1968 Chevelle SS 396: Ultimate Restoration Guide

Leana Rogers Salamah

-Nov 21, 2025

1968 Chevelle SS 396: Ultimate Restoration Guide

Owning a 1968 Chevelle SS 396 is like holding a piece of American automotive history. Its powerful engine, iconic design, and impressive performance have made it a highly sought-after classic car. But, restoring one can be a complex but rewarding project. This guide provides a detailed roadmap, covering everything from initial assessment to the final touches, ensuring your Chevelle SS 396 returns to its former glory. This guide is built from years of hands-on experience and expert insights, providing a comprehensive approach to breathe new life into your classic muscle car.

Understanding Your 1968 Chevelle SS 396
Initial Assessment and Planning
Disassembly and Preparation
Bodywork and Paint
Engine and Drivetrain Rebuild
Interior Restoration
Assembly and Finishing Touches
Maintenance and Care

Understanding Your 1968 Chevelle SS 396

Before diving into the restoration process, it's essential to understand the specific characteristics of the 1968 Chevelle SS 396. This iconic car, which helped define the muscle car era, came equipped with a range of powerful big-block V8 engines. The SS (Super Sport) package added distinctive styling cues like a blacked-out grille, special badging, and a domed hood. Knowing the history and specifications of your car is crucial for an authentic restoration.

Key Features and Specifications

Engine Options: 396 cubic inch (6.5L) V8 engines were standard, with various horsepower ratings from 325 to 375 hp, depending on the specific configuration. This engine is the heart of the Chevelle SS.
Transmission: Manual and automatic transmissions were available, including the Muncie M21 four-speed manual, which is highly desirable for its performance. This impacts drivability.
Exterior: The 1968 model year featured a redesigned body with a more aggressive stance, including a new front end, revised rear end, and updated trim. The iconic styling is immediately recognizable.
Interior: Interiors featured bucket seats, a center console (optional), and SS-specific trim details. Restoration often involves recreating these features.

Verifying Your Chevelle's Authenticity

VIN Decoding: The Vehicle Identification Number (VIN) provides crucial information about the car's origin, engine, and options. Decoding the VIN helps ensure your restoration remains true to the factory specifications.
Casting Numbers: Check engine block, cylinder head, and transmission casting numbers to confirm their authenticity. Original components increase the car's value.
Trim Tag: The trim tag, located under the hood, provides details about the car's original paint color, interior trim, and factory options. This information is invaluable during the restoration.

Initial Assessment and Planning

The initial assessment is a critical phase in any 1968 Chevelle SS 396 restoration. It sets the stage for the entire project and helps avoid costly mistakes. This involves a comprehensive evaluation of the car's condition, detailed planning, and setting a realistic budget. — Dave Richard's Trade Charts: A Trader's Guide

Evaluating the Car's Condition

Exterior: Inspect the body for rust, dents, and prior repairs. Rust is a common issue, particularly in the lower panels, floors, and trunk. Assess the overall condition of the sheet metal.
Engine and Drivetrain: Check the engine's compression, and inspect for oil leaks. Evaluate the transmission's function and assess the condition of the rear axle. This ensures mechanical reliability.
Interior: Examine the seats, dashboard, headliner, and carpets for damage. Determine the extent of necessary upholstery and trim work.
Electrical System: Inspect the wiring harness for corrosion and damage. Ensure all electrical components, such as lights, gauges, and accessories, are functioning correctly. This ensures safety and functionality.

Creating a Restoration Plan

Set Goals: Determine your restoration goals. Are you aiming for a concours-quality restoration, a driver-quality restoration, or something in between? This will influence the scope and budget of the project.
Prioritize Tasks: Break down the restoration into manageable stages: disassembly, bodywork, engine rebuild, interior restoration, and final assembly.
Research and Documentation: Gather as much information as possible about your car, including factory specifications, restoration guides, and parts catalogs. Document the entire process with photos and notes.

Budgeting for Your Restoration

Estimate Costs: Research the cost of parts, labor, and materials. Budgeting should include contingency funds for unexpected issues.
Source Parts: Identify reliable sources for parts, including both new and used components. Consider the quality and cost of each part.
Allocate Funds: Allocate funds for each stage of the restoration. Regularly track expenses to stay within your budget. Don't underestimate costs.

Disassembly and Preparation

Disassembly is a meticulous process that requires patience and organization. This stage involves carefully removing all components from the car, cataloging everything, and preparing the body for restoration. Proper disassembly will ensure you understand how the car was assembled and will greatly aid in the reassembly.

Tools and Equipment

Basic Tools: Wrenches, sockets, screwdrivers, pliers, and a complete set of hand tools are essential for all aspects of the restoration.
Specialty Tools: Tools like a body panel removal tool, a spring compressor, and a gear puller may be required for specific tasks. Consider renting these tools.
Safety Equipment: Safety glasses, gloves, and a respirator are essential to protect yourself during the disassembly process. Always wear the correct personal protective equipment.

