Budget C5 Corvette Racecar

[monteboy84]

So, this isn't really Pro-Touring, but thought some here would enjoy seeing what I've been up to since selling my PT Monte Carlo, and I've learned a lot here over the years so I wanted to give back with a butt-load of build pictures :) I'm re-capping this build thread from Corvette Forum, so the car is 'done', but I'm copying the whole build process here. As with any car, it's never truly done, so it continues to evolve between races...

(01-09-2014)
So, I have an 01 Z06 that I love driving, it's a great car with phenomenal performance. That said, I've been involved in racing for a number of years and have always wished I could afford to run a Vette. For cost reasons, I was looking at C4's and came very close to buying one on here for $5500, which is very fair for a prepped track car, my only concern being that C4's don't have nearly the demand of C5's and seem to sit unsold for a long time, something that I didn't want to deal with if I ever have to sell. So, by random chance I found a rebuildable 1999 M6 Coupe in Missouri on Craigslist, it had a tweaked frame in the RF and was missing the motor and a few other things but was otherwise a very solid car for an unbelievable price.


Also, I want to say this right now: If I end up in the poor house or the nut house, I place full blame on Randy Rippie for peer pressuring me into the C5 :willy: :crazy2:


There is a very new series that I plan to run this in, but will be building the cage to be legal for ST1, T1, etc so that it's not obsolete if something happens to this series. With that said, I have some very basic guidelines for this car:
- Reasonable Build Cost without half-assing the important things
- Reliable, there's nothing worse than an unreliable racecar
- Cheap to maintain, this will bring some sacrilege to the project, keep reading
- Safe. I'm not real concerned about dying, but I don't want to be drooling on myself for the rest of my life or disfigured in a fire....
- Legal. I've always heard racers say "Everyone cheats, most just don't get caught." BS, we've won a lot of races without cheating, if people can't win without cheating there's something wrong with the series.


I don't want to have to spend cubic dollars beefing things up, and I don't want to have big money tied up in a fancy race motor build of magic dust and unobtanium, been there done that and I don't miss it. The series I'm looking at has Power-Weight classing, so here's my motor choice: 4.8L Vortec. It makes perfect sense, they're plentiful across the US for $2-300 and stout little motors, perfectly comfortable running 6500-7000 RPM's. Since it has less power than the original motor, the whole drivetrain should stay dead nuts reliable. If I blow it up (which is highly unlikely) I slap my intake and accessories on the spare motor and get back to racing, no waiting on an engine builder or mortgaging my house to pay for it. The only mod that I'll be doing is a rocker trunion upgrade, other than that even the cam will be stock.


I have already sourced 2 batwing pans, a stock LS1 intake/rails/injectors/TB and have 2 sets of stock exhaust manifolds so I can have a spare motor somewhat mocked up ahead of time.


Beyond that, a rough list of mechanical plans:
- New Slave/TOB
- Rebuilding Prop Shaft
- Brand New LS3 Accy Drive Kit from Pace(GM)
- Steel Shift Forks
- Billet Synchro Keys
- Oil/Trans/Diff Coolers


Suspension:
- Z06 Springs
- Bilstein Shocks Edit: Can't run Bilstein Sports, so Z06 shocks? TBD....
- New bushings - Would love to go spherical but can't justify the cost, will probably make my own from Delrin.


Brakes:
- C6 Front calipers (To hopefully reduce spreading), stock rears
- DRM SS Front pistons
- Raybestos ST43 pads to start out with, supposedly these are the shiznit for long races?
- DRM Braided hoses
- DRM Ducts, LG Spindle Plates or homemade
- Z06 Rear Ducts


Other:
- Full cage with Nascar door bars on both sides, 1.75 x .120 DOM to be legal everywhere and as safe as possible.
- Forward-tilting front-sucking radiator mod with extractor hood
- Splitter - This will probably be plywood, don't laugh until you see it done :yesnod:
- Rear Diffuser - homemade, looking at material options
- Fire System
- Passenger Seat for track days and street use, it WILL remain street legal
- Fixed Headlights for weight, cost, simplicity
- Full containment seat with 6-point harness. Safety.


That's all I've got for now, here are a couple pictures from before I rinsed all of the road salt off :ack:
https://static1.pt-content.com/images/pt/2015/06/IMG_2588_zps61c14bde-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_2588_zps61c14bde.jpg.html)


https://static1.pt-content.com/images/pt/2015/06/IMG_2598_zps5e8028b0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_2598_zps5e8028b0.jpg.html)


https://static1.pt-content.com/images/pt/2015/06/IMG_2596_zps9446854e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_2596_zps9446854e.jpg.html)


The frame shop called yesterday to say it will be ready soon, hopefully when I get home from SHOT Show on the 20th :cheers:


Thanks for looking, stay tuned for updates!
Matt

[monteboy84]

02-13-2014

It's back! I picked up the car from the frame shop this week, they did a great job and the price was very fair.

Before:
https://static1.pt-content.com/images/pt/2015/06/IMG_2539_zpsd9e7f1f6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_2539_zpsd9e7f1f6.jpg.html)

After:
https://static1.pt-content.com/images/pt/2015/06/IMG_3034_zpsc27cf512-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3034_zpsc27cf512.jpg.html)

Not the same camera angle, but you get the idea. Everything is squared up nicely, I'll be running a cage tube from the front downbars to a point ahead of this repaired area in order to strengthen it and avoid flex from the weakened section. I need to get everything cleaned off and oiled up, between the prior owner leaving it outside and the long salty ride home, it's pretty nasty...

All loaded up
https://static1.pt-content.com/images/pt/2015/06/IMG_3032_zps9321c372-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3032_zps9321c372.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3033_zps200f0a6e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3033_zps200f0a6e.jpg.html)

Snagged this steering wheel and NRG release for cheap on the auction site, a little gentle scrubbing with an old toothbrush and some hot water has the suede looking good as new.
https://static1.pt-content.com/images/pt/2015/06/IMG_3051_zps0e4c6c92-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3051_zps0e4c6c92.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3052_zps3976a0e3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3052_zps3976a0e3.jpg.html)

Picking up the motor tomorrow in order to keep things moving this weekend, planning to get the 4.8 fitted with C5 pan, intake, exhaust and make some solid mounts this weekend. Hoping to get it set into the car this weekend, possibly fired up this week. This first time going together will basically be a mockup of the car in stock form with the 4.8 in order to get it inspected so that the state can issue a rebuilt title, after that it will come back apart for the cage and other fun stuff.

Next on my list is to buy seats and probably shocks. Word has it that there's also a box of DRM goodies on their way to my front step :rock:

Thanks for looking, more coming soon!

[monteboy84]

02-17-2014
Lots of progress this weekend! Picked up a 4.8 on Friday afternoon, got it cleaned up and dropped in the car this weekend. I had a box of DRM goodness waiting on my doorstep Friday as well, so I managed to get the SS brake pistons installed before I got the calipers on. I also have a solid rack bushing, brake ducts, SS lines, and an oil cooler adapter that will go on as things progress, the parts all look top-notch and Randy got them here in a hurry so that I can get everything installed while it's still easy to get at :cool:

Anyway, I don't have time to caption all of these right at the moment but here are a bunch of pictures showing what we accomplished this weekend, I'll edit in captions sometime this week. Saturday I had other plans so all of the work you see here was done on Sunday-funday 9am-10pm. Hope you enjoy!

Here's the 4.8 before I got it loaded up at the junkyard
https://static1.pt-content.com/images/pt/2015/06/IMG_3071_zpsa084b84d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3071_zpsa084b84d.jpg.html)

New wheel painted and installed with NRG release
https://static1.pt-content.com/images/pt/2015/06/IMG_3072_zpsc628a9af-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3072_zpsc628a9af.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3073_zps963fcf9e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3073_zps963fcf9e.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3074_zpsd2603652-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3074_zpsd2603652.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3075_zps524a8cef-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3075_zps524a8cef.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3076_zps26f24afa-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3076_zps26f24afa.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3077_zps60dd6403-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3077_zps60dd6403.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3078_zpsd3b5b9ca-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3078_zpsd3b5b9ca.jpg.html)

Crappy pic, but here's the input shaft all cleaned up:
https://static1.pt-content.com/images/pt/2015/06/IMG_3079_zps6b17cf69-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3079_zps6b17cf69.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3080_zps8336e4ce-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3080_zps8336e4ce.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3081_zps55efb8b4-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3081_zps55efb8b4.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3082_zps3ab4b3c0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3082_zps3ab4b3c0.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3084_zps3bfeaaa6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3084_zps3bfeaaa6.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3085_zps74991ec7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3085_zps74991ec7.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3086_zps4bda77e4-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3086_zps4bda77e4.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3087_zpsf7b4e673-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3087_zpsf7b4e673.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3088_zps6fc9d1ac-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3088_zps6fc9d1ac.jpg.html)

All dried up after washing:
https://static1.pt-content.com/images/pt/2015/06/IMG_3089_zps9034b40c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3089_zps9034b40c.jpg.html)

Hauled the motor home in my Denali, here it is after pulling the intake and coil packs...
https://static1.pt-content.com/images/pt/2015/06/IMG_3090_zps97c6de85-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3090_zps97c6de85.jpg.html)

Parts washer: oil pan, valve covers, front caliper bodies:
https://static1.pt-content.com/images/pt/2015/06/IMG_3091_zpseb18d232-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3091_zpseb18d232.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3092_zps53237ae5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3092_zps53237ae5.jpg.html)

Mmmm clean
https://static1.pt-content.com/images/pt/2015/06/IMG_3093_zpsa9cec8f5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3093_zpsa9cec8f5.jpg.html)

Dirty!
https://static1.pt-content.com/images/pt/2015/06/IMG_3094_zps7ff0127e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3094_zps7ff0127e.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3095_zps79a15c0c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3095_zps79a15c0c.jpg.html)

[monteboy84]

https://static1.pt-content.com/images/pt/2015/06/IMG_3097_zpsc947e56a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3097_zpsc947e56a.jpg.html)

Valvetrain looks good, I'll revisit this to rebuild trunions and valvesprings after we get it fired up.
https://static1.pt-content.com/images/pt/2015/06/IMG_3098_zpsad591638-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3098_zpsad591638.jpg.html)

Valve Covers: Clean
https://static1.pt-content.com/images/pt/2015/06/IMG_3099_zps7dc73d5b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3099_zps7dc73d5b.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3100_zps96d1ed21-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3100_zps96d1ed21.jpg.html)

Soaping down with diluted Purple Power
https://static1.pt-content.com/images/pt/2015/06/IMG_3102_zpsbea8bf19-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3102_zpsbea8bf19.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3103_zps3e55a225-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3103_zps3e55a225.jpg.html)

Much better:
https://static1.pt-content.com/images/pt/2015/06/IMG_3104_zps54d3093b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3104_zps54d3093b.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3105_zps6ae57633-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3105_zps6ae57633.jpg.html)

LS3 Crate engine takeoff water pump from the 'bay
https://static1.pt-content.com/images/pt/2015/06/IMG_3106_zpsd48dbc7e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3106_zpsd48dbc7e.jpg.html)

Installed:
https://static1.pt-content.com/images/pt/2015/06/IMG_3107_zps5af13b77-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3107_zps5af13b77.jpg.html)

Batwing pan installed with new gasket and pickup tube
https://static1.pt-content.com/images/pt/2015/06/IMG_3108_zps60838609-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3108_zps60838609.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3109_zpsb74dd837-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3109_zpsb74dd837.jpg.html)

Truck balancer pulled
https://static1.pt-content.com/images/pt/2015/06/IMG_3110_zpsa0be89f1-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3110_zpsa0be89f1.jpg.html)

LS3 Corvette takeoff balancer installed with ARP bolt, it's reusable so that I don't have to buy one if I blow this motor.
https://static1.pt-content.com/images/pt/2015/06/IMG_3111_zps74be2d35-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3111_zps74be2d35.jpg.html)

