By Tommy Lee Byrd – Images by the Author
When it comes to converting an old muscle car into a modern-day performer, you have plenty of options. The aftermarket support for Chevy muscle cars is excellent, and you can pick and choose components to dial in the handling and performance of your car. Kevin Biggs has owned this 1966 Chevelle SS396 for several years and has put thousands of miles on it, thanks to a stout 502ci big-block and TREMEC six-speed manual transmission. The car had some mild modifications, like lowered suspension and disc brakes, but he was ready to take it to the next level. For this, he called upon Dan Kauffman and Derek Bradley at Pooles Mill Rods in Cumming, Georgia, for a complete chassis and drivetrain swap to turn his street cruiser into an aggressive Pro Touring monster.
Kevin studied his options, and it was determined that a full chassis upgrade was more practical than piecemealing a suspension system on the stock frame. Speedtech Performance got the call for one of its Extreme series frames, which features box welded construction, added bracing, and a long list of upgraded mounting positions, providing vastly improved suspension and steering geometry. The Speedtech chassis uses tubular control arms up front, along with a pair of JRi double-adjustable coilovers and a splined sway bar for a bulletproof combination. Sweet Manufacturing rack-and-pinion steering makes for quick steering response. The frontend features Speedtech forged spindles, utilizing C7 Corvette hubs, which offers easy fitment of Baer 14-inch rotors and six-piston calipers.
Out back, Speedtech uses a torque arm setup rather than a conventional factory four-link, offering added stability. Another pair of JRi coilovers ride out back, and the rear suspension is kept level with a splined sway bar. The 54-inch-wide, 9-inch rearend features 3.70:1 gears, 31-spline axles, and a Detroit Truetrac differential. Another pair of 14-inch Baer disc brakes roll out back. Rolling stock consists of Forgeline AL203 wheels, sized 18×11 up front and 18×12 out back, and Kevin is running a square tire size configuration of 315/30R18 for incredible grip.
For horsepower, Kevin had grown comfortable with the thirsty big-block but he wanted more, so he opted for an LS swap to bring the Chevelle into the modern era. He chose a Chevrolet Performance LS7, which was already an outstanding combination, producing 505 hp in naturally aspirated form. Pooles Mill Rods swapped the stock cam for a Brian Tooley Racing PDS Stage 3 camshaft and associated valvetrain components. The bottom end and cylinder heads are all stock, but the top end features a Whipple 2.9L supercharger, which makes 7 pounds of boost with a moderate pump gas tune. The car put down 760 hp to the wheels thanks to the tuning efforts of Lance Disharoon at Millcreek Calibration.
The engine features Ultimate headers, and a custom 3-inch stainless steel exhaust by Dan Kauffman. The blown LS7 is kept cool with a Wizard Cooling radiator and dual SPAL electric fans. Kauffman built the intake piping as well as the engine bay closeout panels. He also massaged the inner fenders to accept the extremely wide tires and wheels and smoothed the stock firewall. A great mixture of black and gray finishes gives the engine bay a killer look. Kevin reused the TREMEC T-56 six-speed that was in the car before.
Kevin wanted to retain the car’s aesthetics, so great care was taken to protect the paint, trim, and glass during the chassis and engine swap. The paint and body has some age on it but still presents well and it allows Kevin to get out and drive without worrying about chips. The only modifications to the original sheetmetal included a new trunk pan, wider wheeltubs, and a raised rear floor section to provide adequate suspension travel for the ultra-low stance. Inside, he upgraded from stock bucket seats to TMI buckets but retained the original console. Pooles Mill Rods 3-D printed the A/C control bezel as well as the center A/C vents, giving it a truly custom look.
The chassis swap process only took a few months and Kevin’s Pro Touring conversion was ready to hit the highway. Since completion, Kevin has enjoyed the added horsepower and handling capabilities of his Chevelle, as it’s a night-and-day difference from the old setup. The stance, the wheels, and the immense horsepower provide big-time wow factor, while the unchanged body and interior still remind him of all the fun times he’s had in the car through the years.
Kevin gave his Chevelle a serious attitude adjustment, and the guys at Pooles Mill Rods helped get this build across the finish line in a timely manner. Kevin is thrilled with the results and enjoys ripping his old Chevelle through the East Tennessee back roads every chance he gets.
Check out this story in our digital edition here.
TECH CHECK
Owner: Kevin Biggs, Ooltewah, Tennessee
Vehicle: 1966 Chevrolet Chevelle SS
Engine
Type: LS7
Displacement: 427 ci
Compression Ratio: 11.0:1
Bore: 4.125 inches
Stroke: 4.000 inches
Rotating Assembly: Forged crank, titanium rods, stock pistons
Cylinder Heads: GM castings, 259cc intake runners, 70cc combustion chambers
Valvetrain: 2.205/1.610 valves, Brian Tooley Racing valvesprings
Camshaft: Brian Tooley Racing PDS Stage 3, 231/248 duration at 0.050, 0.617/0.595 lift
Ignition: Stock coils
Intake: Whipple 2.9L supercharger
Assembly: Pooles Mill Rods
Exhaust: Ultimate headers, custom 3-inch stainless exhaust, Flowmaster mufflers
Ancillaries: Holley valve covers, Wegner Automotive front drive system, Mighty Mouse Solutions catch can
Output: 760 hp
Drivetrain
Transmission: TREMEC T-56 Magnum six-speed, McLeod clutch, Lakewood bellhousing
Rear Axle: Narrowed 9-inch (54 inches), Detroit Truetrac, 31-spline axles, 3.70:1 gears
Chassis
Frame: Speedtech Performance Extreme Series
Front Suspension: Tubular control arms, splined sway bar, JRi coilovers
Rear Suspension: Torque Arm, splined sway bar, JRi coilovers
Brakes: Baer 14-inch rotors, six-piston calipers
Master Cylinder: Baer
Wheels & Tires
Wheels: Forgeline AL303 18×11 and 18×12
Tires: Falken 315/30ZR18
Interior
Seats: TMI bucket seats
Steering: Ididit tilt column, Sparco steering wheel
Console: Stock with custom details by Pooles Mill Rods
Shifter: American Powertrain
Dash: Stock
Instrumentation: Auto Meter
HVAC: Vintage Air
Audio: Kenwood head unit, hidden speakers
Exterior
Paint: Old paint, Madeira Maroon
Hood: 1966 Super Sport
Grille: Stock
Bumpers: Stock
Lights: LED