Step-by-Step Disassembly Guide

Interior: Remove the seats, carpets, headliner, door panels, and dashboard. Be careful not to damage the interior trim pieces.
Exterior: Remove the trim, bumpers, lights, and any other exterior components. Label and store all parts in labeled boxes or bags. Taking pictures as you go will help with reassembly.
Engine Compartment: Remove the engine, transmission, and all related components, such as the radiator, wiring, and accessories. Drain all fluids before removal.
Suspension: Disconnect the suspension components, including the springs, shocks, and control arms. This will ensure proper access to the body and frame.
Body from Frame (if necessary): If significant rust or structural damage is present, separate the body from the frame. This allows for thorough restoration of both.

Organization and Documentation

Labeling: Label each part with its location and function. Use tags, masking tape, or a dedicated labeling system.
Photography: Take detailed photos of each step of the disassembly process. These photos will be invaluable during reassembly.
Inventory: Create an inventory list of all parts removed. This will help you keep track of everything and identify missing or damaged parts.

Bodywork and Paint

Bodywork and paint are among the most visible aspects of a 1968 Chevelle SS 396 restoration. This stage involves repairing rust, dents, and other imperfections, followed by the application of primer and paint to achieve a flawless finish.

Rust Repair and Metal Fabrication

Rust Removal: Remove rust using methods such as media blasting, chemical stripping, or mechanical grinding. Ensure all rust is removed to prevent future problems.
Metal Patching: Weld in replacement panels to repair rust damage. Ensure the replacement panels are properly aligned and welded.
Body Straightening: Use body hammers, dollies, and other tools to straighten dents and imperfections. This ensures a smooth surface for painting.

Priming and Body Preparation

Surface Preparation: Sand the entire body to remove any imperfections and create a surface for the primer to adhere to. Proper preparation is essential.
Primer Application: Apply a high-quality primer to protect the metal and provide a base for the paint. Multiple coats of primer may be required. Follow manufacturer's instructions.
Block Sanding: Sand the primed surface to create a perfectly smooth surface for the paint. Block sanding involves using a long sanding block to ensure a flat finish.

Painting the Body

Paint Selection: Choose the correct paint type and color for your Chevelle. Consider using the original factory color for authenticity.
Paint Application: Apply the paint in a well-ventilated paint booth or a clean, dust-free environment. Apply multiple coats of paint, allowing each coat to dry according to the manufacturer's instructions.
Wet Sanding and Buffing: Wet sand the painted surface to remove any imperfections, followed by buffing to create a high-gloss finish. This removes any minor flaws.

Engine and Drivetrain Rebuild

The engine and drivetrain are the heart of a 1968 Chevelle SS 396. Rebuilding these components ensures optimal performance and reliability. It's recommended to work with a reputable machine shop to ensure accuracy.

Engine Rebuild Process

Disassembly: Disassemble the engine, carefully labeling all parts. Inspect all components for wear and damage.
Machine Work: Send the engine block, cylinder heads, and other components to a machine shop for cleaning, machining, and inspection. Ensure accurate machining.
Parts Replacement: Replace worn or damaged parts, such as pistons, rings, bearings, and seals. Use high-quality replacement parts. Consider the pros and cons of original vs. aftermarket parts.
Assembly: Reassemble the engine, following factory specifications. Ensure all components are properly torqued and aligned.

Transmission and Differential Rebuild

Transmission: Rebuild the transmission, replacing worn clutches, seals, and bearings. Follow the manufacturer's instructions.
Differential: Rebuild the rear differential, replacing gears, bearings, and seals. Ensure the correct gear ratio is used.
Testing: Test the engine and drivetrain after the rebuild to ensure proper function. Check for leaks and proper performance.

Choosing the Right Components

Performance Upgrades: Consider upgrading components like camshafts, carburetors, and headers to improve performance. This can significantly impact the Chevelle's performance.
Reliability: Choose high-quality components to ensure reliability. Do your research and pick the best parts.
Authenticity: Balance performance upgrades with maintaining the car's original appearance and specifications. This impacts the value of the restoration.

Interior Restoration

The interior restoration brings the Chevelle SS 396 back to its original beauty. This stage involves restoring or replacing the seats, dashboard, headliner, and other interior components. — Cheap Colorado Springs Apartments: Your Guide

Upholstery and Trim Work

Seat Restoration: Restore or replace the seat upholstery, foam padding, and springs. Ensuring proper fit and finish is crucial.
Door Panels: Restore or replace the door panels, ensuring they match the original specifications. Replacing them with new parts is often easier.
Headliner: Replace the headliner, ensuring it is properly installed and stretched. Use the correct type of material.