Blew the water out from the knock sensor holes and checked for corrosion, everything looked good so I made silicone dams around them before setting on the LS1 intake.
https://static1.pt-content.com/images/pt/2015/06/IMG_3112_zpsbba1347d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3112_zpsbba1347d.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3114_zps46089b70-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3114_zps46089b70.jpg.html)

Coil packs from the truck are on as well
https://static1.pt-content.com/images/pt/2015/06/IMG_3115_zpsdc300755-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3115_zpsdc300755.jpg.html)

Throttle body steam lines need to go
https://static1.pt-content.com/images/pt/2015/06/IMG_3116_zpse0ac6e82-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3116_zpse0ac6e82.jpg.html)

Gone
https://static1.pt-content.com/images/pt/2015/06/IMG_3117_zps1b25014f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3117_zps1b25014f.jpg.html)

Manifold EGR ports, need to plug these for EGR delete. Could use a block-off plate, but I wanted something more permanent.
https://static1.pt-content.com/images/pt/2015/06/IMG_3118_zps25a5a771-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3118_zps25a5a771.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3119_zps21629c41-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3119_zps21629c41.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3120_zpsec9fc33a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3120_zpsec9fc33a.jpg.html)

Welded
https://static1.pt-content.com/images/pt/2015/06/IMG_3121_zpse9fdf482-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3121_zpse9fdf482.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3122_zpsb04ebddc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3122_zpsb04ebddc.jpg.html)

[monteboy84]

Flanges cleaned up
https://static1.pt-content.com/images/pt/2015/06/IMG_3123_zps925d3f47-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3123_zps925d3f47.jpg.html)

This is to keep you from getting the impression that I keep my work area tidy :ack:
https://static1.pt-content.com/images/pt/2015/06/IMG_3124_zpsf09f9195-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3124_zpsf09f9195.jpg.html)

DRM SS Piston Goodness...
https://static1.pt-content.com/images/pt/2015/06/IMG_3126_zpse45e4290-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3126_zpse45e4290.jpg.html)

Installed
https://static1.pt-content.com/images/pt/2015/06/IMG_3127_zps9eceaa59-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3127_zps9eceaa59.jpg.html)

New GM TOB/Slave installed in preparation for the motor
https://static1.pt-content.com/images/pt/2015/06/IMG_3129_zpse2990b9e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3129_zpse2990b9e.jpg.html)

Throttle Body on
https://static1.pt-content.com/images/pt/2015/06/IMG_3130_zpsf0611603-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3130_zpsf0611603.jpg.html)

LS6 Flywheel, 8k mile takeoff
https://static1.pt-content.com/images/pt/2015/06/IMG_3131_zps03fc5cc9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3131_zps03fc5cc9.jpg.html)

Installed with ARP Bolts for safety
https://static1.pt-content.com/images/pt/2015/06/IMG_3133_zps0d714fd0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3133_zps0d714fd0.jpg.html)

Clutch installed
https://static1.pt-content.com/images/pt/2015/06/IMG_3135_zps9d26b207-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3135_zps9d26b207.jpg.html)

Aaand I skipped a bunch here, but there was cursing, bleeding, more cursing, a little more bleeding, some wrenching, and then bam, it's in place. There's dad reattaching the driver's side Upper Control Arm
https://static1.pt-content.com/images/pt/2015/06/IMG_3137_zpsdbbfc3d6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3137_zpsdbbfc3d6.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3138_zps0c6d2dbb-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3138_zps0c6d2dbb.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3139_zps9e493598-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3139_zps9e493598.jpg.html)

Some Z06 wheels thrown on so that I can sell the thinspokes
https://static1.pt-content.com/images/pt/2015/06/IMG_3140_zps978e6a3f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3140_zps978e6a3f.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3141_zps0da444ad-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3141_zps0da444ad.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3142_zpsa58f0be3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3142_zpsa58f0be3.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3143_zps251f32df-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3143_zps251f32df.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3144_zps7f13da7f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3144_zps7f13da7f.jpg.html)

We made solid aluminum motor mounts, you can see a bit of them here
https://static1.pt-content.com/images/pt/2015/06/IMG_3145_zpsee0ba2d0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3145_zpsee0ba2d0.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3146_zps835cdb0a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3146_zps835cdb0a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3147_zpsaed727f9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3147_zpsaed727f9.jpg.html)

That's all for now, more to come next weekend, hopefully be able to start it by then so stay tuned :cheers:
https://static1.pt-content.com/images/pt/2015/06/thats_all_folks-1.jpg

[monteboy84]

03-17-2014
Sorry for the hiatus, been working on the car but haven't kept the thread updated.

The truck steam line interfered with the LS1 intake, so I cut it apart and created hose ribs with a flaring tool, then cut off and welded the original outlet closed. Having these divorced, I'll just run a rubber hose to each side and combine them before running to the tank. Cheap and easy but still fairly clean.
https://static1.pt-content.com/images/pt/2015/06/IMG_3378_zps2a36f722-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3378_zps2a36f722.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3379_zps36330c5a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3379_zps36330c5a.jpg.html)

Stuck storing it outside until I get it back to my garage, the MN weather hit it with some snow :( The radiator cage was pulled from the frame in the wreck, which ripped out 3 of the 4 riv-nuts and tweaked the holes. My solution was to straighten the holes and weld regular nuts into the holes, then grind flush and paint.

https://static1.pt-content.com/images/pt/2015/06/IMG_3226_zpse6e22aca-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3226_zpse6e22aca.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3228_zpsdea66fd8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3228_zpsdea66fd8.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3225_zpsf5a66ca3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3225_zpsf5a66ca3.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3230_zps9c521da5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3230_zps9c521da5.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3227_zpse72d7c25-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3227_zpse72d7c25.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3249_zps0ff47ed1-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3249_zps0ff47ed1.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3248_zps1256d7c0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3248_zps1256d7c0.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3251_zps1a206def-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3251_zps1a206def.jpg.html)

I'll paint this cage later, it's going to be modified a bit so I'm just using it to assemble the car in stock form at this point.
https://static1.pt-content.com/images/pt/2015/06/IMG_3252_zps37f86ebc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3252_zps37f86ebc.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3253_zpsa3ddf43c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3253_zpsa3ddf43c.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3251_zps1a206def-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3251_zps1a206def.jpg.html)

Replaced the stock rubber rack bushing with a solid aluminum one from DRM. It fit perfectly, I just nipped off one side of the flange to make the install easier with the rack still in the car.

Stock:
https://static1.pt-content.com/images/pt/2015/06/IMG_3232_zps39fe335c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3232_zps39fe335c.jpg.html)

Old vs. New
https://static1.pt-content.com/images/pt/2015/06/IMG_3237_zpse35f21c0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3237_zpse35f21c0.jpg.html)

Ground flange for clearance
https://static1.pt-content.com/images/pt/2015/06/IMG_3238_zps29e4ac54-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3238_zps29e4ac54.jpg.html)

Stock piece removed
https://static1.pt-content.com/images/pt/2015/06/IMG_3235_zps09202213-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3235_zps09202213.jpg.html)

High-tech bushing press tool
https://static1.pt-content.com/images/pt/2015/06/IMG_3243_zps08afd34a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3243_zps08afd34a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3247_zps3a23c513-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3247_zps3a23c513.jpg.html)

I had to lay out the wiring in order to determine where everything is supposed to run. I've never had one of these cars apart before so this has been a bit of a learning experience but it's really not bad at all.
https://static1.pt-content.com/images/pt/2015/06/IMG_3255_zps084ca287-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3255_zps084ca287.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3254_zps1fc4cc00-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3254_zps1fc4cc00.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3256_zps072fd8a0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3256_zps072fd8a0.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3258_zps48a88a44-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3258_zps48a88a44.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3257_zpsab600ea1-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3257_zpsab600ea1.jpg.html)

[monteboy84]

https://static1.pt-content.com/images/pt/2015/06/IMG_3259_zps01cd622a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3259_zps01cd622a.jpg.html)

Headlight wiring, this will get tidied up later.
https://static1.pt-content.com/images/pt/2015/06/IMG_3260_zps68cbc57e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3260_zps68cbc57e.jpg.html)

F45 Electronic Shock wiring and ABS speed sensor wiring, the taped up plugs are for the F45 and will be removed as they'll never be used again.
https://static1.pt-content.com/images/pt/2015/06/IMG_3261_zpsad7376d7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3261_zpsad7376d7.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3262_zpse222a0a7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3262_zpse222a0a7.jpg.html)

Apparently I missed a bunch of progress pictures so I'll have to take some next weekend. The motor is still missing accessories that I need to order, but it's otherwise ready to run. I fought with NO COMM issues all weekend before realizing that my PCM had been bricked. The wiring is now all in place and I'm almost ready to put the front end back on. I'll be out of town next weekend but I'm hoping to have a productive weekend at the end of March with a lot of new goodies to bolt on.

Thanks for watching!

[monteboy84]

Oy Vey. This weekend was humbling, we still have not be able to make the car run. When it still wouldn't talk to the replacement PCM, we started checking power and grounds, only to realize that one of the harness grounds had been connected to power when the starter was wired up :ack: In dad's defense, it comes out of the same wire bundle, fit perfectly, and the truck block didn't have the same threaded ground point as the car block. Anywho, relocating that ground allowed us to use the PCM that we thought was junked.

We flashed a stock tune into the computer with the Tech 2 and did a Theft Relearn, the car will communicate with the PCM with the ignition on, but only until you try to crank the engine, at which point it instantly goes to NO COMM. Beyond that, the engine will not crank continuous, it will just bump over slightly and then cut out unless I unplug the Blue connector from the PCM, then it will crank continuous but obviously not fire.

I've got the Serial Data isolated to just the BCM/PCM/DATA lines so nothing else can interfere, but all of these test out fine so I'm at a loss. I've had the ignition apart and cleaned the contacts even though they looked great, I even depinned the original data wire from the PCM and ran a new one outside the car to the STAR connector, no change. Tried a new battery, checked every ground and cleaned them even though they looked great, added an additional engine ground cable just in case. I even tried unhooking the solenoid wire (purple) and using a remote start button to bypass it in case it was shorted somewhere in the harness, no change :crazy2: I've never had any other car act so weird, and we've diagnosed some real oddballs over the years....

Oh well. I'll play with it some more next weekend when I have more time to trace wires and try isolating potential trouble areas. We'll get it figured out eventually, my only real concern is that it will take so much time to sort out that I'll be in a pinch to get it done for testing before the first race. Tick tock....

[monteboy84]

04-03-2014
Great news, it runs! Apparently some idiot (namely, yours truly) never hooked up the coil ground when they fitted the harness onto the motor, after some endless diagnostics and testing we found it dangling in the trans tunnel. Hooked it up and Voila, fire and smoke! The car sounds great, my GM Accy Drive kit showed up from Jeg's yesterday so I'll be able to finish off the front of the engine and put the stock radiator in for some basic road testing.

Getting some sun
https://static1.pt-content.com/images/pt/2015/06/IMG_3472_zps29da94c7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3472_zps29da94c7.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3440_zps9da92ec3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3440_zps9da92ec3.jpg.html)

Rats-nest
https://static1.pt-content.com/images/pt/2015/06/IMG_3441_zps65fdb46e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3441_zps65fdb46e.jpg.html)

It probably won't run now, Rennline Porsche Battery disconnect.
https://static1.pt-content.com/images/pt/2015/06/IMG_3439_zps9d7ce439-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3439_zps9d7ce439.jpg.html)

[monteboy84]

04-04-2014
More goodies!

LS3 Corvette Accessory Drive from GM:
https://static1.pt-content.com/images/pt/2015/06/IMG_3493_zps4de5359e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3493_zps4de5359e.jpg.html)

New endlinks, we'll see how they hold up :cool:
https://static1.pt-content.com/images/pt/2015/06/IMG_3494_zps5ce0893a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3494_zps5ce0893a.jpg.html)

[monteboy84]

04-07-2014
Had a decent weekend on the Corvette, Saturday I was busy with a family even most of the day, but still managed a fair amount of progress in the time I had available. I got the accessory drive installed and managed to get the radiator position mocked up.

