View Full Version : Project Nighthawk 1969 Camaro - Ground up rebuild
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I have loved muscle cars since I was a kid. As an adult, watching the masters like Chip foose and his counterparts on countless car shows on sky tv strengthened that love even more. I knew some day, I would build the car of my dreams, and that day is finally here.
I am going to build a car that embodies everything I love about motoring. Retro style, Lots of usable power, and as much 21st century auto tech. as I can get in. I want a retro bruiser with all the mod cons.
The current plan is, 600hp LS9 motor,
Ridetech (http://www.ridetech.com/) full air Suspension upgrades and sway bars managed by Accuair ride management
Rotiform (http://www.rotiform.com/)
modern design red leather interior
modern lighting
digital computer controlled dash and electronics
lots of custom gizmos and gadgets
Paint wise I am thing of a dark but heavily metalic grey. Almost like shadow chrome you get on some wheels.
Bespoke body mods including front valance, rear diffuser, side skirts and rear gill.
Lots of carbon trim
The majority of the build work will be taken care off by the excellent Retro Power (http://www.retropower.co.uk)
This build thread will serve as summary of the build. For full blow by blow updates and pictures, follow the build on
the project facebook page http://www.facebook.com/ProjectNighthawk
and on Twitter here https://twitter.com/#!/ProjNighthawk
Phase one was to come up with some designs. Mike Gillett did an excellent job of turning my ramblings into renders.
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more designs Design concepts and rendering (http://www.facebook.com/media/set/?set=a.283406758405769.68551.283403115072800&type=3&l=1ca38c1318)
Next, I needed a car to base the build on. I found a beautiful 69 camaro SS clone in hugger orange that had already had some resto work in the past, but you guys convinced me it was too good/original to base the build on, so that was promptly sold and replaced with this rotter off a shell.
Unfortunately I had to buy the shell blind, but the seller assured me it was a perfect base car due to my extensive plans and that structurally it was sound
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see the full gallery of base car (http://www.facebook.com/media/set/?set=a.283422345070877.68558.283403115072800&type=3&l=8321edbaa3) pics
The car was delivered straight to Retro Power (http://www.retropower.co.uk) from the seller.
I had heard lots about the abilities of Callum and Nat at retro power, and had read countless forum posts and mag articles about their previous builds.
Seeing their metal work skills on some of their previous projects, and their very reasonable costs and working practices made them a winner.
The boys got straight to work tearing the car apart ready for blasting, which is when we found out, things werent as rosey as the first seemed.
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Full gallery of the car pre blasting (http://www.facebook.com/media/set/?set=a.283423631737415.68560.283403115072800&type=3&l=03aa299f9d)
After that, there wasnt much car left for blasting! but we had come too far now to turn back so on it went for media blasting and zinc priming
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Full gallery of blasted car (http://www.facebook.com/media/set/?set=a.283423631737415.68560.283403115072800&type=3&l=03aa299f9d)
LeighP
04-24-2012, 06:07 AM
Ouch...tin worm been having a few midnight snacks.....nasty! I hate rusty cars.
Thanks
be sure to like the face book page here http://www.facebook.com/ProjectNighthawk
or follow the project on @projNighthawk (https://twitter.com/#!/ProjNighthawk) for the full blow by blow updates
prosuperstar
04-25-2012, 12:00 AM
"I knew some day, I would build the car of my dreams, and that day is finally here."
I like where this car is going its gonna be killer, but when are you gonna post a thread for the car your going to build?
T.E.D. Jordan
04-25-2012, 01:13 AM
I've lurked on here for a while now, watching the great builds and seeing a car thats going to be built in the UK has made me join to say I'll be watching!
I've read about retro power in retro cars magazine and the work they've done looked great in the articles I saw. Keep up the great work!
Jordan
"I knew some day, I would build the car of my dreams, and that day is finally here."
I like where this car is going its gonna be killer, but when are you gonna post a thread for the car your going to build?
I dont get it? This is my build thread. Do you mean me build it personally? If so, while I could do a lot of the build my self, with a very young family, I dont have the time to put in.. and I want it done quick so I can enjoy it while I am still you lol.
I have done the next best thing and found a bunch of guys I trust to build the car to my standards, and I have done all the research, project management and design.
Once the metal work is done, I will probably do the interior and technology fabrication myself.
prosuperstar
04-25-2012, 11:36 AM
I dont get it? This is my build thread. Do you mean me build it personally? If so, while I could do a lot of the build my self, with a very young family, I dont have the time to put in.. and I want it done quick so I can enjoy it while I am still you lol.
