C3 78' Corvette LS1/T-56 with Holset HX-55 Turbo build

[User-C3]

I thought I would post my project. I have a thread on LS1Tech as well as Corvette Forum but I think this is a pretty good site to get some quality input and feedback.

The current setup of the car.

1978 Corvette
LS1 and T-56
Holset HX55 Single turbo
Full performance VBP suspension (Love the setup, handles good, performes decent on the track. It came on the car when purchased. Thinking of ways to improve and get mor low)

One of the main things with my build is my very small budget. I try to fab as much as possible, and work out of my garage after the 8 to 5


Currently finishing up the turbo, fabing a complete custom interior, and a rewire.

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Engine setup after initial LS swap
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[User-C3]

I used the factory fuel tank and added a sump.
I made a pan
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Drilled some holes
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And added some metal
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I went with a dual inline fuel pump setup. The second pump will be triggered by a hobbs switch. Had been running just one pump until the turbo instal is done
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[User-C3]

The battery tray compartment had been removed by the previous owner. my battery now resides in an aluminum battery box under the floor behind the driver seat.
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I also fabbed a harness bar setup that also ties in the back to give a bit more stiff until I get around to fabbing a cage.
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[User-C3]

My initial intercooler setup was going to be A2A, but after realising the plumbing issues and clearances I decided to switch to a A2W.
I made a custom radiator surround that doubled as my intercooler mount. I made a simple wood jig based off the stock surround to give me the mounting locations. The main square of the jig is the exact dimensions and lay back angle of the radiator.
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[User-C3]

This is the pump I decided to run for now. It's a jabsco pump I picked up for $30 used but still brand new. About $60 cheaper than the bosche units and can run dry without damaging the pump. I made a little aluminum bracket for it and mounted it on an existing mount spot on the inner fender of the driver side nice and tucked away.
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I didnt want the pump running all the time when it isnt needed so I spent a good amount of time figuring out a solid solution for a trigger. I also wanted a gauge to monitor the intake air temps. I wanted all this and didnt want to spend a lot of money as in the theme with every new thing I do to the car. I found this little Love 12 volt thermastatic controler. It has a digital readout and can be set at any temperature. I will probably keep it set around 110-120f so the pump will only kick in once the temps go above that. I found this $90 unit for $15..... Score!! and found a stainless braded thermocoupler for $2
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This is the water to air intercooler I decided to go with. It will package very nicely inline with the piping. Its not the biggest but I think the way I am seting up the rest of it there should be sufficient cooling. The core is essentially the same size as most w2a units out there. I wanted a barrel but this one is a fraction of the cost.
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For the water tank I decided to go with a vintage stainless steel fire extinguisher. It's nice and light and will look real cool mounted in the center behind the seats. It has a large enough opening to put in ice if I want.
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For the heat exchanger, I found this sprint car, or midget racing radiator on ebay. its 2" thick, 26" long, and 8" tall. This thing is legit and will cool wonders. Looked up the manufacturer and found they are going from $200-400. Picked this beaut up for a whopping $35. Cheaper than a small oil cooler. I started making a mount for it to bolt up to where the FMIC was going. I decided to do a V-mount setup and think it will catch great air from the front spoiler and not effect the engine radiator.
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[User-C3]

Made a bracket to hold the antique fire extinguisher, aka my intercooler water tank. Its going to be mounted centered behind the seats. in the cabin.

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here you can see my attachement method to the mount. 2 leather belts. looks pretty sweet, and I am going to do some matching accents with the interior once I get started on it. you can also see my mediocre sketch in this pic.
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I drilled a hole in the bottom of the tank and welded in a fitting for the hose feed, I'm using the original hose barb off the top side for the return into the tank. I removed it tapped the whole and fitted a hose barb on the inside with a hose going to the bottom. This way I wont be listening to the water pouring back into the tank sounding like someone is taking a piss while I drive.
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I also had to modify my airfilter to fit my clearances. The filter I had, I wanted to use if I could and save the money on buyng a new one custom for my clearnaces. I cut the filter element down, and removed all the glue/sealant they use to bond the element to the metal base. I cut down the rubber side as well. The rubber inlet was only 4" and my turbo is a 5" so I got a rubber reducer that fit my turbo and the filter rubber just fit inside of that. I cut down the reducer to be just big enough to do the job. I then bonded the 2 together.
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I ended up using bondo glass to seal the element back to the metal. wasnt sure it would work, but it ended up working great.
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Perfect fit
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[User-C3]

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[User-C3]

After finishing the intercooler tubing I figured I should check my welds after smoothing them out, I inspected everything for pinholes and went back over anything that looked suspect but figured I should do a pressure test. Here is what I did, pretty simple and cheap.
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I got my blow off valve all sorted out as well.
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I made a support bracket for the intercooler
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This was part of my first attempt at an intercooler bracket that would wrap around the intercooler and aslo act as a heat shield. It ended up just becoming a nice little accent piece to cover the top hole.
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[User-C3]

Made my heat shield for the turbo. did the old stove pot method. Love it

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The bracket I made was already a quazy heat shield in itself, but I ended up welding 2 allen bolts to it to mount the shield.
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Its all in the details...
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I also finished smoothing out my welds on the intercooler piping, and whent with a brushed finish. if its scratched up later I can just hit it with some sand paper.