Love me some new parts, this accessory drive kit is a fantastic value, for just over $500 shipped there is absolutely no reason to scrounge for used parts.
https://static1.pt-content.com/images/pt/2015/06/IMG_3497_zpse2724ccd-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3497_zpse2724ccd.jpg.html)

Blurry, ack.
https://static1.pt-content.com/images/pt/2015/06/IMG_3499_zps063206a0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3499_zps063206a0.jpg.html)

PS/Alternator bracket in place, tight quarters with the EBCM here.
https://static1.pt-content.com/images/pt/2015/06/IMG_3500_zpsae654645-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3500_zpsae654645.jpg.html)

Everything bolted on, my PS pressure hose didn't show up so I had to loop it for now. Radiator in place to check fitment and wire routing, I absolutely hate how tight it is to work in here, GM should have laid it forward from the start. :toetap:
https://static1.pt-content.com/images/pt/2015/06/IMG_3502_zps5212418c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3502_zps5212418c.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3503_zpse352be94-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3503_zpse352be94.jpg.html)

New radiator, unfortunately it's too tall in this position. This is a Ron Davis radiator that Randy found me used from Joe Gibbs. It's a pretty standard size and the oil cooler is huge so the little 4.8 should live a long, happy life.
https://static1.pt-content.com/images/pt/2015/06/IMG_3510_zps1ba03fcb-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3510_zps1ba03fcb.jpg.html)

Might work better with some material removed from the crash bar. I'm not cutting into the frame rails at all, the series I'm in doesn't care but I'd like it to be legal for other series later if I sell it.
https://static1.pt-content.com/images/pt/2015/06/IMG_3511_zps0d36518b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3511_zps0d36518b.jpg.html)

Peeled open a bit, there's an internal support that needs to be cut.
https://static1.pt-content.com/images/pt/2015/06/IMG_3513_zps050a2916-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3513_zps050a2916.jpg.html)

Gone
https://static1.pt-content.com/images/pt/2015/06/IMG_3514_zps4d243a91-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3514_zps4d243a91.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3515_zps773340b5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3515_zps773340b5.jpg.html)

This might work, there will be a front splitter ducted to the radiator and the hood will be ducted to the topside. I'll have to run a different thermostat housing to make the lower hose fit, but the upper hose will be no problem.
https://static1.pt-content.com/images/pt/2015/06/IMG_3517_zps91229259-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3517_zps91229259.jpg.html)

Needs more clearance though....
https://static1.pt-content.com/images/pt/2015/06/IMG_3518_zps9ee32fbe-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3518_zps9ee32fbe.jpg.html)

Here too
https://static1.pt-content.com/images/pt/2015/06/IMG_3520_zps8c196a8c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3520_zps8c196a8c.jpg.html)

What the hell, we'll make it install from below. The cut in this picture is actually straight, but the material sprung out when I cut it, I'll fix this later.
https://static1.pt-content.com/images/pt/2015/06/IMG_3523_zpscac1dd00-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3523_zpscac1dd00.jpg.html)

Filler neck will get cut off and capped.
https://static1.pt-content.com/images/pt/2015/06/IMG_3521_zps6b086a2f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3521_zps6b086a2f.jpg.html)

Added a spreader bar back in to restore some strength. I honestly would have cut the front bar out completely but I like having the factory attachment points for the trim pieces in their original place.
https://static1.pt-content.com/images/pt/2015/06/IMG_3522_zps7778cf9e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3522_zps7778cf9e.jpg.html)

That's it for now, I need more material to finish mounting the radiator. It installs from below and will be accessible without removing much of the front body work or splitter.

[monteboy84]

04-14-2014
First on my list for the weekend was to finish mounting the radiator. I started by cutting a 1/2x1 16ga tube off to fit between the frame rails, then drilling a hole in each end for bolting. I then made a couple of 1/8" thick tabs that will be welded onto the frame on each side so that this bar can be bolted in. I wanted it removable because it's right in front of the engine and EBCM, so it would be a real PITA if it were welded in place.
https://static1.pt-content.com/images/pt/2015/06/IMG_3537_zpseeac83f1-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3537_zpseeac83f1.jpg.html)

So, I mocked the radiator into position, then slid this bar in to mark its location with a scribe. I measured from these marks to the rest of the frame to make sure it was square and even.
https://static1.pt-content.com/images/pt/2015/06/IMG_3538_zps03b1dfbc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3538_zps03b1dfbc.jpg.html)

Then I ground the paint off without removing my marks, and welded the tabs into place. The bottom flange of the radiator now sits on this tube like so...
https://static1.pt-content.com/images/pt/2015/06/IMG_3540_zpsa3814ebd-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3540_zpsa3814ebd.jpg.html)

....which made me realize that I needed more clearance up front. Out comes the sawzall.
https://static1.pt-content.com/images/pt/2015/06/IMG_3541_zpsaac5c384-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3541_zpsaac5c384.jpg.html)

Much better. This allowed me to capture the top of the radiator by bolting in a 3/4" square tube through the front of the old bumper. The radiator is now secured into place (Will add foam strips later to protect it) without actually fastening through the radiator. I try to avoid bolting to the radiator because chassis flex and vibration can cause it to crack over time.
https://static1.pt-content.com/images/pt/2015/06/IMG_3544_zpsafd6cc8a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3544_zpsafd6cc8a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3545_zps19da5e3d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3545_zps19da5e3d.jpg.html)

Then it was time to rework the inlet/outlet arrangement, so I started by making a nipple.
https://static1.pt-content.com/images/pt/2015/06/IMG_3560_zpsd3fd1198-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3560_zpsd3fd1198.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3566_zps95a98d07-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3566_zps95a98d07.jpg.html)

Then I cut it up, turned it, cut it again, and voila, glued it onto the radiator tank. (Please excuse my welding, still practicing my aluminum skills :willy:)
https://static1.pt-content.com/images/pt/2015/06/IMG_3561_zpsaa12f5dc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3561_zpsaa12f5dc.jpg.html)

Then I made a cap for where the radiator cap used to be.
https://static1.pt-content.com/images/pt/2015/06/IMG_3562_zps06f10b60-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3562_zps06f10b60.jpg.html)

This welding was even worse than the last one by the time I got it sealed up :(
https://static1.pt-content.com/images/pt/2015/06/IMG_3563_zpsed6c1bc0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3563_zpsed6c1bc0.jpg.html)

I also made aluminum straights for my upper hose
https://static1.pt-content.com/images/pt/2015/06/IMG_3567_zps1f8dfb03-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3567_zps1f8dfb03.jpg.html)

I also doctored up this thermostat housing, but the cast aluminum welded like garbage, so I ordered a billet replacement to put on in its place.
https://static1.pt-content.com/images/pt/2015/06/IMG_3556_zps68634b65-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3556_zps68634b65.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3558_zpsd04ee368-1.png (http://s124.photobucket.com/user/monteboy84/media/IMG_3558_zpsd04ee368.png.html)

Anywho, this all allowed me to get the hoses in place. I'll still need to come back and add a steam vent line from the opposite end of the radiator to dump into the surge tank. The more I work with this, the for inclined I am to remove the big ugly brace that I welded in before, I'm thinking that I'll either move it to the front of the frame rails or somewhere down below, we'll see.
https://static1.pt-content.com/images/pt/2015/06/IMG_3570_zps2ca56f98-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3570_zps2ca56f98.jpg.html)

Then for fun, I mocked up the fenders and bumper cover to check fit. I should be gluing the inner fenders in place this Friday night, can't wait!
https://static1.pt-content.com/images/pt/2015/06/IMG_3579_zpsa9091e2d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3579_zpsa9091e2d.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3580_zps0cc4d680-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3580_zps0cc4d680.jpg.html)

Ordered a whooooole bunch of parts this weekend, so next weekend should be pretty fun. :thumbs:

[monteboy84]

04-28-2014
Seats came in this weekend so I fabbed up some mounts to utilize the stock mounting points. These seats are not FIA, so they will also have braces behind them once the cage is in.

Seats are NRG Large Fiberglass buckets. These things are ridiculously cheap @ $250 each, shipped, but the quality is pretty good. I wanted to get Sabelt seats but unfortunately that wasn't in the budget at this point. What I'll probably do is swap these out 1 at a time as money allows in the next year, but for now I'm really happy with what I got for the money.

When they arrived
https://static1.pt-content.com/images/pt/2015/06/IMG_3648_zps09470ccd-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3648_zps09470ccd.jpg.html)

Test-fitting before removing the stock belt setup
https://static1.pt-content.com/images/pt/2015/06/IMG_3654_zpsd14cf6f2-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3654_zpsd14cf6f2.jpg.html)

Blank flats to start with
https://static1.pt-content.com/images/pt/2015/06/IMG_3655_zps980165f9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3655_zps980165f9.jpg.html)

Little bit'o drillin', then some bendin' yields this
https://static1.pt-content.com/images/pt/2015/06/IMG_3656_zpsb1d9546f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3656_zpsb1d9546f.jpg.html)

Repeat times 3
https://static1.pt-content.com/images/pt/2015/06/IMG_3657_zps6dcfc2aa-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3657_zps6dcfc2aa.jpg.html)

Test-fit rails with seat
https://static1.pt-content.com/images/pt/2015/06/IMG_3658_zpsa92ad5fc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3658_zpsa92ad5fc.jpg.html)

Cut a center bar, determine location based on floor markings of where the sub belt cutout was on the seat
https://static1.pt-content.com/images/pt/2015/06/IMG_3660_zps3bbbca6c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3660_zps3bbbca6c.jpg.html)

Spend too much time making some harness tabs
https://static1.pt-content.com/images/pt/2015/06/IMG_3661_zpsdf579f48-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3661_zpsdf579f48.jpg.html)

Use an angle grinder cutoff wheel to rough the profile
https://static1.pt-content.com/images/pt/2015/06/IMG_3662_zpsa24fce96-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3662_zpsa24fce96.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3663_zps598aa84b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3663_zps598aa84b.jpg.html)

Blend the shape with a flap wheel
https://static1.pt-content.com/images/pt/2015/06/IMG_3664_zps28ae50c7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3664_zps28ae50c7.jpg.html)

Tada! Follow this procedure to put $30 worth of labor into $6 worth of mounting tabs :cheers:
https://static1.pt-content.com/images/pt/2015/06/IMG_3666_zps2d600239-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3666_zps2d600239.jpg.html)

Tack it all together, using a heatshield to protect the 'glass floor.
https://static1.pt-content.com/images/pt/2015/06/IMG_3667_zps8422e0e0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3667_zps8422e0e0.jpg.html)

Check tab fit with the seats
https://static1.pt-content.com/images/pt/2015/06/IMG_3669_zps5f56dc64-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3669_zps5f56dc64.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3668_zps2c117b44-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3668_zps2c117b44.jpg.html)

Weld it up...
https://static1.pt-content.com/images/pt/2015/06/IMG_3674_zpsa39f6fff-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3674_zpsa39f6fff.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3673_zps1bf4a996-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3673_zps1bf4a996.jpg.html)

Some undercut here :(
https://static1.pt-content.com/images/pt/2015/06/IMG_3672_zpsf4b16cc3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3672_zpsf4b16cc3.jpg.html)

Bend up sub belt loop, tack in place.
https://static1.pt-content.com/images/pt/2015/06/IMG_3675_zps555850c8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3675_zps555850c8.jpg.html)

Still need to finish welding that sub loop
https://static1.pt-content.com/images/pt/2015/06/IMG_3676_zps4bbbd171-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3676_zps4bbbd171.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3677_zps3bfde53e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3677_zps3bfde53e.jpg.html)

Skipped a few steps in pictures, but located, drilled, and tapped the hole pattern, then took Gr8 bolts and thinned the heads out for floor clearance. With the head in place and threaded holes, these should be as strong or stronger than any weld stud, and are easily replaceable.
https://static1.pt-content.com/images/pt/2015/06/IMG_3678_zpsff0fad48-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3678_zpsff0fad48.jpg.html)

Repeat for passenger side, both seats in place. I'll remove and paint these mounts when the cage is done. I'm also liking the extinguisher being between the seats, it's in a decent location for weight but easily reachable from either side.
https://static1.pt-content.com/images/pt/2015/06/IMG_3682_zps4a2a5f2b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3682_zps4a2a5f2b.jpg.html)

Got the Z06 front spring installed too. Here it is with the stocker, this is a bad picture, but the springs look very similar in size and cross-section, the Z spring being a bit flatter as you'd expect with the higher rate.
https://static1.pt-content.com/images/pt/2015/06/IMG_3691_zpsbd5b6d5b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3691_zpsbd5b6d5b.jpg.html)

[monteboy84]

Hacked off the stock rubber adjusters, going to try frost plugs tacked on as a race-only alternative. The domed shape will slide easy on the control arm and provide a single point of contact during suspension travel.
https://static1.pt-content.com/images/pt/2015/06/IMG_3692_zps37c7a232-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3692_zps37c7a232.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3693_zps047b3892-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3693_zps047b3892.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3697_zpsa801434c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3697_zpsa801434c.jpg.html)

Worked pretty slick, nothing fancy but it should get the job done. I slathered some grease on the control arm for now, but will swap these with delrin later depending on how much wear I see on the arm over time.
https://static1.pt-content.com/images/pt/2015/06/IMG_3699_zps5320b977-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3699_zps5320b977.jpg.html)

[monteboy84]

Cage tubing showed up, gonna make sparks this weekend :rock: I've installed a few cage kits before, and assisted on full chassis builds, but this will be my first full custom cage done on my own. Using 1.75 x .120 wall DOM to ensure it's legal everywhere and as safe as possible.

