabricate custom one-off fenderwell headers for the Nova. This header is for the driver side.

 

High-angle view into the completed engine bay showcasing eight polished upright velocity stacks, FAST EFI management, aluminum radiator, and individual coil packs.
Sticking through a hole in the hood will be the individual stacks of an Inglese electronic fuel-injection system.

 

Underside view of a rectangular tube subframe connector held tightly against the floor pan and unibody frame rail with screw jack stands.
To stiffen the chassis, a weld-in kit from Chassis Engineering was added to tie front and rear subframes together.

 

Undercarriage perspective looking forward toward the rear axle showing tubular ladder bars, driveshaft safety loop, driveshaft, and wide Mickey Thompson tires.
The rear suspension uses the original leaf springs with a Chassis Engineering installation kit and ladder bars to hold the Lincoln rear axle is place.

 

Cut-out white factory center B-pillar upright section resting on the concrete shop floor after being unpicked and removed for the two-door conversion.
With all four doors out of the way, the factory B-pillars were removed. Note the gap in the roof where the B-pillar attached—this would have to be patched.

 

014 Driver-side cabin opening of the 1966 Chevy II wagon with the doors and center post removed to convert the body from a four-door to a two-door.
New two-door sedan doors from AMD replaced the originals. The factory hinges and hardware was reused.

 

 

 

 

Fabricators hanging and aligning a black two-door sedan door onto the wagon body to establish the new B-pillar position.
With the new doors hung, the next step was to install the new B-pillars and fill the gap left by removing the rear doors.

 

Side profile of the wagon body with a black two-door driver door installed, showing the modified rear door gap area ready for custom sheetmetal filler panels.
As the new front doors are longer than the originals, the rear doors were shortened to fill the openings.

 

Cut factory rear door skin and window frame assembly mounted on a wire stand with handwritten fabrication measurements.
The rear doors and window frames were cut, shortened, and welded back together.

 

Metal fabricator using a spirit level across the bare-metal seam welds between the quarter panel and door pillar to ensure straight body lines.
Here the edges of the passenger side rear door and quarter-panel are aligned and prepped for welding.

 

Fabricators test-fitting a black stamped steel quarter panel filler patch over the welded-up rear door opening on the wagon body.
Portions of two-door patch panels were used to blend the body lines in the now-extended quarter-panels with the doors. Note the section at the top that would have to be filled.

 

Metal technician using a pneumatic DA sander on the rear quarter panel and rocker seam to smooth welds and body filler.
The modified rear doors and patch panels were welded in place and ground smooth.

 

Looking forward along the interior door jamb showing the relocated and primed B-pillar post on the 1966 Chevy II two-door conversion.
After the new Auto Metal Direct B-pillars were welded in place and blended into the sills and quarter-panels, the modifications are impossible to detect.

 

Side three-quarter view of the Chevy II wagon with welded-up rear door filler panel in primer, black front door, and vintage chrome roof luggage rack.
The perfect alignment of the body lines and the uniform door gaps are testaments to Larry and Cameron Sparks’ metalworking abilities.

 

Front three-quarter view of the assembled two-door Nova wagon in full gray primer showing velocity stacks protruding through the hood opening.
With the bodywork completed, the Nova was primed, covered in guidecoat, and ready for a final block sanding.

 

Rear three-quarter outdoor view of the completed two-door conversion body wearing gloss white paint and a metallic turquoise roof.
Along with making the body straight as an arrow, team Sparks was responsible for covering the body in the original colors, Sea Foam Green over Ermine White.

 

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