Full-Frame Nova

Modern Rodding TECH

InTheGarageMedia.com

1. Fitting a full frame underneath a unibody car can be a challenge. DSR handles the task with high-end design and fabrication.

Full-Frame Nova

Divers Street Rods Installs an Art Morrison Enterprises Chassis Under a ’67 Chevy II

By Tommy Lee Byrd

Photography by Diny Divers

he availability of complete custom frames has changed the game for hot rodders, especially those in the Pro Touring segment of the hobby. Chassis and suspension technology has come a long way from the days of hacking the front suspension out of a Mustang II or Chevy Nova in a junkyard. These days, a full frame makes a lot of sense, but make no mistake—a full frame swap is a lot of work, no matter how you slice it. In the case of this ’67 Chevy II Nova, it goes a step further, thanks to the extreme fabrication efforts of Divers Street Rods (DSR) located in Sultan, Washington.

DSR ordered a new reproduction of the ’67 Chevy II Nova body from Real Deal Steel and a custom chassis from Art Morrison Enterprises (AME). The process of converting a unibody car to a full frame is already complicated because many of the body’s original structural areas must be removed to make room for the chassis. Part of the Air Sport product line, the chassis was designed to use air suspension and provide the absolute lowest ride height possible. DSR took that a step further by channeling the body over the chassis. With that in mind, DSR gutted the brand-new body, removing the original style floorpans, trunk pans, and firewall. This allowed them to place the body exactly where they wanted it.

DSR already had a specific tire and wheel combination in mind, so the tires were ordered to provide a nice mock-up for additional modifications. The AME chassis was ordered with a 112-inch wheelbase, 2 inches longer than the original Nova wheelbase. This was intentional, and DSR stretched the wheel openings to account for the added wheelbase and the extremely low stance. Other body modifications included stretched front fenders, a stretched hood, shaved door handles, shaved driprails, and much more, but the real focus of this article are the extreme measures taken to convert this unibody car to a full-frame Pro Touring beast.

DSR built a floor structure out of rectangular tubing, and then used flat sheetmetal for a smooth undercarriage. The custom wheeltubs, firewall, fender supports, and radiator supports are additional custom details fabricated by the crew at DSR. The result of countless hours of design and fabrication is a ’67 Chevy II Nova that sits lower than most and has a distinct look with subtle wheelbase alterations. DSR started from scratch with a brand-new body and chassis and made it a truly unique car inside and out.

2. DSR took delivery of this brand-new ’67 Chevy II Nova body from Real Deal Steel. The bodies are available in several configurations and are available with mini-tubs already installed.

From day one of the build, DSR planned to use an AME chassis beneath the new body. Because of the full frame and the desired engine placement, only the shell of the body is used. The factory-style floors and firewall have been removed.

3. From day one of the build, DSR planned to use an AME chassis beneath the new body. Because of the full frame and the desired engine placement, only the shell of the body is used. The factory-style floors and firewall have been removed.

The AME Air Sport chassis features a three-link rear suspension with Watt’s Link and provisions for airbags. DSR modified the chassis with custom crossmembers to accommodate the channeled body.

4. The AME Air Sport chassis features a three-link rear suspension with Watt’s Link and provisions for airbags. DSR modified the chassis with custom crossmembers to accommodate the channeled body.

Initial placement of the body over the frame pointed out the interferences with the stock floor and firewall. To get the stance dialed in, the body will need to sit over the chassis and all new floors will be fabricated.<br />

5. Initial placement of the body over the frame pointed out the interferences with the stock floor and firewall. To get the stance dialed in, the body will need to sit over the chassis and all new floors will be fabricated.

Tire and wheel fitment also plays a huge role in the mock-up stage of the build. In this case, DSR is using a set of Pirelli tires, sized 245/35R19 up front and 355/25R21 in back.

6. Tire and wheel fitment also plays a huge role in the mock-up stage of the build. In this case, DSR is using a set of Pirelli tires, sized 245/35R19 up front and 355/25R21 in back.

The massive rear tires measure 14.4 inches in total width and 28 inches in diameter. These measurements are crucial, and physically mocking up the tires is very helpful to determine the next steps.

7. The massive rear tires measure 14.4 inches in total width and 28 inches in diameter. These measurements are crucial, and physically mocking up the tires is very helpful to determine the next steps.

After the tires are mocked-up and measurements are taken for the rear tubs, the DSR crew can begin fabricating a structure for the custom floorpans.

8. After the tires are mocked-up and measurements are taken for the rear tubs, the DSR crew can begin fabricating a structure for the custom floorpans.

Rectangular tubing is used for the subfloor structure. It follows the framerails, allowing for several mounting points with body mounts sandwiched in between.

9. Rectangular tubing is used for the subfloor structure. It follows the framerails, allowing for several mounting points with body mounts sandwiched in between.

DSR fabricated the giant wheeltubs and attached them to the subfloor structure with a custom flange. Cleco fasteners and clamps hold the tub in place during the fitment process.

10. DSR fabricated the giant wheeltubs and attached them to the subfloor structure with a custom flange. Cleco fasteners and clamps hold the tub in place during the fitment process.

With both rear tubs fabricated and fitted you can get an idea of just how low this Nova is going to sit. The wheeltubs are tucked up as high as possible in the body and fit flush against the framerails.

11. With both rear tubs fabricated and fitted you can get an idea of just how low this Nova is going to sit. The wheeltubs are tucked up as high as possible in the body and fit flush against the framerails.

Next is a full body mockup on the chassis table. Hanging the front fenders and mocking up the tires helps determine the necessary body modifications needed for proper fitment.