[monteboy84]

Dad and I made some progress on the cage this weekend :rock:

https://static1.pt-content.com/images/pt/2015/06/IMG_3735_zps888b3e6b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3735_zps888b3e6b.jpg.html)

Started by cutting out access holes for mounting the main hoop to the frame.
https://static1.pt-content.com/images/pt/2015/06/IMG_3737_zps78f142cf-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3737_zps78f142cf.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3742_zps80d989c3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3742_zps80d989c3.jpg.html)

Trimmed the sill fiberglass for door bar attachment.
https://static1.pt-content.com/images/pt/2015/06/IMG_3743_zpsfc1748d0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3743_zpsfc1748d0.jpg.html)

Made these plates at work in advance, need to make them wider. I guesstimated based on pictures and measurements off the fiberglass on my Z06, so basically this was a guesstimate :thumbs:
https://static1.pt-content.com/images/pt/2015/06/IMG_3744_zpsd83d64fe-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3744_zpsd83d64fe.jpg.html)

Passenger side, the bar notch up top would eventually be raised a bit higher.
https://static1.pt-content.com/images/pt/2015/06/IMG_3747_zps7995581e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3747_zps7995581e.jpg.html)

Removed the roof halo and cut back the steel for clearance.
https://static1.pt-content.com/images/pt/2015/06/IMG_3748_zpsee474079-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3748_zpsee474079.jpg.html)

With the cage done, this will be trimmed for clearance and reinstalled, then covered with a new roof halo panel.
https://static1.pt-content.com/images/pt/2015/06/IMG_3749_zpsf1ea4c5c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3749_zpsf1ea4c5c.jpg.html)

Mounting my new bigscreen :cool:
https://static1.pt-content.com/images/pt/2015/06/IMG_3750_zps29136024-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3750_zps29136024.jpg.html)

Using the cardboard for a template actually
https://static1.pt-content.com/images/pt/2015/06/IMG_3751_zpsa81f95db-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3751_zpsa81f95db.jpg.html)

Then, used the template to fit the main hoop outside the car
https://static1.pt-content.com/images/pt/2015/06/IMG_3752_zpsbcbc0ce2-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3752_zpsbcbc0ce2.jpg.html)

Fits good :cheers:
https://static1.pt-content.com/images/pt/2015/06/IMG_3753_zps1e115d9d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3753_zps1e115d9d.jpg.html)

Used the angle finder to determine how the bottom of the hoop would be cut for fitment on the frame.
https://static1.pt-content.com/images/pt/2015/06/IMG_3755_zpse5a47055-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3755_zpse5a47055.jpg.html)

Frame cleaned up with a flap wheel
https://static1.pt-content.com/images/pt/2015/06/IMG_3757_zpsb5fda82f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3757_zpsb5fda82f.jpg.html)

More access through the wheelwell
https://static1.pt-content.com/images/pt/2015/06/IMG_3756_zps89632a57-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3756_zps89632a57.jpg.html)

Fitting the mount plates
https://static1.pt-content.com/images/pt/2015/06/IMG_3758_zpsc995ab6f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3758_zpsc995ab6f.jpg.html)

Rear downbars fitted
https://static1.pt-content.com/images/pt/2015/06/IMG_3760_zps3a1c30ad-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3760_zps3a1c30ad.jpg.html)

Here's a quick notching tutorial, I use a program called tubemiter.exe, you can find it on the google. It's extremely fast and the templates were perfect.

Wrap the template onto the tube
https://static1.pt-content.com/images/pt/2015/06/IMG_3763_zps618f0150-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3763_zps618f0150.jpg.html)

Trace it out
https://static1.pt-content.com/images/pt/2015/06/IMG_3764_zps28672a41-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3764_zps28672a41.jpg.html)

Rough cut with a suicide wheel on the angle grinder :rock:
https://static1.pt-content.com/images/pt/2015/06/IMG_3765_zps49599095-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3765_zps49599095.jpg.html)

Then clean it up with a flap wheel quick
https://static1.pt-content.com/images/pt/2015/06/IMG_3767_zps22cd14ef-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3767_zps22cd14ef.jpg.html)

Different joint, same method, fits awesome
https://static1.pt-content.com/images/pt/2015/06/IMG_3773_zps1e5ab1cc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3773_zps1e5ab1cc.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3772_zps3f7597fc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3772_zps3f7597fc.jpg.html)

[monteboy84]

Tack the diagonal in place
https://static1.pt-content.com/images/pt/2015/06/IMG_3776_zps22cbd90a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3776_zps22cbd90a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3775_zps2ce42968-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3775_zps2ce42968.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3774_zps74aa93bb-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3774_zps74aa93bb.jpg.html)

Here's the bender setup we used, good old made in Murica' equipment, the electric pump worked awesome
https://static1.pt-content.com/images/pt/2015/06/IMG_3778_zpsd69e5da5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3778_zpsd69e5da5.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3777_zps22efe919-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3777_zps22efe919.jpg.html)

Everything tacked in, there's dad preparing to pop it out for welding
https://static1.pt-content.com/images/pt/2015/06/IMG_3779_zps7adefc9d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3779_zps7adefc9d.jpg.html)

Ready to weld
https://static1.pt-content.com/images/pt/2015/06/IMG_3780_zps1a7cab52-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3780_zps1a7cab52.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3783_zpsf68dd58e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3783_zpsf68dd58e.jpg.html)

Not as good as I'd like, but plenty close to wirefeed, TIG would have to be closer.
https://static1.pt-content.com/images/pt/2015/06/IMG_3781_zps9bb0ee17-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3781_zps9bb0ee17.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3782_zps1ef5a14c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3782_zps1ef5a14c.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3785_zps202ba33a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3785_zps202ba33a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3786_zpsb0c2469c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3786_zpsb0c2469c.jpg.html)

Ugly weld from yours truly :toetap:
https://static1.pt-content.com/images/pt/2015/06/IMG_3787_zps56a659cb-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3787_zps56a659cb.jpg.html)

Welded up!
https://static1.pt-content.com/images/pt/2015/06/IMG_3788_zps996b6d31-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3788_zps996b6d31.jpg.html)

Plates welded in
https://static1.pt-content.com/images/pt/2015/06/IMG_3789_zps08ac1629-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3789_zps08ac1629.jpg.html)

Back in place
https://static1.pt-content.com/images/pt/2015/06/IMG_3791_zps4a2088cc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3791_zps4a2088cc.jpg.html)

Mounting plates back here were a real pain to weld, the body adhesive was burning and off-gassing, which screwed up the front weld. In hindsight, I should have cut larger access holes.
https://static1.pt-content.com/images/pt/2015/06/IMG_3792_zpsde880261-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3792_zpsde880261.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3793_zps91e32deb-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3793_zps91e32deb.jpg.html)

Not bad for a couple amateurs though...
https://static1.pt-content.com/images/pt/2015/06/IMG_3794_zps83ae5286-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3794_zps83ae5286.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3796_zps0c03f95d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3796_zps0c03f95d.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3798_zps10c8d38c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3798_zps10c8d38c.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3800_zpsdf46000f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3800_zpsdf46000f.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3799_zps9429628e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3799_zps9429628e.jpg.html)

That's all for now, thanks for looking! I've got pics of dash removal to post later :willy:

[monteboy84]

05-12-2014
More progress this weekend. Got the A-pillar bars added to the cage, as well as the windshield bar, dash bar, and the driver side door bars. Dad gutted the doors and made some cool brackets to relocate the power window motors so that they'll clear the cage bars that go into the door.

My nephew came to help out on Saturday morning, it's a little tough keeping him engaged since he's too young to be much help on the stuff we're doing now, but it's still fun having him around. He gets all fired up about racing, says that if I want, he'll "drive the car for me so I can get a trophy" :cool:
https://static1.pt-content.com/images/pt/2015/06/IMG_3834_zps339bccb8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3834_zps339bccb8.jpg.html)

Needed more clearance on the pillar
https://static1.pt-content.com/images/pt/2015/06/IMG_3835_zps19546cff-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3835_zps19546cff.jpg.html)

Bending to fit the template
https://static1.pt-content.com/images/pt/2015/06/IMG_3837_zps4d904db8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3837_zps4d904db8.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3836_zps650b30e9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3836_zps650b30e9.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3838_zps5f584ee9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3838_zps5f584ee9.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3839_zps62dcf700-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3839_zps62dcf700.jpg.html)

Test-fit with the upper bend
https://static1.pt-content.com/images/pt/2015/06/IMG_3840_zpsf2fa9203-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3840_zpsf2fa9203.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3841_zps0ba9c6c5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3841_zps0ba9c6c5.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3842_zps5e34b3ba-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3842_zps5e34b3ba.jpg.html)

Tacked in, no base plates yet
https://static1.pt-content.com/images/pt/2015/06/IMG_3843_zpsbcedbfaa-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3843_zpsbcedbfaa.jpg.html)

Notch needs final fitting too
https://static1.pt-content.com/images/pt/2015/06/IMG_3844_zps5d168631-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3844_zps5d168631.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3845_zpsd3af7fe0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3845_zpsd3af7fe0.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3846_zps4b7a19a3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3846_zps4b7a19a3.jpg.html)

Other side done
https://static1.pt-content.com/images/pt/2015/06/IMG_3848_zpsfe7e0735-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3848_zpsfe7e0735.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3849_zpsc0b91bba-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3849_zpsc0b91bba.jpg.html)

Nice fit-up, this improves with the base plates installed
https://static1.pt-content.com/images/pt/2015/06/IMG_3850_zps260c2300-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3850_zps260c2300.jpg.html)

Windshield bar fitted
https://static1.pt-content.com/images/pt/2015/06/IMG_3851_zps38682837-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3851_zps38682837.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3852_zps8affccf9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3852_zps8affccf9.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3853_zps2a392397-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3853_zps2a392397.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3854_zps3c394263-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3854_zps3c394263.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3855_zps9b2f5fb9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3855_zps9b2f5fb9.jpg.html)

Dusted off a 'nipple' from the weld that formed when a piece of slag fell out of the tip at the end of the weld :(
https://static1.pt-content.com/images/pt/2015/06/IMG_3856_zpsc1d23704-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3856_zpsc1d23704.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3857_zpsb24a31f9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3857_zpsb24a31f9.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3858_zps07251495-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3858_zps07251495.jpg.html)

[monteboy84]

Sa-weet.
https://static1.pt-content.com/images/pt/2015/06/IMG_3859_zpsf81bd072-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3859_zpsf81bd072.jpg.html)
https://static1.pt-content.com/images/pt/2015/06/IMG_3860_zps81b29843-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3860_zps81b29843.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3861_zps1cabe8d6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3861_zps1cabe8d6.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3862_zpscbe968ad-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3862_zpscbe968ad.jpg.html)