I have done the next best thing and found a bunch of guys I trust to build the car to my standards, and I have done all the research, project management and design.
Once the metal work is done, I will probably do the interior and technology fabrication myself.
So sorry just bad english on my part. I now I understand
Cheers,
Just thought you guys may want to see the latest rendering.
http://www.facebook.com/photo.php?fbid=294527123960399&l=32d7571bd9
jtm311
04-26-2012, 02:34 AM
Good Luck with the build.
John
Guys.. as you can see, I need a lot of sheet metal! Who are the best makers of panels? also does anyone make carbon outer door skins and rear quarters?
Mr.VENGEANCE
04-26-2012, 11:34 AM
some AWESOME renderings..
CamaroJoe
04-26-2012, 12:23 PM
Very cool renderings looks like it will be a really nice project!
jtm311
04-28-2012, 02:58 PM
Should look sweet!
John
zipsimons
04-29-2012, 05:33 PM
I love everything about it! Definitely going to be one to follow!
Thanks guys.. like the facebook page or follow on twitter for the latest updates.. I will post summaries here.
At the moment, still looking for a good supplier for the sheet metal
small project Update.
thanks to
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I have almost an entire camaro in a box on its way by boat to me.
Should be here by late july then the fun can begin
If you ever wondered what a camaro kit looks like in a box.. here it is :D
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Amit
After what feels like for ever, the parts have finally arrived at retro power HQ
Again big thanks to Auto Metals Direct for helping us out with the panels. Not easy to come by in the UK
Big truck full of camaro
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Flat pack camaro
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Next step are to formulate a plan and start gluing all this together.
Dont forget to like the facebook page below or follow us on Twitter for blow by blow updates.
Summaries will be posted up in this thread
Its update time.
I decided the ultimate camro wouldnt really be the ultimate camaro on the stock subframe and stock rear end.
So after discussions with RetroPower, we have decided to build a complete chassis from box steel. Retropower have tracked down a chassis bed, and work starts 24th Sept :)
In the mean time, I have asked Jason at theGMR (http://thegmr.com/) to start work on the rear end.
I chose GMR because after talking to him for 5mins, I realised he knows his rear ends! He was a font of knowledge and information
So this is what we decided to build
a 9" full floater made up of
Chromoly 325inch series housing with strengthening trusses
GMR PT-R Aluminium rear hubs with tapered bearings - These are works of art!
Strange Engineering 35spline Hytuf Axels
Strange Engineering HD Aluminium 3.7 third member with chromoly yoke
Strange Engineering S-track Diff.
I decided to go with strange engineering for the complete third member after doing a lot of research on how they have been performing on road and track.
With the top quality components I have gone with, this rear end will be capable of taking as much power as I can throw at it, and leave me headroom for future upgrades.
This rear end should be much lighter than stock, and MUCH stronger. I would of loved to have gone for the titanium housing, but I have to draw the line somewhere and the what I have speced above far exceeds the needs of this project.
Onto the build
Jason starts with a chromolly housing built in the USA from US sourced steel. Note the large hole. This is not a bird feeder, but actually an oversized oil filler/teeth inspection window
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Axel tubes welded on
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Fully seemed welded. Even the parts that will be hidden
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Trusses tacked in place. No axel flex here!
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Going to town on the welding
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Thats all for now, more to follow.
Keep an eye on the pic album here Rear end build Album (https://www.facebook.com/media/set/?set=a.359443710802073.85153.283403115072800&type=3), if you cant wait for updates
I promised updates would start coming thick and fast ;)
I will let the pics do the talking
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Thats the central housing complete, next steps, axel snouts and hubs
Amit
More updates from Jason at theGMR
Jason uses high tech custom designed tooling to ensure he can draw a straight line around the tube. No wonky cuts here!
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Holes drilled to allow the snout to be plug welded to the axel tubes for final fit
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More custom designed tooling from GMR to make sure centre section bolt holes are in exactly the right place
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Another jig used to ensure perfect alignment for the axel snouts. A precision ground alignment bar that spans the entire length of the housing both snouts are set at the same time, making them very straight to each other. Dont want to be driving in circles!