Dashboard and Console

Dashboard Restoration: Restore the dashboard, repairing any cracks or damage. This often involves stripping the original finish and repainting.
Gauges: Restore or replace the gauges, ensuring they are functional and accurate. Rebuild them if needed.
Center Console: Restore or replace the center console, including the shifter and any other components. Restoring the console can be a challenge.

Carpets and Accessories

Carpets: Replace the carpets with new, high-quality carpets. Choose the correct color and style for your car.
Accessories: Restore or replace interior accessories, such as the steering wheel, armrests, and door handles. Small details make a big difference.

Assembly and Finishing Touches

Assembly is the final stage of the restoration, where all the components are put back together. This stage requires careful attention to detail and patience.

Assembling the Body

Chassis to Body: Carefully lower the body onto the frame (if separated). Ensure all components align correctly.
Exterior Components: Install the bumpers, trim, lights, and other exterior components. Pay attention to fit and finish.
Interior Components: Install the seats, dashboard, headliner, and other interior components. Ensure all components are properly installed.

Electrical and Mechanical Systems

Wiring: Connect the wiring harness, ensuring all connections are secure and functioning correctly. Check the fuses.
Brakes and Suspension: Install the brakes and suspension components, ensuring they are properly adjusted. Check everything carefully.
Engine and Transmission: Install the engine and transmission, connecting all necessary components. Ensure all fluids are topped off.

Final Adjustments and Details

Alignment: Have the car professionally aligned to ensure proper handling and tire wear. This is vital for safety.
Testing: Test all systems, including the engine, transmission, brakes, and electrical system. Test everything thoroughly.
Final Inspection: Perform a final inspection to ensure everything is correct and complete. Double-check everything to catch any mistakes.

Maintenance and Care

Once your 1968 Chevelle SS 396 restoration is complete, proper maintenance and care are essential to preserve your investment. Regular maintenance will keep your car in top condition. — DWTS Results Tonight: Who Went Home?

Regular Maintenance Schedule

Oil Changes: Perform oil changes at the recommended intervals, using the correct oil type. Regular oil changes are key for engine life.
Fluid Checks: Check and top off all fluids, including coolant, brake fluid, and power steering fluid. Check all fluids regularly.
Tire Inspection: Inspect tires for wear and tear, and rotate them as needed. Maintaining the tires will make driving safer.

Storage and Preservation

Storage: Store the car in a garage or a climate-controlled environment to protect it from the elements. This protects your investment.
Cleaning: Regularly clean the car to remove dirt and debris. Always keep the car clean.
Preventative Measures: Implement preventive measures, such as using a car cover and adding fuel stabilizer. Preventative measures will extend the life of your car.

Common Problems and Solutions

Rust: Regularly inspect the car for rust and address any issues promptly. Watch for rust in high-risk areas.
Engine Problems: Address any engine problems immediately, such as oil leaks or performance issues. Fix engine problems immediately.
Electrical Issues: Troubleshoot and repair any electrical issues, such as faulty wiring or malfunctioning components. Fix electrical problems immediately.

Frequently Asked Questions (FAQ)

How much does it cost to restore a 1968 Chevelle SS 396? The cost can vary significantly depending on the car's condition, the extent of the restoration, and the quality of parts used. A full restoration can range from $30,000 to over $100,000.
Where can I find parts for my Chevelle SS 396? Parts can be sourced from various vendors, including online retailers specializing in classic car parts, local auto parts stores, and swap meets. Also, check out online forums and communities.
What is the best way to remove rust from my Chevelle? Rust removal can be accomplished through media blasting, chemical stripping, or mechanical grinding. The best method depends on the severity of the rust and the location. Consider what is best for your skills and budget.
Can I restore a 1968 Chevelle SS 396 myself, or should I hire a professional? Restoring a Chevelle SS 396 can be a DIY project, but it requires significant time, skills, and resources. Consider hiring a professional if you lack experience or time, especially for complex tasks like bodywork and paint. The best solution depends on your situation.
How do I determine the value of my restored Chevelle SS 396? The value of a restored Chevelle SS 396 depends on several factors, including its condition, originality, rarity, and market demand. Consult with classic car appraisers and review sales data from reputable sources.
What engine options were available for the 1968 Chevelle SS 396? The 1968 Chevelle SS 396 was available with various 396 cubic inch (6.5L) V8 engines, with horsepower ratings ranging from 325 to 375 hp, depending on the specific configuration.
What are the key differences between a Chevelle SS and a standard Chevelle? The Chevelle SS featured a more powerful engine, a blacked-out grille, special badging, a domed hood, and other unique styling elements. These distinctive features set the SS apart from the standard Chevelle models.

Conclusion

Restoring a 1968 Chevelle SS 396 is a labor of love that can bring you immense satisfaction. By following this comprehensive guide, you can successfully navigate the restoration process, from initial assessment to final assembly. The key is to be organized, patient, and detail-oriented. The result will be a stunning classic car that reflects your hard work and dedication. Enjoy the journey of bringing this iconic muscle car back to life!