Clearance notching for door bars
https://static1.pt-content.com/images/pt/2015/06/IMG_3863_zps149a3a35-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3863_zps149a3a35.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3864_zps4ddc419a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3864_zps4ddc419a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3865_zpsfc231a46-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3865_zpsfc231a46.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3866_zps5305b65e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3866_zps5305b65e.jpg.html)

Door bar fitted to template
https://static1.pt-content.com/images/pt/2015/06/IMG_3867_zps25db2bdc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3867_zps25db2bdc.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3869_zpsf78ffb0e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3869_zpsf78ffb0e.jpg.html)

Test-fitted
https://static1.pt-content.com/images/pt/2015/06/IMG_3871_zpsadff51ad-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3871_zpsadff51ad.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3872_zpsa2b80b7a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3872_zpsa2b80b7a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3873_zps0dc3455a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3873_zps0dc3455a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3874_zps599189a7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3874_zps599189a7.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3875_zps60fdb2c5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3875_zps60fdb2c5.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3876_zpsb6b8c071-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3876_zpsb6b8c071.jpg.html)

Slight miscalculation in the upper clearance notch, but it'll work.
https://static1.pt-content.com/images/pt/2015/06/IMG_3879_zpsf9f3c453-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3879_zpsf9f3c453.jpg.html)

Cope fits perfect
https://static1.pt-content.com/images/pt/2015/06/IMG_3880_zps075596fa-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3880_zps075596fa.jpg.html)

Duplicating
https://static1.pt-content.com/images/pt/2015/06/IMG_3884_zpsc663ebe6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3884_zpsc663ebe6.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3885_zps0849e92f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3885_zps0849e92f.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3887_zpsefaa1359-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3887_zpsefaa1359.jpg.html)

Notice that there isn't an 'S' bend in the door bars. This series doesn't allow them on new builds, mainly because they weaken the bars significantly. I wanted to show here that it's possible to run the bars without an S-bend while still maintaining the OE door gasket. By stopping my clearance notches just shy of the gasket surface, I was able to run the bars out into the door without an S-bend. They're very strong and provide lots of room inside the car.
https://static1.pt-content.com/images/pt/2015/06/IMG_3888_zpsca271f9d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3888_zpsca271f9d.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3891_zps7367ce19-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3891_zps7367ce19.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3894_zps583e4020-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3894_zps583e4020.jpg.html)

Cheating on the verticals, bars are 6" C-C, holesaw in the Bridgeport makes quick work of them.
https://static1.pt-content.com/images/pt/2015/06/IMG_3895_zps140c81db-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3895_zps140c81db.jpg.html)

[monteboy84]

https://static1.pt-content.com/images/pt/2015/06/IMG_3897_zps71bf58d0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3897_zps71bf58d0.jpg.html)

Template for the lower verticals
https://static1.pt-content.com/images/pt/2015/06/IMG_3899_zpsb1a9f944-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3899_zpsb1a9f944.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3900_zpsef0518d7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3900_zpsef0518d7.jpg.html)

Fitted!
https://static1.pt-content.com/images/pt/2015/06/IMG_3906_zps95dd5eef-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3906_zps95dd5eef.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3907_zps99b81f5c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3907_zps99b81f5c.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3908_zpsaf13f0ce-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3908_zpsaf13f0ce.jpg.html)

Welded
https://static1.pt-content.com/images/pt/2015/06/IMG_3909_zpsbdc6579d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3909_zpsbdc6579d.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3910_zps7890e2a2-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3910_zps7890e2a2.jpg.html)

More clearance needed now with the verticals installed. There's the slick window motor mount that dad made. We'll have a power feed and basic window switch on each door, so the power windows will be operable without any need for the door control modules
https://static1.pt-content.com/images/pt/2015/06/IMG_3911_zpsfdd07a5f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3911_zpsfdd07a5f.jpg.html)

Fits good now
https://static1.pt-content.com/images/pt/2015/06/IMG_3912_zps32b863de-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3912_zps32b863de.jpg.html)

Lots of clearance for the seat and driver
https://static1.pt-content.com/images/pt/2015/06/IMG_3913_zps882d80a5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3913_zps882d80a5.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3914_zpse70fefed-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3914_zpse70fefed.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3915_zps2e15dd14-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3915_zps2e15dd14.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3916_zpsf125358a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3916_zpsf125358a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3918_zps8913afa1-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3918_zps8913afa1.jpg.html)

More to come next weekend, we're testing on the 19th so it's officially crunch time! Thanks for looking

[monteboy84]

05-16-2014
Here's a sneak peek of the fancy new switch panel that I designed and had laser-cut last night at work. Made of .060" aluminum, mounts 6 waterproof switches with individual fuse holders as well as 3 12v power ports below. I put in holes for gauges right now but don't know if I'll actually use them or not. This panel fits in place of where the original radio and hvac control were mounted before. I feel like I should paint it or something, but that seems like it might start me down the slippery slope of waxerdom. One day it's a painted switch panel, next thing you know I'll be running airbrushed FRC's :toetap:

https://static1.pt-content.com/images/pt/2015/06/IMG_3924_zps90ebd959-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3924_zps90ebd959.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3925_zps567a4a44-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3925_zps567a4a44.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3926_zps5d12340b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3926_zps5d12340b.jpg.html)

[monteboy84]

05-20-2014
Wowzer, crazy weekend working on the car! We had planned to test at BIR yesterday, but after dad and I worked until midnight on Friday and 8am-2am Saturday, we finally pulled the plug at 3am yesterday morning and accepted the car wasn't going to be far enough along for the test day to make sense. That being said, we made a ton of solid progress and the car is to a stage of completion that I'm very happy with, we'll be able to easily have it race-ready next weekend in preparation for a last-minute test/shakedown day on the 30th and racing on the 31st. Dick came out to help on the car all weekend as well, he's once of our teammates and was happy to get his hands dirty.

Unfortunately, with all of that progress, my documentation for the weekend is a bit lacking. I've got a couple of in-process shots, but mostly I was scrambling to get stuff done so the camera was an afterthought.

Fitting passenger door bars. I'm pretty proud of this, I had saved my bar template from the driver side, and it was less than 1/8" off when I stuck it in the passenger side. That tells me we did a damn good job of making everything symmetrical in the car.
https://static1.pt-content.com/images/pt/2015/06/IMG_3932_zps637fa989-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3932_zps637fa989.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3933_zps4c7b3151-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3933_zps4c7b3151.jpg.html)

Welded up!
https://static1.pt-content.com/images/pt/2015/06/IMG_3934_zpsad0f26b8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3934_zpsad0f26b8.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3936_zps4af996fb-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3936_zps4af996fb.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3935_zps0805eab4-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3935_zps0805eab4.jpg.html)

The notches in the door jamb came out much better on this side, the top one was too deep on the driver side, but thankfully you can't look at both sides at the same time ;)
https://static1.pt-content.com/images/pt/2015/06/IMG_3937_zpsb22a4000-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3937_zpsb22a4000.jpg.html)

Fitted and stitch welded the original panels back in place. Had to add some material around the tube to make the fit just right.
https://static1.pt-content.com/images/pt/2015/06/IMG_3938_zps6eb0d7d8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3938_zps6eb0d7d8.jpg.html)

Masked the tubes and blew some paint on the filler panel
https://static1.pt-content.com/images/pt/2015/06/IMG_3940_zps02673e62-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3940_zps02673e62.jpg.html)

Both sides done
https://static1.pt-content.com/images/pt/2015/06/IMG_3939_zps39be19d0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3939_zps39be19d0.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3970_zps7f99abc4-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3970_zps7f99abc4.jpg.html)

Halo bar clearanced to fit over the cage and set back in place
https://static1.pt-content.com/images/pt/2015/06/IMG_3942_zps8b4e4d36-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3942_zps8b4e4d36.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3948_zps0c23a741-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3948_zps0c23a741.jpg.html)

Getting ready to weld
https://static1.pt-content.com/images/pt/2015/06/IMG_3949_zpse09e823a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3949_zpse09e823a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3946_zps52cdcc92-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3946_zps52cdcc92.jpg.html)

Fully rewelded and gave it a quick coat of paint.
https://static1.pt-content.com/images/pt/2015/06/IMG_3952_zps910694c8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3952_zps910694c8.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3951_zpsbe6d2328-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3951_zpsbe6d2328.jpg.html)

Had to notch the new halo piece to clear the cage as well. The bars fit almost straight in line with where the roof pins were, so there will be some work needed to get the roof secured. I also need to seal these notches to keep the car somewhat weatherproof.
https://static1.pt-content.com/images/pt/2015/06/IMG_3953_zpsef995ca6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3953_zpsef995ca6.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3954_zps3a6e4f33-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3954_zps3a6e4f33.jpg.html)

3M Windoweld Urethane. This stuff is wild, dad uses it for everything it seems, but this is one application where GM used it originally.
https://static1.pt-content.com/images/pt/2015/06/IMG_3955_zps48fad3e5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3955_zps48fad3e5.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3956_zpsbf97468e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3956_zpsbf97468e.jpg.html)

Holding the ends in while the glue sets. We ended up pop-riveting the flange down becase the original screws didn't really hold any tension.
https://static1.pt-content.com/images/pt/2015/06/IMG_3957_zpsaf54082e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3957_zpsaf54082e.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3958_zpsd3045563-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3958_zpsd3045563.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3959_zps4447e377-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3959_zps4447e377.jpg.html)

Painted the bottom of the battery mount and threw some foam tape on to keep it from rattling on the fiberglass it sits on.
https://static1.pt-content.com/images/pt/2015/06/IMG_3962_zpse0904c05-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3962_zpse0904c05.jpg.html)

Mounting tab welded on
https://static1.pt-content.com/images/pt/2015/06/IMG_3963_zps321efe9c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3963_zps321efe9c.jpg.html)

[monteboy84]

https://static1.pt-content.com/images/pt/2015/06/IMG_3964_zpsb9547a18-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3964_zpsb9547a18.jpg.html)

Welded the battery mount in place, along with the harness loops that I made on Friday. The battery mount is welded to the cage harness bar and the tab I welded to it is welded on top of the panel behind the seats.
https://static1.pt-content.com/images/pt/2015/06/IMG_3965_zps327d62a3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3965_zps327d62a3.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3966_zpsc13d6a37-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3966_zpsc13d6a37.jpg.html)

Put a holesaw into the filler neck to remove the flapper and 'unleaded' restrictor for quicker fueling on pit stops.
https://static1.pt-content.com/images/pt/2015/06/IMG_3968_zps4e61b04f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3968_zps4e61b04f.jpg.html)

Dad made a perfect cold air box for the intake. He had an SLP air cleaner lid from a 4th gen F-body laying around, turned upside down with an aluminum shroud it will pull plenty of air through the inlet we made in the top of the bumper. This keeps it isolated from the hot air off the radiator and will hopefully help the wee little motor breathe on the track.
https://static1.pt-content.com/images/pt/2015/06/IMG_3986_zps0fb72aab-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3986_zps0fb72aab.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3991_zps2e4c3654-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3991_zps2e4c3654.jpg.html)

Also made a cover for the missing rear tub out of .080" aluminum
https://static1.pt-content.com/images/pt/2015/06/IMG_3971_zps69001205-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3971_zps69001205.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3972_zps73f941cc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3972_zps73f941cc.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3990_zps34921c6f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3990_zps34921c6f.jpg.html)

Here are the seats and harnesses in place
https://static1.pt-content.com/images/pt/2015/06/IMG_3987_zpsf61e6446-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3987_zpsf61e6446.jpg.html)

Aaand some teaser shots of the semi-complete car. We took it down the road and bedded in the brakes a bit, the ST43 pads are insane, it literally feels like your eyes are popping out of your face when you use full braking.
https://static1.pt-content.com/images/pt/2015/06/IMG_3992_zps62654eb6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3992_zps62654eb6.jpg.html)

Interior shot
https://static1.pt-content.com/images/pt/2015/06/IMG_3993_zps61826520-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3993_zps61826520.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3994_zpsacd9bc6e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3994_zpsacd9bc6e.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3988_zps8650f5c5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3988_zps8650f5c5.jpg.html)

I love love love this car, having a blast with the build and can't wait to get it on the track.