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Tacked in place for now
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Jason is cleary actually a women as he is able to tap a thread, bolt in the drain plug and take a picture at the same time
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The completed GM9 Chromoloy bare housing, ready for suspension and brake mounts of your choice
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As you can see, light as a feather. With the Motto “Lighter – Stronger – Faster” the gmr products are designed accordingly and this GMR9-325 housing is no exception. The GMR9-325 housing with 3.25" housing tubes, 3/8" faceplate, large filler cap, and rear truss section is only 1 pound more then a Currie F9 with 3" tubes and NO TRUSS installed! Now, that is a serious weight – strength ratio!
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Tomorrow should be an exciting day.
Going to visit retropower to discuss the custom chassis build.
Tomorrow should be an exciting day.
Going to visit retropower to discuss the custom chassis build.
Well was a productive day.
We decided we are going to build a full perimeter chassis with smooth floor. This car is going to be as stiff as a tank.
Will post up some cad drawings in a couple of days
LeighP
09-23-2012, 03:49 AM
I love seeing work like that rear end....auto art!
Ron.in.SoCal
09-23-2012, 08:30 AM
Well was a productive day.
We decided we are going to build a full perimeter chassis with smooth floor. This car is going to be as stiff as a tank.
Will post up some cad drawings in a couple of days
Atta boy! Should be FUN :cheers:
Has to be done right?
Us in the UK dont get quite as many bolt on options as you guys.. but heyho.. makes for a unique build
And we continue, but the rear end is in sight ;) see what i did there
Hardcore tapered bearings and crush tube live inside the hub. The crush tube is the exact size to ensure you cant over tighten the hub nut allowing the hub housing to spin freely
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Billet hub housing bolted in place with brake rotor adapters
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Jason expertly measures the axel lengths so we can get them ordered from Strange Engineering
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Next up, the great Strange Engineering pro HD aluminium housing, complete with chromoly yoke, Strange S-trac diff, and 3.7 gearset.
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These babies have more bite than jaws!
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Complete third member bolted in place
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finally the fully assembled rear end (minus the shafts)
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Next stage, install the gun drilled hy-tuf 35 spline axles from strange, and then we move onto the brakes.
Peter Mc Mahon
09-27-2012, 01:32 AM
Nice rearend!
why thank you sir ;) I try
oh wait you mean the axel
Amit
GrnDragon
09-27-2012, 07:59 AM
Man you and I think alike!!!
I also named my 69 Camaro build Night Hawk (I wrote Nite Hawk in the thread title but that just looked dumb so I changed it to Night everywhere but couldn't change the thread name).
We also have the similar taste in parts, I am running the catalog of GMR parts too. I also went with a full perimeter frame.
That is some NICE stuff you are posting, I know first hand.
I am torn on the engine choice, and originally was set on a whipple/TVS supercharged LS engine but I am now considering an all aluminum stack fuel injected BBC. It will all come down to cost for me, once I am ready to buy the engine.
oh i see.. :)
off to your thread to see if I can steel any ideas lol.
Yeah I am also torn on the engine. I want LS9 for its engineering, design, lightweight, good gas mileage, performance etc, but just dont think it looks nice enough so considering a blown LS7, or maybe a nelson racing engine :D :D but again will depend on cost at crunch time.
Retropower
10-03-2012, 12:41 AM
Hi Amit!
Since I've been stuck in front of the PC for a few hours recently ;-) thought I would sign up on here.
Think we're still a little while away from any CAD worth posting up on here sadly, all the little bits take ages to draw up, and that's just bits of chassis! Also a hell of a lot to measure!! If somebody had a CAD model of a standard front end that would save me this afternoon's measuring session!
cheers
Nat
AmKenpo1
10-03-2012, 05:21 AM
Nice rearend!
Yeah he must work out.
Very nice stuff going into this car keep the posts coming.
Wil.
cobraguy65
10-03-2012, 05:35 AM
That rear axle is Sweet.
Yeah he must work out.
Very nice stuff going into this car keep the posts coming.
Wil.
lol only the best for Nighthawk
So we have an update from retropower on the body rebuild.
Stu at retro power has started cutting out the wroten panels and is replacing them with GM Approved repair panels provided by AutoMetalsDirect (http://www.autometaldirect.com/).
As you will see throughout the build, these panels are as good as OEM.
First up, Stu gets the shell mounted on the chassis jig and tackles the front cowl area
As always, the full public album is available here The Body Rebuild (https://www.facebook.com/media/set/?set=a.369897753090002.88167.283403115072800&type=1&l=920d70d844)
But here is a preview.
