Proto-GT Sterling Project ~ Faye ~

[455SterlingProject]

Howdy everyone, figure its about time i make a build log. Meant to do this over a year ago and well, life lol.

Little over a year ago i purchased an oddball sterling off BAT (Auction) That had no interaction from the seller and had too many unknowns for anyone to bid. Luckily for me, i found this forum rather quickly and thus the original owners forum post about it (Thread Here). I quickly learned that while aged there was a very good engine hidden in the back (Olds 455 block o bigs lightly modded to 463) and alot of fun to be had once rebuilt. So a single $2100 bid later plus 2150 in shipping, she arrived at my door. Battery swap and a jumpstart later (didnt have the keys for a few weeks) Me and a buddy actually got it running and did a lap around the block no issues. She was alive and well. Well, not super well.

This was where the fun really began because after this point i stripped the interior and fully inspected everything. While Russ had kept it garaged its whole life, the kid who bought it from him a year prior left it outside in his driveway uncovered and the elements did a number on everything. From what Russ told me (I did get in contact with him via his email for his original for sale post) The kid bought it and immeditely asked Russ how to change the battery. There wasnt a chance in hell it was going anywhere. So thus it sat until he had to move cross country to North Carolina the kid posted it to BAT.

While the bones were good the wiring wasnt fully done and some bits had shorted and burned up. The custom coolant water tank had 3in of fallout in the bottom due to the original antifreeze separating and was now rusting away. While the gas tank itself was good i simply hated the idea of a 26 gallon bomb being lesss then 4in from the engine and 2in from my back. I get rear ended by someone on their phone and im getting insta-cremated. It all needed redoing.

And so the project ive affectionately nicknamed Faye (Cowboy Bebop if any of yall are familar haha) began~



Russ's Original Build Sheet. I never got the photos and such shown in the listing. I barely even got the car itself and keys. Kid refuses to answer a phonecall. Was like 4 texts total i ever got. Amazing i even got the car to begin with honestly.

 

[455SterlingProject]

First jobs were just in removal of all wiring, tubes, and such. Overall went smoothly as removals always do.

Rebuilding the front of the engine SUCKED. The front timing cover also acts as the mount for the entire engine and due to the geared timing its a juggle of getting the hold bolt in place while also getting the gasket and RTV set then bolted down with the water pump at the same time so it all seals. I want to meet the person at OLDS who thought making the water system pass through the timing plate was a good idea. I STG i grew 2 new hands just to get this done. I pray to whatever diety wishes to listen that i never have to take that back off. Found out after that i had mis-measured and got the wrong water pump (They had 3 versions of couse) but its only like a 1/4 out of alignment so i think it will be fine. I bought 2 spare belts just to be safe. Once its on the road we'll see how it does but its idled and rev'd with no issues since.

 

[455SterlingProject]

Wiring REDO i decided to go for the American Autowire 'Highway 15 Plus' Kit. Having installed 95% of it now i can definitely recommend it. Not perfect but honestly for the price and what you get i have zero complaints. All of the wire is high quality and the switchware was solid. I picked my kit up just under $600.

After the front cover i did the valve cover gaskets, valley pan, and oil change. Luckily the inside looked perfect for 5k miles. No rust issues from sitting for so long which was great to see. The original Quadrajet failed inbetween driveway runs (Secondaries stopped opening for some reason). Either going Edelbrock 1906 AVS2 650CFM or if my buddy can figure out the issue the old Quad.

Brakes were next. Calipers look good and the lines were replaced by Russ around 2022 it seems. The brake master however was shot. Russ took a toronado master and cut the top to RTV fittings to the res under the fronk. Sitting for so long water did get in and pit up the master. Took a TON of researching but im currently attempting to use a 1997 Eurovan Master. 1in bore and same flange as the original. I say attempting as my current one is DOA and not building pressure so im trying to Warranty it. Hard to do so when the manufacture is asking for the Vin LOL.

 

[455SterlingProject]

That about sums up the current status. Last photo is how she currently sits. I have mounted new fuel cells but no photos this minute. Getting close to the end. Another 2k in parts roughly and she'll be done and on the road. Im trying to aim for December but we'll see. Its been a journey. I originally told myself itll be done by last winter but that came and went so fast. Owning 3 other semi rare/exotic vehicles really ties one up for time and monies lol.

But as i say now, aint nothing to it but to do it and she wont run if you cant work. Time to get at it~

 

[sector]

Excellent write up. Good to hear that this one will be saved as so many just get neglected and eventually destroyed. Keep us updated, as such stories also create motivation.

 

[455SterlingProject]

Got the defective brake master swapped finally. Need to bleed the rears still but fronts are bled and it holds good pressure. Tanks roughed in place, just need to finish the line run once i get the back wall halves and new carb installed.

The Eurovan master cylinder fits perfectly in place, just needs a slight angle to clear steering. 1/4 drill bit works for now but i will be 3D Printing a proper bracket soon. I'll share that file on here aswell incase someone wants to do the same.

All thats really left is new carb, harnesses, and tires as far as new purchases go. I can taste the finish line.

 

[sector]

And those tanks don't interfere with seats? You have enough leg room?

 

[455SterlingProject]

And those tanks don't interfere with seats? You have enough leg room?

So the original tank setup actually goes to the exact same height point but then angles up at 60 degrees for another 4-5in for even higher capacity. I havent test fit the seats yet but it should be an identical fit. Im 6ft flat and i already had to have the seat like 5in forward to comfortably reach the pedals. The driver side pan is dropped about 2-3in which helps dramatically. I still contenplate dropping the original tank back in but the bomb risk if i get rear ended is just so dang high.

 

[sector]

Interesting, I am 5'11, my car has 4" drop floor and I still had to remove seat rails from miata seats to comfortably fit in my car. In my car the floor to roof measurement is 34". I know that your Sterling is a GT with taller roof so I am curious what you have for the floor-to-roof measurement.

 

[455SterlingProject]

Been away on vacation all last week. Took a quick measurement while i winter prepped the cooling system today. Measured out to 34 same as yours. The only thing i can think is the seat angle and pedal box distance/setup? Stock setup is very leaned back. Sitting more upright im close to the roofline but def still have SOME room, the current seats are somewhat sunkin in with age. That could contribute but hard to really say.

 

[sector]

Thanks for sharing that info.