[monteboy84]

05-27-2014
Kicked some butt this weekend! Put in a lot of hours on the car with dad and my gf at the shop, it all ended up with having the car on the road for an 80 mile maiden voyage from my family's shop to my home last night. Now that the major work is done, I can do smaller tasks on weeknights from my garage and simply drive it to their shop if I need to do more demanding projects.

Once again with the rushed pace all weekend, I did a poor job of documenting the process, but I'll share what I was able to capture.

I wired up the battery disconnect switch and ran cable to the rear-mounted battery location. Most C5 racecars have a basic disconnect on the small cable that runs from the battery to the underhood fuseblock. While this will certainly kill the car and a lot of circuits, it still leaves a hot cable running to the starter as well as a fuseblock full of hot circuits inside the car. This will still pass Tech in most series, but I'm not a fan because it's not a true battery cutoff, it's basically a glorified ignition switch. Instead, I opted to use a 6 pole disconnect that kills every circuit past the switch, leaving only the heavy duty cable from the battery to switch as a hot wire. This works by cutting off the battery cable and ignition separately, while closing a path to a grounded resistor in order to protect the alternator from voltage spikes.

Wired up
https://static1.pt-content.com/images/pt/2015/06/IMG_4002_zps60a4f4a9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4002_zps60a4f4a9.jpg.html)

Ran the cable and ignition wires back along the dash bar
https://static1.pt-content.com/images/pt/2015/06/IMG_4003_zpsf9276e6a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4003_zpsf9276e6a.jpg.html)

Soldered wire to both leads off the resistor and heat-shrunk it for protection
https://static1.pt-content.com/images/pt/2015/06/IMG_4004_zps2d4f5703-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4004_zps2d4f5703.jpg.html)

Mounted to the factory dash bar and grounded
https://static1.pt-content.com/images/pt/2015/06/IMG_4005_zpsf65828c6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4005_zpsf65828c6.jpg.html)

Got an oil cooler adapter from Randy at DRM, this one was used but still in great shape. It gives a convenient port for the factory oil temp sender to thread in as a nice feature alongside the AN10 ports
https://static1.pt-content.com/images/pt/2015/06/IMG_4008_zpsdd818672-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4008_zpsdd818672.jpg.html)

The truck motor came with a block heater that occupied the exact same space as the oil cooler adapter, so I had to remove it and replace it with a factory brass plug.
https://static1.pt-content.com/images/pt/2015/06/IMG_4009_zps2f5633a6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4009_zps2f5633a6.jpg.html)

My radiator orientation requires a splitter with ducting in order to cool properly, so I started construction on one. Building a cardboard template for this would be tough to do right, so I opted to build the initial design from plywood and then swap it for HDPE plastic later on.
https://static1.pt-content.com/images/pt/2015/06/IMG_4010_zps04210fed-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4010_zps04210fed.jpg.html)

Transferring the nose profile down onto the panel
https://static1.pt-content.com/images/pt/2015/06/IMG_4011_zps98a53cca-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4011_zps98a53cca.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4012_zpsfe0f02c6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4012_zpsfe0f02c6.jpg.html)

Added a C7ish profile and cut it out
https://static1.pt-content.com/images/pt/2015/06/IMG_4013_zps59579d02-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4013_zps59579d02.jpg.html)

Test-fitted
https://static1.pt-content.com/images/pt/2015/06/IMG_4014_zpsc6dfe9b1-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4014_zpsc6dfe9b1.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4016_zps8a97f1eb-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4016_zps8a97f1eb.jpg.html)

Made side panels for the inner ductwork
https://static1.pt-content.com/images/pt/2015/06/IMG_4018_zps3dc0f455-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4018_zps3dc0f455.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4019_zpsfaad485c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4019_zpsfaad485c.jpg.html)

Mounts to modified swaybar clamps
https://static1.pt-content.com/images/pt/2015/06/IMG_4020_zps2169c49d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4020_zps2169c49d.jpg.html)

Assembled with T-nuts to keep the bottom smooth
https://static1.pt-content.com/images/pt/2015/06/IMG_4021_zpse7fe304d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4021_zpse7fe304d.jpg.html)

Starting on the grille insert
https://static1.pt-content.com/images/pt/2015/06/IMG_4022_zpsd1d4d2f9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4022_zpsd1d4d2f9.jpg.html)

Frame tacked together
https://static1.pt-content.com/images/pt/2015/06/IMG_4023_zps5474bc43-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4023_zps5474bc43.jpg.html)

Rods added for triangulation to stiffen the plywood panel across this opening. This grille frame is steel to keep large debris from getting scooped up into the radiator, I've seen a loose started go through a radiator and hatch a race motor before, best to add some weight and protect the car.
https://static1.pt-content.com/images/pt/2015/06/IMG_4025_zpsadd079f0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4025_zpsadd079f0.jpg.html)

Painted, screen fitted with safety wire, and an angled back panel was added for ducting.
https://static1.pt-content.com/images/pt/2015/06/IMG_4026_zps5dd302bf-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4026_zps5dd302bf.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4027_zpsc6c3dce1-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4027_zpsc6c3dce1.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4028_zps3a3e5cde-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4028_zps3a3e5cde.jpg.html)

Back on the car
https://static1.pt-content.com/images/pt/2015/06/IMG_4029_zps29c16023-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4029_zps29c16023.jpg.html)

I wish I had pictures of this out of the car, but here's the trans/diff cooler that dad assembled. It has dual Tilton pumps and a cooling fan all mounted on a modular frame so that it can be dropped out of the car as an assembly. Pretty awesome setup, just need to wrap the exhaust in order to keep the heat isolated.
https://static1.pt-content.com/images/pt/2015/06/IMG_4030_zpsa9facfc7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4030_zpsa9facfc7.jpg.html)

Nevermind the crooked exhaust tips ;)
https://static1.pt-content.com/images/pt/2015/06/IMG_4031_zps49a43a78-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4031_zps49a43a78.jpg.html)

[monteboy84]

Got the Depo lights mounted as well as the stock corner markers
https://static1.pt-content.com/images/pt/2015/06/IMG_4032_zps5a51eb15-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4032_zps5a51eb15.jpg.html)

On the road! Stopped along the way home to check some things over and make sure nothing was melting or rubbing.
https://static1.pt-content.com/images/pt/2015/06/IMG_4033_zps08c0fac5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4033_zps08c0fac5.jpg.html)

Hood is taped down because I haven't mounted the Aerocatch pins yet, classy eh? :)
https://static1.pt-content.com/images/pt/2015/06/IMG_4034_zps003040b8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4034_zps003040b8.jpg.html)

Looks especially evil in the dark, waxers will run from my brake dust and water spots :willy:
https://static1.pt-content.com/images/pt/2015/06/IMG_4035_zpsd4b44d6a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4035_zpsd4b44d6a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4036_zps78507893-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4036_zps78507893.jpg.html)

Well that's it for now, I'm DD'ing the car this week as a shakedown ahead of our May 30th test and race the day after. As you can see, there's some bodywork still needed, particularly ducting the hood, but that will come in time. I also need to fit the window net, sticker it, blah blah blah, but it runs and drives great for now. The coolant stayed at 197 steady and the oil never got over 130 degrees, so on the track it should be perfect. The car is no speed match for my Z06, but it pulls strong, the handling and brakes are phenomenal. It pulled 33 mpg average on the interstate with the stock tune, might be a pretty solid econobox with some tuning :D

Thanks for looking, see you at the track!

[monteboy84]

05-27-2014
Thanks guys! Found some pictures of my swaybar clamps that I forgot to post last weekend. I added the tab onto these in order to mount my splitter. It's a very simple setup but worked great, the whole undertray swings down on these when the cable are unhooked, so it's a simple thing to work on the front of the car.
https://static1.pt-content.com/images/pt/2015/06/IMG_3973_zps998c3bb7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3973_zps998c3bb7.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3974_zpsf7c07a42-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3974_zpsf7c07a42.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3976_zps91663691-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3976_zps91663691.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_3978_zps2a53ebb2-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_3978_zps2a53ebb2.jpg.html)

[monteboy84]

06-05-2014
Well we finally made it on-track. The test day went good and we were able to correct a number of minor issues (power steering cooler, water boiling over on shutdown, insufficient splitter cables, and a few others) in order to make the car reliable. Following testing on Friday, we headed back to the shop to finish last minute stuff like window net, tow hooks, and the seat back brace. It was raining pretty hard Saturday morning, and something got wet on our way to the track, so for the first 20 minutes or so the motor was cutting out around 4000 rpm's. Once things got warmed up it was fine though, and the car worked great.

All loaded up, I actually drove the car to the shop and then to and from the track on the test day.
https://static1.pt-content.com/images/pt/2015/06/IMG_4054_zps73cc31e7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4054_zps73cc31e7.jpg.html)

Final corner weights, I opted to even up the front tires and keep the split on the rears, figuring that this would be the most predictable arrangement.
https://static1.pt-content.com/images/pt/2015/06/IMG_4061_zps5ac31a4f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4061_zps5ac31a4f.jpg.html)

Cut a hole in the hood in preparation for Heat Extractors from Track Spec Motorsports
https://static1.pt-content.com/images/pt/2015/06/IMG_4063_zps13cb3eef-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4063_zps13cb3eef.jpg.html)

Final alignment settings. Some of these were maxed out due to the car's previous frame damage, but thankfully the tires wore very even and the car worked great with these specs.
https://static1.pt-content.com/images/pt/2015/06/IMG_4062_zps9523aef9-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4062_zps9523aef9.jpg.html)

Hanging out with her sister car
https://static1.pt-content.com/images/pt/2015/06/IMG_4053_zps82311245-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4053_zps82311245.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4052_zpsa2c624e3-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4052_zpsa2c624e3.jpg.html)

Numbers on
https://static1.pt-content.com/images/pt/2015/06/IMG_4049_zpse52899e8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4049_zpse52899e8.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4050_zpsa634150b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4050_zpsa634150b.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4048_zps816880cf-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4048_zps816880cf.jpg.html)

Tow hook on

https://static1.pt-content.com/images/pt/2015/06/IMG_4076_zps0840509e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4076_zps0840509e.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4079_zps0416902d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4079_zps0416902d.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4078_zps958d09dc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4078_zps958d09dc.jpg.html)

Rear hook on too
https://static1.pt-content.com/images/pt/2015/06/IMG_4077_zpsb838f93b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4077_zpsb838f93b.jpg.html)

Test day at the track
https://static1.pt-content.com/images/pt/2015/06/IMG_4073_zpsea6f8a60-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4073_zpsea6f8a60.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4071_zpsf8e12b64-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4071_zpsf8e12b64.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4074_zps18d62c89-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4074_zps18d62c89.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4072_zpsa479fa8d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4072_zpsa479fa8d.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4070_zps66105e4d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4070_zps66105e4d.jpg.html)

Here's a cool picture from the race, taken by Alex Bellus, a professional from here in the Twin Cities
https://static1.pt-content.com/images/pt/2015/06/PWRChart_zps1401a757-1.jpg (http://s124.photobucket.com/user/monteboy84/media/PWRChart_zps1401a757.jpg.html)

Here's a short video as well, the car sounded great
https://static1.pt-content.com/images/pt/2015/06/th_IMG_4088_zpsdb715b59-1.jpg (http://i124.photobucket.com/albums/p40/monteboy84/IMG_4088_zpsdb715b59.mp4)

So, with the issues I had early on, I pitted a couple times and managed to go 2-off, causing me to pit again for the grille to get cleaned out. That put us back into about 23rd place, but once the car worked well and I could stay out, I managed to race my way up to 6th place. With a tank of fuel gone, I pitted to refuel and change drivers. We had radio issues so the team wasn't ready in the pits, and our slow stop dropped us to 14th place. Dave ran well and brought us back up to 7th place during his stint, which we held through the driver change and about 1.5 hours with Dick in the car. Unfortunately, Dick had a mishap on track and made contact with a tire wall outside of T13. The damage is all cosmetic, but it took us out of the race for the day. We could have fixed it, but I opted to load up and save the pieces for next time. It needs repairs to the splitter and inner fender, as well as a new fender and bumper cover, but it won't be a bad fix. I should have time to get some paint on it this time as well ;) Oh well, life goes on, next race isn't until 8/9 at MAM in Iowa so I'm taking a breather for a few weeks before making repairs.

https://static1.pt-content.com/images/pt/2015/06/IMG_4090_zpse7c7de30-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4090_zpse7c7de30.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4089_zps4f39e55a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4089_zps4f39e55a.jpg.html)

Thanks for following along :cheers:

[monteboy84]

07-10-2014
Welp, after a brief hiatus from sleepless car-building insanity, I dove in and fixed the car up to get it ready for the next (Mid America August 9th) World Racing League event. So far, I have the bodywork repaired and am driving the car, but still plan to build a diffuser and spoiler before this race.

