I think I can unbolt the bumper and front clip and replace with a newer hidden bumper from a newer model Caprice, add headlights and form my own fiberglass clip, with supplies from a major home improvement chain.
I am thinking of using a headlight with a good angle to the surface, like the projector headlights off a Mazda Miata... shown in picture above.
Instead of doing a grill block, I would make the grill shorter than OEM, and as far forward possible, And it would be the only surface parallel to the wind, because air flows trough it. Then the rest of the bumper cover, would be streamlined to make the nose sleek and smooth, instead of boxy, like it is now. What do you think?
85 Chevrolet. 30 MPG or bust!
Looks like a good idea.
See the notes from basjoos in my thread from a week or 2 ago titled "air dam cross section". Basically he recommended extending the hood line forward and down, on a gentle slope, to get air to go up over the car. My air dam extension had already been built on a different plan but I do like his concept.
Currently getting +/- 50 mpg in fall weather. EPA is 31/39 so not too shabby. WAI, fuel cutoff switch, full belly pan, smooth wheel covers.
something to keep in mind is the rear of the car causes as much, if not more drage then the front, because of turbulance, so you might think about making the rear of the car match the front.
I think that with some foam, and fiber glass you should have great sucsess!