The shell is mounted to the chassis table to maintain its shape once most of its cut out :|
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Stu goes wild with the cutting gear. We are building a custom permiter chassis which means custom floor pans and trans tunnnel etc.. so not a lot worth keeping. This will also allows us a 40mm body drop ;) The complete bulkhead and cowl area is chopped out ready for replacement.
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The excellent AMD repair sections are spot welded back in place
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Coming together in OEM form. Later in the project, this area will be cleaned up with all the holes removed, and a nice clean firewall fabbed with simple bead lines rolled in for strength. No need for brake servo or wiper motor hole as I have some trick stuff up my sleve for these :)
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The front section all complete
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Stu then unpicks the roof skin ready for the next phase of repairs which will start in a couple of weeks
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Enjoy, and be sure to check out the full gallery of pics here The Body Rebuild (https://www.facebook.com/media/set/?set=a.369897753090002.88167.283403115072800&type=1&l=920d70d844)
And onto the next thrilling installment in the rebuild saga.
This week, we have moved onto the rear end.
The Full picture set of the story so far can be found here The Body Rebuild Continues (https://www.facebook.com/media/set/?set=a.369897753090002.88167.283403115072800&type=1&l=920d70d844)
First of all, we strip her back to the core structure. As you can see, not much original metal is staying
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The excellent rear panel from AMD is then tacked in place.
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To ensure alignment, the outer panels were temporarily refitted.
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Then they were removed so the repair work could continue. The wheels tubs were also removed to be replaced by some nice reworked AMD tubs
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The outer skin of the pillar support rib wasnt looking too great
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so it was cut out
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a repair section was fabbed
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and welded back in good as new
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New wheels tub fitted, after some minor rework to maximize clearance
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more rot - before
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during
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and as after. You would never know it was there. Great repair skill from Stu @retropower
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Starting to look like a car again, but still a long way to go. Again outer panels still temporarily fitted to test alignment.
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Next installment, we start on the left hand side, and I should have some updates on the front struts
The body rebuild continues!
I have just posted another 40+ step by step pictures to my public gallery here
The Body Rebuild (https://www.facebook.com/media/set/?set=a.369897753090002.88167.283403115072800&type=1&l=920d70d844)
but a few highlights for the thread
This rear parcel tray panel isnt looking so hot
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So lets chop it all out
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In with the new inner panel
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and the outer panel
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Outer quater can then be spot welded in place.
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Much better. As you can see, fittment on these repro AMD panels is excellent!
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Panel gaps are bad either out of the box! These will be tightend latetr
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Next the roof support was blasted
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and painted
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And thats it for the body repair so far. Next will be the other side, plus the roof skin.
Then the upgrades can start :)
In the mean time, Jason from the GMR finshed of the rear end :) by fitting the brakes
The Full gallery is here Rear end build Album (https://www.facebook.com/media/set/?set=a.359443710802073.85153.283403115072800&type=3)
Sexy red wilwood stoppers will look lovely against the black discs and gold wheels
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Jason uses his nogin and an air line to perfectly locate the caliper braket before welding
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for the parking brake, I decided to use a GMR spot caliper
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and clamped in place with a single bolt in the mech to locate
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and finaly, my xmas present ready to ship :)
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In other news, I have found a new designer to continue the good work Mike Gillet started.
Unfortunetly Mike doesnt have the time to take the project further so victor from Victor Fulton Designs has stepped in to get the ideas out of my head and onto paper.
Here is a sneak peak from Victor.
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This is by no means the final render, just victor showing off.
Please check out his facebook page here Victor Fulton Designs (https://www.facebook.com/pages/Victor-Fulton-Designs/425670274147650.) And drop him a line if you need any design work. I is offering an incredible deal for his first 5 customers
Thats all folks.. unitl next time.
As always I would love to hear your feedback/comments
and please join in the banter on facebook and tell your friends :)
5spd540
12-07-2012, 01:22 PM
That is a sweet car and build you are doing
Thanks... You've seen nothing yet..
Just a minor update so you guys dont forget me :)
I would like to say a big thanks to II Much Fabrication (http://blog.iimuchfabrication.com/?p=346) for hooking us up with their fuel and diff vents
As you guys know by now, I am a sucker for great engineering. Even on the most minute part of the car. These are designed to vent the fuel tank, and diff case, allowing the systems to breath without odur and leakage.
I will be using two of these, one to vent the diff case, and one to vent the fuel tank.
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We are a long way off installing these, but hey, collect the parts and the project will continue.