The inner fender took some moderate damage, but it's all hidden by the fender and I had the broken pieces, so I opted to repair it. After roughing up the cracked areas with a sanding disc, I started to lay on some glass and resin.
https://static1.pt-content.com/images/pt/2015/06/IMG_4330_zps1c2a3638-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4330_zps1c2a3638.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4332_zps5e4cf5c0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4332_zps5e4cf5c0.jpg.html)

This area on the bottom front was broken completely off at the bonding seam and cracked up pretty well, so I riveted the piece back on and glassed it in.
https://static1.pt-content.com/images/pt/2015/06/IMG_4334_zps55076a0e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4334_zps55076a0e.jpg.html)

Once the resin cured, I did some quick clean-up
https://static1.pt-content.com/images/pt/2015/06/IMG_4335_zps154a22da-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4335_zps154a22da.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4336_zpsc8e5f4c2-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4336_zpsc8e5f4c2.jpg.html)

...and blew some black paint on it. Nothing too fancy, this is all covered once the fender is on.
https://static1.pt-content.com/images/pt/2015/06/IMG_4337_zps0cdf49f5-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4337_zps0cdf49f5.jpg.html)

I skipped a bunch of steps here, but only because I worked until 3am to get it done for Cars n Coffee. I patched up the splitter and straightened out the metal ductwork that mounts to it. The replacement fender was yellow, so I Plasti-dipped it black to keep from looking to sloppy for now. Eventually, I'll be patching the hood and doing a better job of paintwork on the areas that need it on the car....which are numerous.
https://static1.pt-content.com/images/pt/2015/06/IMG_4341_zpse87a9ca8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4341_zpse87a9ca8.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4340_zps5ac37cf8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4340_zps5ac37cf8.jpg.html)

Stopping for fuel on the way to C&C, I borrowed my Z06 to my uncle and his gf for the day.
https://static1.pt-content.com/images/pt/2015/06/IMG_4342_zpsb09a43a6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4342_zpsb09a43a6.jpg.html)

Here's the car as of yesterday, I've been DD'ing it again to work the bugs out. Well that, and the damn thing pulls 33mpg on the interstate :thumbs::rock:
https://static1.pt-content.com/images/pt/2015/06/IMG_4363_zpsa60ec1fa-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4363_zpsa60ec1fa.jpg.html)

Next up: Spoiler build and Trackspec Motorsports Heat Extractor Install!

[monteboy84]

07-14-2014
Much to the chagrin of my girlfriend, I spent a fair amount of time with the racecar in my garage yesterday. After I saw them on here and developed a case of the 'gotta-haves', John at Trackspec Motorsports was very helpful in getting their louvered Heat Extractor panels out to me a few weeks ago, so I was happy to finally get them installed on the car.

As you've already seen, I cut the hood open before the BIR race in order to help relieve underhood pressure and help the radiator breathe. This opening was cut based on these extractor panels, but intentionally undersized to prevent error before the actual parts arrived. So, with the panels here, I measured them, laid out the correct opening size, and started cutting. Used carefully, a Sawzall works great for cutting fiberglass.
https://static1.pt-content.com/images/pt/2015/06/IMG_4373_zpsb5399b57-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4373_zpsb5399b57.jpg.html)

The picture above shows the reinforcement channel still in place, but with the depth of the louvers I had to remove it completely. With that done, I began more precise fitting of the center louver panel.
https://static1.pt-content.com/images/pt/2015/06/IMG_4375_zps13247b5d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4375_zps13247b5d.jpg.html)

These were originally made primarily for racing hoods that tend to be more flat. My hood is original so it has a groove molded down the center that doesn't work just right with the flat panel, but some quick hand-forming of the back edge allowed it to fit nicely. John informed me that they have a simple solution in the works for this, so most people won't have to bend the panel like I did.
https://static1.pt-content.com/images/pt/2015/06/IMG_4376_zps925cda34-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4376_zps925cda34.jpg.html)

I added some more mounting holes and used 1/8" Cleco's to hold in place as I worked outward
https://static1.pt-content.com/images/pt/2015/06/IMG_4377_zpsfe0f4bac-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4377_zpsfe0f4bac.jpg.html)

I rolled the sides down a bit, again to fit the contour of this stock hood, and added Cleco's to secure it during test-fitting.
https://static1.pt-content.com/images/pt/2015/06/IMG_4378_zps2828da2b-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4378_zps2828da2b.jpg.html)

Center panel fully fitted, moving on to the sides...
https://static1.pt-content.com/images/pt/2015/06/IMG_4382_zpsa80144a0-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4382_zpsa80144a0.jpg.html)

They sent some really nice templates for the side cutouts. After playing around with placement, I finalized a location and traced the template shape with blue painters' tape.
https://static1.pt-content.com/images/pt/2015/06/IMG_4384_zpsb1845805-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4384_zpsb1845805.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4383_zpsea4b9742-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4383_zpsea4b9742.jpg.html)

Then I drilled some 1/4" holes in the corners, and started hacking away with my trusty Sawzall.
https://static1.pt-content.com/images/pt/2015/06/IMG_4385_zps0ca5b428-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4385_zps0ca5b428.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4386_zps6548bf79-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4386_zps6548bf79.jpg.html)

Then I laid out the other side to duplicate position
https://static1.pt-content.com/images/pt/2015/06/IMG_4388_zps6ef251bc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4388_zps6ef251bc.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4389_zps981cb5cc-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4389_zps981cb5cc.jpg.html)

and ran a holesaw through the underside of the hood to provide ventilation without losing too much strength
https://static1.pt-content.com/images/pt/2015/06/IMG_4390_zps43d822c6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4390_zps43d822c6.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4391_zpsc24c1db1-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4391_zpsc24c1db1.jpg.html)

After using the holesaw, I went after the cut edges of fiberglass with some 220 grit to soften them up, and put a quick coat of flat black on the exposed under-structure of the hood, sorry for not having pictures of this step.

The finished product looks fantastic, and the way it pulled sanding dust out of the hood when I got it on the road tells me they're working perfectly :thumbs:

https://static1.pt-content.com/images/pt/2015/06/IMG_4393_zps2fbf752a-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4393_zps2fbf752a.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4394_zps6951f255-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4394_zps6951f255.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4395_zpscfcf3f91-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4395_zpscfcf3f91.jpg.html)

:flag:

[monteboy84]

09-04-2014
Who doesn't like pictures of racecars?? :thumbs: Here are a few nice shots of my car from the World Racing League 15-hour race at MAM in Iowa. Photo credit goes to Alex Bellus for the awesome work :cool:

We finished 4th out of a ~25 car field. Should have finished 2nd or 3rd but there were a couple of issues that popped up and kept us off the podium. Being a fresh car, I'm still getting all of the bugs worked out and documenting fuel mileage so that we can do a better job planning pit stops and other strategy. As you can see, I built a wing for the car and I'm happy to say it made a HUGE difference in the feel of the car. Before, the aero was so imbalanced that the car felt loose and twitchy, always like the back end was going to step out in fast corners, it was a huge hindrance to speed because you couldn't be confident in the car. With the wing, it's planted, balanced, and stuck to the track, the car feels great and works awesome.

I won't be running the car again until heading down to TWS in December for the next WRL event. My to-do list includes a transmission swap after I put billet synchro keys, a steel 3-4 fork, and brass shift pads on the shift forks. This one started getting feisty late in the race and will no longer go into 1st gear. I'm also hoping that I have time to paint the car once I decide on what I want for a paint scheme...

https://static1.pt-content.com/images/pt/2015/06/AZB_2385_zps33d45837-1.jpg (http://s124.photobucket.com/user/monteboy84/media/AZB_2385_zps33d45837.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/AZB_2160_zpsfa7f3be2-1.jpg (http://s124.photobucket.com/user/monteboy84/media/AZB_2160_zpsfa7f3be2.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/AZB_6530_zpsea312673-1.jpg (http://s124.photobucket.com/user/monteboy84/media/AZB_6530_zpsea312673.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/AZB_6826_zps2367fb26-1.jpg (http://s124.photobucket.com/user/monteboy84/media/AZB_6826_zps2367fb26.jpg.html)

[monteboy84]

10-09-2014
As I mentioned, the original transmission decided to get a bit snippy and not go into 1st anymore, as well as being picky about 2nd and 3rd as well. It seems that maybe it wasn't a fan of track abuse and heat :thumbs:

So, I took my spare trans apart and gave it a quick inspection before installing some reliability goodies:
- 3-4 synchro billet keys
- 3-4 Steel Shift Fork
- 1-2 and 3-4 Bronze Shift Fork Pads
- Drilled case with an AN6 port aimed at the input shaft for the trans cooler. The input shaft gets very hot on these due to fluid starvation, the idea here is to feed it fluid for cooling and in order to keep the bearing well-oiled.

The new trans looked great inside, I'm not sure how many miles were on it but it couldn't have been many.

Tailshaft housing pulled
https://static1.pt-content.com/images/pt/2015/06/IMG_4903_zpsf63a9d80-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4903_zpsf63a9d80.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4904_zpsa2599df8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4904_zpsa2599df8.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4905_zpsd2c5cf6d-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4905_zpsd2c5cf6d.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4908_zps9f7058da-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4908_zps9f7058da.jpg.html)

I put everything from the mainshaft onto an aluminum tube as I took it off, this made reassembly much easier and foolproof than simply throwing everything into a tray.
https://static1.pt-content.com/images/pt/2015/06/IMG_4910_zps75d9ba38-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4910_zps75d9ba38.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4911_zps5f8762b7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4911_zps5f8762b7.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4912_zps80f2f66e-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4912_zps80f2f66e.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4913_zps13a682d2-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4913_zps13a682d2.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4914_zps2293e434-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4914_zps2293e434.jpg.html)

Cooling port added
https://static1.pt-content.com/images/pt/2015/06/IMG_4935_zpseefb3fe7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4935_zpseefb3fe7.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4936_zps4de9e2d8-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4936_zps4de9e2d8.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4937_zps88dc597f-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4937_zps88dc597f.jpg.html)

Skipped some steps, but here's the start of reassembly...
https://static1.pt-content.com/images/pt/2015/06/IMG_4938_zps4fb3dbee-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4938_zps4fb3dbee.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4939_zpsfeb8bba7-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4939_zpsfeb8bba7.jpg.html)

Greased all of the bearings before reassembly
https://static1.pt-content.com/images/pt/2015/06/IMG_4941_zpsb111ca06-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4941_zpsb111ca06.jpg.html)

Used 'Right Stuff' for case sealant. This is my first manual transmission teardown, so I had to take the case on and off a few times to get it right :)
https://static1.pt-content.com/images/pt/2015/06/IMG_4942_zpsec6dd002-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4942_zpsec6dd002.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4943_zps3f7a7d91-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4943_zps3f7a7d91.jpg.html)

Tada!
https://static1.pt-content.com/images/pt/2015/06/IMG_4945_zpsb735f462-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4945_zpsb735f462.jpg.html)

Prop shaft couplers were pretty ugly, better do them too...
https://static1.pt-content.com/images/pt/2015/06/IMG_4978_zps7b478c18-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4978_zps7b478c18.jpg.html)

