Martin called and said the car was ready. After two and a half weeks the car drives better than it has since May.
According to the work order notes the "lower orbits were too shallow and would bind on turns. As turn increased, so would the bind. "...broke both upper ball joints (they both had cracks in them). Geometry was extreme for wheel offset".
Some of this really doesn't make any sense to me but Martin showed me the parts he replaced. The lower control arm bushings were new and now useless because the lower cam adjustment bolts were worn and the bushing holes were too wide for the cam bolt so there was plenty of play in them.
The car drives a world better than it did, I'm so used to driving my truck that I've forgotten what a 44 year old car IS supposed to drive like. It's funny how that works.
As of last Thursday I've become unemployed. It couldn't have come at a worse time. I may end up driving my truck more to stretch my dollars out until I get a job again.
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This is the most expensive journey I've ever embarked on: the quest for alignment.
I found another shop through my uncle called Reinegger's Frame and Wheel.
I dropped the car off today with Martin, the owner. I told him exactly what was happening and he says he could dial the car in. He says he's very familiar with these cars and can't understand why Terry (Freeman Frame) couldn't fix it.
A while later he called me and said he and his staff had a good laugh after they started tearing into my car. He said the left and right lower control arm bushings were in the wrong sides. "No wonder this car can't be dialed in". He said the bushings needed to be replaced but he wanted to go with a factory set.
About an hour later he called saying he located a guy in New Hampshire that seemed to have the last three sets in the country. He added that the left lower ball joint needed replacement too.
I asked him what we were looking at as far as cost went. Here's what he told me:
The labor to install the bushings, left lower ball joint, steering box setting adjustment and shipping cost for the bushings was going to $935. The cost of the parts was $243.74. So I'm looking at spending about $1200 more to get the car done.
My wife flipped when I told her. I'll give her credit: she's been very understanding throughout this whole process but she couldn't believe I needed to spend this much more. She called Martin back and he explained everything to her. She calmed down. We went to Pep Boys to see about getting our money back. Al, the manager who was there back then was gone as was the original mechanic. The new manager said he'd open up a claim for us and apologized.
Going to Pep Boys was a mistake. Freeman Frame should've known better. The cost to fix this issue has gotten way out of hand. I think this will be the last old car I drive.
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Two Mondays ago I called Terry. The car has been at his shop for four weeks now. I sent the center link and idler arm to Doug at Global West Suspension. He installed their "Del-A-Lum" kit and sent them back to Terry to reinstall. Terry says it "helped" but didn't solve the problem. It still goes out 1/8" of an inch at the toe.
I called Doug and asked him to talk to Terry. Checking back later Terry said he didn't talk to Doug. Doug says he called. 
Bottom line is the car still isn't fixed. Terry says he's "done" with it. I picked it up Friday and drove it home. It was toe out. I called Doug yesterday and asked what is so hard about getting a simple Nova suspension dialed in. He said he didn't know why someone with 28 years of experience couldn't figure it out. He had me take pictures of the suspension and email them to him.
Later he said the front end rode a little high and the driver's side lower control arm eccentric needed an adjustment. Finally I said "Look. Why don't I just drive the car down to your shop in San Bernardino (400 miles away) and let "you do the work? You seem to be the only one who knows what to do here". My company is shutting down for three weeks in December and I could spend the first week down there in a Motel 6 if need be. He said to check back with him closer to the date. So we'll see what happens.
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Last Wednesday I hadn't heard from Terry in a week and a half so I called him up. He said he's tried everything he can think of but again, nothing solves the problem.
I contacted Jim Merritt, an Inliner and former '64 Nova wagon owner to seek his advice. He suggested calling Global West Suspension.
Thursday I described my situation to Doug at Global West. He said that he was surprised that a shop that has been around for 28 years couldn't solve the problem. Eventually I put Doug in contact with Terry and Friday it was decided that I should send Doug my idler arm and center link for a modification. He has a machine shop and has done this modification countless times. He is 99% sure that this will take care of the problem.
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After 3 weeks of driving it was time for a check. I brought it back Friday to Freeman Frame. They said the toe was half an inch out again. The guy put it back to zero, drove it and said it felt like it had gone out again just in the trip around the block. But when he put it on the rack and it read zero.
Ok. let's try replacing the the inner tie rods. He had a left one in stock. The guy drove it and said it drove fine. I got on the freeway home and it felt worse and the wheel was now cocked!
So I brought it back. He had another car on the rack so I just gave him the keys and left.
Something is loose and even the pros can't find it.
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