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I also welded in a bung for my IAT sensor, and installed my thermocouple for my temp gauge/ intercooler pump trigger.
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[User-C3]

Here is what I came up with for my exhaust for now. It's single shorty side pipe exiting out the passenger fender right off the turbo. I want to have the pipe just peeking out the fender but with no sort of muffler and only a few inches of tubing I dont think it will make for an ideal street driving sound track. The ideal setup would be running under the car exiting before the passenger rear tire something slim and sleek, but I have zero clearance to runn it off the turbo under the car. For the cover plate I used some aluminum and came up with something that should serve the purpose. I'm not 100% sure how I feel about it right now, but over all I think it works.

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[User-C3]

As of this week I have started the interior fabrication. I am doing all aluminum custom one off dash, center consol, and door panels. Hopefully when its done it will be something pretty unique. I am also debating if I want to go the full route and clay this up to make everything a bit softer and then make molds. If there is enough people who may be interested in custom aftermarket light weight fiberglass or carbon fiber interiors I may start reproducing them.


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I'm really happy with the start of this. The flat that extends down from the main top pad will eventually be a smoked lens with two recesset gauges behind it. It will only be known once the gauges are lit up. The interior will have a sort of bomber style feel, debating how much raw aluminum I want to leave exposed, but as I get farther along it will most likely just work itself out.

This new little tool kit is going to have a big roll on the interior
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[cornfedbill]

Great fab work! Keep it up.

[KnightMare]

I want to see the fire extinguisher mounted. Great work!

[Aficionado]

Always glad to see another Shark taking the PT route--looking good!!

[Martin71RS]

WOW !!! that's some serious fabricating you are doing there....keep up the good work :-)

[User-C3]

Thanks for all the compliments guys, much appreciated.

I made all my intercooler hoses yesterday. I used some braided line I had that was for a pressure washer. I cut to fit each location and had the fittings pressed on from a local hydraulic shop right by my house. This picture showes the line and the fitting before pressing or clamping, or whatever you want to call it.
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Here is what the intercooler tank/ AKA bad ass fire extinguisher looks like in the car. Seats are out for interior fab but you get the idea. I'm planning on tinting the back glass pretty dark so it wont be so in your face from outside the car.
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Did a bit more work on the IP. Made the under surface of the top pad, welded everything and rounded off the radiuses and fillets on the edges. Still manny hourse of filing and finishing on this piece alone but its starting to take shape.
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And how its starting to look and fit in the car.
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[andrewb70]

Awesome build. Any details about the turbo?

Andrew

[rfalker1]

I agree this is awesome! BUT WHAT ARE U building the car for?? Street, track or double duty??

[ryeguy2006a]

It is so much easier to see the build pictures on this site rather than ls1tech.com. Awesome build.

[User-C3]

Awesome build. Any details about the turbo?

Andrew

Thanks.... The turbo is a Holset HX55.. They dont go by standard measurements so its a bit tricky to figure out. I did measure it though
Exhaust
inducer = 80mm
exducer= 70mm

Compressor
inducer= 68mm
exducer= 100mm



I agree this is awesome! BUT WHAT ARE U building the car for?? Street, track or double duty??

Thank you.... The car will be double duty for sure. Mostly getting driven on the street, but will be seeing a lot of hard track time after its done


It is so much easier to see the build pictures on this site rather than ls1tech.com. Awesome build

Thanks



Not much progress on the vette lately. Done some more work to the IP but nothing too substantial to show yet. For the water tank I used the existing hose barb that was on the fire extinguisher but had to make a fitting for the water line. I ended up pounding a fitting over the barb. I havnt tested it yet but I am pretty sure it is sealed nice and tite. I then smoothed it out some , but didnt care to make it perfect because I like the rough look on the copper, it matches the lid.
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Had to share a picture of the hose off..... It looks pretty bad!!!! LOL
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I also started making my new tool to help with the interior. Here is a quick design I did to help keep me on track. Should have it done in the next day or so.
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[User-C3]

Slow but sure.... the IP top pad is now securely mounted with. It takes just 2 wing nuts to secure or unbolt it and it really solid. I have also made the center console side walls.
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Here is a good view of the width of each wall. I am getting better at this aluminum welding and shaping stuff.
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This picture shows the IP to center console interface. Not too bad for the first attempt and test fit. The centerconsole wall is just sitting there with no support. Once I figure out the fastner solutions I should have the alignment all sorted out. I'm planning on using wingnuts on all mounting points to make for quick and easy removal and instal.
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I also brazed the connection between the fitting I pressed over the fire extinguisher barb to ensure the seal.
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[rustomatic]

Dude, it is clear that you're not new to this stuff! It's cool to see the influence of your bike affliction on the car parts you make; it is however odd to see Harley and Ducati (996?) in the same room. Your work is awesome, and a great new inspiration to the nuts on this site--keep it up!