Hopefully back soon with some more drawings, and fab pic of the front end
Amit
A little more progress to report.
Victor has done a great job sketching out some of my ideas. We are heading in the right direction, but not there yet.
Some of these are a little wild, but gives a flavor of the attack car I want to build.
Middle left is my fav front end, with the centre grill slats, and middle right is my fave rear/side view.
Retropower have a lot of work ahead :)
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In the meant time Jason @ theGMR.com has completed the front uprights. We just need to get them shipped over to the UK so we can continue with the chassis build
The fabricated front uprights are based on the Corvette C6 uprights. Being made from steel, they are much stronger than stock and aftermarket parts made from ally. They dont suffer from deflection during hard cornering. Also they only weigh 1lb over the stock items.. but strength is way up
Jason starts with a load of machined parts. The hub face and upper and lower ball joint mounts
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All the parts that make up 1 pair of uprights
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One unique feature of theGMR uprights is they have matched the stock lower ball joint taper perfectly using a custom built reamer. They will not disclose the exact taper but we can assure it is not either of the standard 7 or 10 degree tapers.Their uprights matches the stock taper perfectly to ensure quality fitment with the stock GMR components.
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1.5" thick steel tooling is used to ensure there is no deflection of movement during the welding process
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The fully welded uprights
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As you can see, only 1.1lb heavier than stock but so much stronger
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The uprights can accept stock GM hubs, or the awesome GMR hubs. Guess what we are using on nighthawk
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The completed upright with the calipers and discs bolted on
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Fully completed fabricated GMR upright and hub, with brakes installed
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Hopefully we will have more updates coming soon. In the meantime, like the facebook page to keep up with my musings and other great projects I find.
uk68327
02-28-2013, 01:20 AM
I love the sketches - bottom left (front view) looks killer!
Nice looking spindles!
That bottom left is just a little too much for me.
Looks too much like a modern audi or Merc.
I want something a bit in between
KnightMare
03-01-2013, 12:50 PM
heck send me one of those grills for my 69! They look great
Vdubwardo
03-01-2013, 07:22 PM
wow! this is sick! keep up the good work!
Who knows.. I might put some parts into production if there is interest once the car is done.
Thanks for the comments
jtm311
03-03-2013, 04:01 PM
Amazing work, really nice.
John
KnightMare
03-04-2013, 08:54 PM
Who knows.. I might put some parts into production if there is interest once the car is done.
Thanks for the comments
Throw in a rear diffuser too
progress update :)
The roof skin is finally on and the exterior body restore is almost done.
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You can see the full step by step pics here with the commentary
The Body Rebuild (https://www.facebook.com/media/set/?set=a.369897753090002.88167.283403115072800&type=1&l=920d70d844)
Now we can start on the custom work :) This is where it gets interesting. The rear end and front uprights are on their way from the US, and the boys are itching to start work on the custom chassis.
But thats not all folks!
unfortunately victor also had to pull out of the design team :( but the good news is, Mike Gillett our original designer is back with his pens blazing!
These are almost final sketches pending any changes needed due to actual build constraints. The rear lights are still work in progress
The front grill and hood vents will be open and closeable at the touch of a button.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif
The rear diffuser is a double decker design. The top slot will be vented to the under side of the car, and will also be blown with hot gases from the exhaust. The feed slot and exhaust bypass will be motor controlled so I can shut them and reduce downforce when not needed. ie cruising. Most of the aero features on this car will be deactivateable to reduce drag under light duty. With an 800bhp V8 and current fuel prices, I need all the efficiency help I can get :)
https://static1.pt-content.com/images/noimg.gif
You can see the full journey of how we got to these sketches here
Concept Drawings (https://www.facebook.com/media/set/?set=a.283406758405769.68551.283403115072800&type=3)
Thats all folks until next time
craigs73
06-05-2013, 05:44 AM
pretty sweet project.........anymore progress?
Thanks Craig
We have been waiting for the axel and front uprights to arrive in the uk. That happened a few days ago.
Chassis design and fab will start soon.
In the mean time, the design of the rear lights have been finalised on my fb page.
Should have a better progress update in a couple of months
Amit
Rag-Rat
06-06-2013, 05:50 PM
Great job of patience and saving that Camaro. I have worked in the parts retail business previously. Being that my extended family is from the UK I used to go to great lengths to help people get speed parts for there projects over there. I'll continue watching for updates.
MCMLXIX
07-24-2014, 09:52 PM
Can we get an Annual Update ... its been a little over a year....
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