12. Next is a full body mockup on the chassis table. Hanging the front fenders and mocking up the tires helps determine the necessary body modifications needed for proper fitment.

The AME chassis was ordered with a 112-inch wheelbase, instead of the stock 110-inch wheelbase, so the DSR crew knew they’d have to adjust the wheel openings to accommodate the stretched wheelbase.

13. The AME chassis was ordered with a 112-inch wheelbase, instead of the stock 110-inch wheelbase, so the DSR crew knew they’d have to adjust the wheel openings to accommodate the stretched wheelbase.

DSR added 3 inches to the rear wheel openings, which centers the axle and allows for the extremely low stance and 28-inch tires. It is currently tack welded but will be finish welded after final testfitment.

14. DSR added 3 inches to the rear wheel openings, which centers the axle and allows for the extremely low stance and 28-inch tires. It is currently tack welded but will be finish welded after final testfitment.

Even in stock form, these early Novas have minimal wiggle room at the leading edge of the front wheel opening. DSR stretched the wheel opening 2 inches on the front side.

15. Even in stock form, these early Novas have minimal wiggle room at the leading edge of the front wheel opening. DSR stretched the wheel opening 2 inches on the front side.

Now that the fender is tack welded and the tire is mocked up we can see the proper placement and adequate clearance. Keep in mind this car will have air suspension, and these mock-ups are with the car completely aired out.

16. Now that the fender is tack welded and the tire is mocked up we can see the proper placement and adequate clearance. Keep in mind this car will have air suspension, and these mock-ups are with the car completely aired out.

Because the body is channeled over the frame, it places the LT5 engine and 8L90 transmission a little higher than usual. A custom transmission tunnel is the beginning of an intricate process of building a trick floorpan for this slammed Nova.

17. Because the body is channeled over the frame, it places the LT5 engine and 8L90 transmission a little higher than usual. A custom transmission tunnel is the beginning of an intricate process of building a trick floorpan for this slammed Nova.

Another piece of the puzzle is the underdash booster and master cylinder. This is accomplished by a Kugel Komponents 90-degree bracket and pedal assembly. This is mocked up, so the firewall and dash can be fabricated.

18. Another piece of the puzzle is the underdash booster and master cylinder. This is accomplished by a Kugel Komponents 90-degree bracket and pedal assembly. This is mocked up, so the firewall and dash can be fabricated.

It might seem a little early to be laying out the wiring harness, but it’s important to have a home for all the car’s electronics before final assembly.

19. It might seem a little early to be laying out the wiring harness, but it’s important to have a home for all the car’s electronics before final assembly.

20. The flat sheetmetal floorpans mount to the underside of the rectangular tubing, giving this Nova a super-slick undercarriage.

The floorpans get a little more complicated toward the back of the car, and DSR fabricates smooth steel pans to cover the three-link crossmember.

21. The floorpans get a little more complicated toward the back of the car, and DSR fabricates smooth steel pans to cover the three-link crossmember.

A custom stainless steel fuel tank from Rock Valley Antique Auto Parts takes up most of the trunk pan area and fits nicely within the framerails. Custom filler panels tie the trunk area together with the wheeltubs.

22. A custom stainless steel fuel tank from Rock Valley Antique Auto Parts takes up most of the trunk pan area and fits nicely within the framerails. Custom filler panels tie the trunk area together with the wheeltubs.

Up front, one of the first steps was placing the LT5 engine and 8L90 automatic transmission in the chassis. Notice how high the engine sits in relation to the fenders.

23. Up front, one of the first steps was placing the LT5 engine and 8L90 automatic transmission in the chassis. Notice how high the engine sits in relation to the fenders.

Since the Chevy Nova originally had a unibody construction with built-in inner fenders and radiator support, the guys at DSR had to start from scratch on the fender and radiator mounting arrangement.

24. Since the Chevy Nova originally had a unibody construction with built-in inner fenders and radiator support, the guys at DSR had to start from scratch on the fender and radiator mounting arrangement.

You’ll notice the custom fender supports built out of square tubing. This ties into the radiator support, while custom lower fender supports extend from the framerails.

25. You’ll notice the custom fender supports built out of square tubing. This ties into the radiator support, while custom lower fender supports extend from the framerails.

The engine bay is starting to get crowded, as more components are mocked up. DSR fabricates a custom cold-air intake pipe and fits the carbon-fiber intake cover.

26. The engine bay is starting to get crowded, as more components are mocked up. DSR fabricates a custom cold-air intake pipe and fits the carbon-fiber intake cover.

With the Real Deal Steel reproduction hood installed, you can see the necessary relief cut for the LT5 engine. A flange will be fabricated for a clean look on the bottom side.

27. With the Real Deal Steel reproduction hood installed, you can see the necessary relief cut for the LT5 engine. A flange will be fabricated for a clean look on the bottom side.

The Nova is sitting on the ground, showing off its slammed stance. The wheelbase adjustments, stretched front fenders, and custom hood treatment give this ’67 Nova a new attitude, thanks to high-end fabrication from the crew at DSR and a custom chassis from AME.

28. The Nova is sitting on the ground, showing off its slammed stance. The wheelbase adjustments, stretched front fenders, and custom hood treatment give this ’67 Nova a new attitude, thanks to high-end fabrication from the crew at DSR and a custom chassis from AME.

Art Morrison Enterprises
(800) 929-7188
artmorrison.com

Divers Street Rods
(360) 799-1327
diversstreetrods.com

Modern Rodding

VOLUME 4 • ISSUE 38 • 2023

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