I used OEM BMW guibos, the German made ones from Lemforder
https://static1.pt-content.com/images/pt/2015/06/IMG_4979_zpse1732a32-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4979_zpse1732a32.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4980_zps129fd196-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4980_zps129fd196.jpg.html)

The torque tube had some of the old coupler material in it :)
https://static1.pt-content.com/images/pt/2015/06/IMG_4981_zpsd851556c-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4981_zpsd851556c.jpg.html)

[monteboy84]

Getting ready to stuff it up into the car
https://static1.pt-content.com/images/pt/2015/06/IMG_4982_zps47a21f09-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4982_zps47a21f09.jpg.html)

Those who know what they're doing will recognize that at this point, I have the shift cover on backward so that later on my first test-drive, I won't have a functional reverse-lockout....Doh!
https://static1.pt-content.com/images/pt/2015/06/IMG_4983_zps89dcc366-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4983_zps89dcc366.jpg.html)

https://static1.pt-content.com/images/pt/2015/06/IMG_4984_zps854752a6-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4984_zps854752a6.jpg.html)

Cooler line hooked up to the new port
https://static1.pt-content.com/images/pt/2015/06/IMG_4987_zps1fd6e3da-1.jpg (http://s124.photobucket.com/user/monteboy84/media/IMG_4987_zps1fd6e3da.jpg.html)

That's it for now, apparently I forgot to take more pictures, but the car is running and driving on the road again and the trans works perfect. Getting geared up to race at TWS in mid-December :rock:

[monteboy84]

12-17-2014
Well, I'm at my first day back at work following the big WRL race at TWS in College Station Texas. Unfortunately this track is not long for this world and will be tilled under in 2015 to make way for a high-end housing development, so that drove our decision to make the trek from MN and race there this winter. Truly awesome event, I think 54 cars in 3 classes took the green on Saturday, and close to the same took the green on Sunday.

The car worked awesome all weekend, it handled great and the motor ran perfect. We did have some issues with excessive fuel consumption, so we actually ran the whole course in 4th gear without any noticeable change to our lap times, while netting a 50% increase in minutes per tank. We still have some improvements to make in driver changes and fueling, as our driver change and fuel stops ran about 3 minutes as opposed to 2 minutes for the Spec Boxsters that we compete with most closely. We did have a couple minor issues on Saturday, where the splitter was pulled down in an off-track excursion, and a brake rotor cracked forcing us to change it out in a pit stop. Ultimately, we ended up finishing 7th overall, 4th in GP1 class on Saturday's 9 hour event, and 4th overall, 3rd in GP1 class on Sunday's 7-hour event. We got to meet Marc Sherrin and his team, great bunch of local Texas Corvette guys who run the Poorvette, an LT1-powered open-top C4. They had some issues on Saturday that kept them off-track most of Saturday, but got things turned around for Sunday and were able to race to a 4th place finish in GP1. Great bunch of guys and lots of fun to race with.

Here are some pictures from the event, I'll post some in-car video as well once I find time to edit it a bit. The Vette got a lot of love from everyone, including some closeted Corvette-loving Porsche drivers :D

https://static1.pt-content.com/images/pt/2015/06/8010805829_657979760987880_7888743553751-1.jpg

https://static1.pt-content.com/images/pt/2015/06/801509082_10153545781828868_254647915707-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010687528_10203564849943384_36767732422-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010678759_10153546975893868_87555395491-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010846286_658881077564415_8706848444661-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010373702_659140824205107_5924984585440-1.jpg


https://static1.pt-content.com/images/pt/2015/06/801491623_10153549334443868_609031729975-1.jpg


https://static1.pt-content.com/images/pt/2015/06/801502202_10155000464095393_662319695769-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010865766_10155000541620393_42386389844-1.jpg


https://static1.pt-content.com/images/pt/2015/06/801511788_10155000535365393_507145894280-1.jpg

Here's most of the field, the 4 Spec Boxsters were actually ahead of the camera at this point, that silver Celica next to me is an awesome little car built by some guys who work at a Trans Am shop in Texas. It's got a 2JZ and ran awesome all weekend, great team of guys. As you can see, LOTS of variety in the field, tons of great racing throughout the weekend.
https://static1.pt-content.com/images/pt/2015/06/8010873357_1549813395262473_873937810643-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010648851_10155000533740393_56818626319-1.jpg

[monteboy84]

I have to say, in the most respectful way possible, that is probably the coolest looking "ugly" car I've ever seen. I bet it is tons of fun to drive, both track and street. Good job!

Thanks! I actually call her Ugly Betty, playing off my Z06 known as Black Betty. Hoping to get the wrap finished before we race at NCM in March, which will be another fun event. It really is a blast to drive, the car is very neutral and comfortable to drive at the limit, the reliability has been fantastic too which really helps make it fun. There's nothing worse than driving cross-country to race and fighting with issues all weekend, this car is all about staying on the track.

Here's a short in-car video from TWS, this was our fast lap of the weekend. Keep in mind that this was done in 4th gear around the whole track to save fuel, I'm confident that we could pick up a few seconds running all-out.
World Racing League TWS - Braunschweig Corvette Fast Lap - YouTube (https://www.youtube.com/watch?v=mMbztqgGaUQ)

[monteboy84]

02-27-2015
The car is getting an updated look, here's a crappy teaser pic from my phone.

https://static1.pt-content.com/images/pt/2015/06/8010996115_10153797888943868_46565802289-1.jpg

[monteboy84]

03-02-2015
Thanks guys!

73Corvette, what can I say, I'm blushing! I appreciate the kind words. Racing has been the one thing that really brought my dad and I together over the last 10-12 years :cheers: I started racing with him and my brother in high school but went on the road racing with some friends of mine, it was a lot of fun but I was spending less and less time with my family which really bugged me. So, I pulled out of that and started doing endurance racing with dad a couple years ago, that's morphed into what you see here. My grandpa doesn't make it out too often since most of the races are out of state, but he enjoys coming to the one MN race that we usually run. It's a blast all around, fun being able to compete and put the skills to use that they taught me over the years.

More pics of the new livery below. I still need to get the spoiler fixed and bolted on but that's easier to do at home versus the bigger ticket items that need done at the shop. Anywho, here it is with the splitter re-mounted and the wrap finished, just missing contingency stickers and all that. The old splitter mounts were less than spectacular so I made a one-piece bar that sits behind the bumper cover. It has tubes that can pivot upward so if it bottoms out it won't damage the vertical strut tubes.

The new mount points also allow me to run Z06 screens without having to hack them up for the tubes to run through :)
https://static1.pt-content.com/images/pt/2015/06/8011044499_10153819222128868_57899943663-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8011046289_10153819222188868_82614039739-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8011025987_10153819222298868_34471168450-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010994169_10153819222378868_66061294759-1.jpg

[monteboy84]

Here are some pictures from the weekend at NCM Motorsports Park, I don't have time to caption or organize them now but will run back through them later, hopefully tonight.


https://static1.pt-content.com/images/pt/2015/06/8011013346_1586714441566159_799568332978-1.jpg

https://static1.pt-content.com/images/pt/2015/06/8022783_1587286961508907_294379700870211-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010930087_1587581761479427_138738765156-1.jpg


https://static1.pt-content.com/images/pt/2015/06/80997070_10204233291734011_6222149495760-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010982235_10204233291253999_48495119435-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8011073561_10153863631148868_23378841187-1.jpg

https://static1.pt-content.com/images/pt/2015/06/8010451053_10153863631088868_50407050845-1.jpg

https://static1.pt-content.com/images/pt/2015/06/8011009959_10153863631213868_42487435850-1.jpg


https://static1.pt-content.com/images/pt/2015/06/801958187_10153863631433868_853489796835-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010426251_10204233292334026_90293759947-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010482498_10204233292854039_65765420517-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8011073400_10204233293654059_68402272159-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010404103_10204233294014068_77062655260-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010645295_10204233294934091_34335769218-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8011070488_10204233296294125_22948408351-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8011070772_10204233296894140_52044801434-1.jpg


https://static1.pt-content.com/images/pt/2015/06/801503947_10204233289493955_294350346961-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010403639_10204233290373977_20555677092-1.jpg


https://static1.pt-content.com/images/pt/2015/06/8010409171_10204233290733986_54743392076-1.jpg

[monteboy84]

05-14-2015
Some cool pictures from our recent event at BIR. It was a solid weekend, we won on Saturday and came in 2nd in class, 3rd overall Sunday after a few off-track adventures in the rain. Overall the car is still working great and I/we are having a blast with it. Every driver that I've put in the car (8 now?) has loved it. Our fast time for the weekend was a 1:46.266 on Sunday, tied exactly with that of a full aero '99 M3 piloted by Chris Orr. A great weekend all-around, lots of fun. Car needs a fender and some work on the front fascia, but for now I'm tending to the lawn and some work on the house.

:cheers:

https://static1.pt-content.com/images/pt/2015/06/WRL15X3-1.jpg

https://static1.pt-content.com/images/pt/2015/06/BraunVette41X3-1.jpg

https://static1.pt-content.com/images/pt/2015/06/BraunVette40X3-1.jpg

https://static1.pt-content.com/images/pt/2015/06/BraunVette22X3-1.jpg

https://static1.pt-content.com/images/pt/2015/06/BraunVette14X3-1.jpg

https://static1.pt-content.com/images/pt/2015/06/BraunVette11X3-1.jpg

https://static1.pt-content.com/images/pt/2015/06/BraunVette29X3-1.jpg

[Centerforce]

About halfway through the build's first page on here, I thought I'd figured out which car this was (and I was right). Great build and love the engine choice for that particular race series, too. It wears the track grime at NCM nicely, if I do say so myself.

[brawls43]

Such a great build. Nice work Matt

[monteboy84]

Such a great build. Nice work Matt

Small world, thanks Greg :usa:

[NOT A TA]

Cool build & story! Thanks for posting it up here.

[brawls43]

:twothumbs You bet. I love checking out all the cool projects over here.

[OutrnNAScaR14]

Awesome build. I daily a C5 also.
You might have mentioned it, but what series is this?

[brawls43]

World Racing League
http://www.worldracingleague.org/
#racewrl

Its an endurance racing series, with classes based on power to weight ratio and modifications.

[bonecrrusher]

As a Vette lover - badass car man!

Loved the build pics - and then onto the racing pics.

Sucks about TWS being bulldozed for some houses.

Question for you - what rear diff cooler setup did you go with?

I've been looking at one for my C6 - and it looks like most guys go with a C6Z rear diff and go from there.

[monteboy84]

Thanks guys! WRL is indeed the series, it's very new but has been growing well, tons of fun for minimal cost. This car is obviously looks like more than a lot of people would/could justify spending on a racecar, but I'm only at about $15k into the whole build as it sits. That said, with the way the rules are, we've had great competition from a number of cars that are both much cheaper, and also more expensive. There's a really cool 2JZ-swapped Celica down in Texas that was damn near a perfect match for us speed-wise. Likewise, there are a bunch of Spec Boxsters that we battle with regularly, as well as a couple of hot E36's that are always a good race.


As a Vette lover - badass car man!

Loved the build pics - and then onto the racing pics.

Sucks about TWS being bulldozed for some houses.

Question for you - what rear diff cooler setup did you go with?

I've been looking at one for my C6 - and it looks like most guys go with a C6Z rear diff and go from there.

Thanks for the kind words! I've put a bunch of hours into this car and am very proud of the results, so it's always good to get compliments on it. As for diff cooling, we actually built our own setup using Tilton electric pumps and some heat exchangers off ebay, along with a Honda Goldwing cooling fan. We plumbed the diff pump feed from the diff drain with a homemade fitting, and put an AN fitting into the rear diff cover to spray onto the pinion. It works well but was a decent amount of work to assemble. For the sake of simplicity, I'd probably get a kit from DRM and call it a day. I have straight pipes on this car and hacked out the rear tub, so there was more room for my diff/trans cooling module versus a more stock car that's harder to package.

[langleylad]

Right on , love your thread