[bonecrrusher]

Love the metal work you've done.

[User-C3]

Work seems to progress so slow. I have been working out the mounting locations for the dash and console, and also started on rewiring. I made a new box around the shifter to still allow for easy engine/trans removal but seal it up and be nice and clean at the same time.
I am still not happy with the sharp points on the top of the IP. I need to round them out to match the curve under them. I will get to that later on when I have the entire picture more complete.

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[User-C3]

Dude, it is clear that you're not new to this stuff! It's cool to see the influence of your bike affliction on the car parts you make; it is however odd to see Harley and Ducati (996?) in the same room. Your work is awesome, and a great new inspiration to the nuts on this site--keep it up!

Thanks, I appreciate it. Yea the bike stuff came first with me, a habit I will never be able to kick. I'm a bit out of the norm when it comes to bikes, like you say about the harley and ducati together. Yes a 996, but I just cant deny cool bikes and cars regardless the name on them.


Love the metal work you've done.

Thanks.....

[User-C3]

Made a switch panel, for the power, ignition, and fans. I have the intercooler pump wired into the fan switch so they turn on at the same time. I used my new bead roller I made. This was my first time using a bead roller, and using this one that I made, the test piece was my panel, so it worked pretty well. I also made the opening in the IP for the gauges I will run inside of it, and also cut the plexy cover to go over it. Painted the inside black so when the plexy is tinted you wont be able to see anything inside except the gauges when they light up.

https://static1.pt-content.com/images/pt/2013/05/IMG_1690_zpse85503a2-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1690_zpse85503a2.jpg.html)

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I also used my HF hydraulic knockout punch tool. Works surprisingly very well. I then used my new dimple dies that also hook up to the hydraulic ram to dimple the piece. Didnt really need to use the dimple dies but they gave me a bit more room for the gauge to sit in and I wanted to try them.
https://static1.pt-content.com/images/pt/2013/05/IMG_1695_zps9d3431c0-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1695_zps9d3431c0.jpg.html)

https://static1.pt-content.com/images/pt/2013/05/IMG_1696_zpsd25c7a44-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1696_zpsd25c7a44.jpg.html)


https://static1.pt-content.com/images/pt/2013/05/IMG_1698_zps3f59fe76-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1698_zps3f59fe76.jpg.html)

https://static1.pt-content.com/images/pt/2013/05/IMG_1699_zps8b5f0029-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1699_zps8b5f0029.jpg.html)

https://static1.pt-content.com/images/pt/2013/05/IMG_1700_zpsd1e7d2a9-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1700_zpsd1e7d2a9.jpg.html)

[bonecrrusher]

That metal work is bitchin.

[BirdsThaWord]

Sweet! Surprised you haven't been kicked off of Corvette Forum yet for making something other than factory correct. Those guys over there can be fussy. I had put a Hairy Glass dash in mine and got all kinds of flak from them. I love what yer doing!
75957

[User-C3]

That metal work is bitchin.

Thanks, I appreciate it.

[User-C3]

Sweet! Surprised you haven't been kicked off of Corvette Forum yet for making something other than factory correct. Those guys over there can be fussy. I had put a Hairy Glass dash in mine and got all kinds of flak from them. I love what yer doing!
75957

Yea, they seem to be pretty straight laced on that site. There isnt much I own that I dont end up modifying and customizing, factory is boaring in my opinion. I would love to see more on your vette. I'm about to start the door panels soon, seems you took a similar approach I have been planning on. Do you have a build thread for it?

[BirdsThaWord]

I actually don't have it anymore, but if you search Corvette Forum for posts by Litevette you can find where I had posted pics on there. I never got to finish it, but I planned to pull the door panels and polish them. I did the holes to match the holes in the Kirkey seats and planned to black out the inside of the door behind them. Was also going to do an insert in the middle of the dash to match. Kind of a polished bomber looking interior was what I was going for. With those dimple dies and fab skills you have I bet you could make some way cooler stuff! Your build is looking great!

[User-C3]

some updates:

The car is coming back from the tuner this week, unfortunatly it is not complete and driving back under its own power. I am having some voltage issues dropping a full volt which is interupting the tuning and injectors. I am also having some issues with building boost. I spent a good deal of the day at the shop on thursday working on the car and bench testing the wastegate and some other things, but thinking the intercooler may be the culprit.

on another note since the car has been out of the garage I have been getting a bit of work done on the center console.

I also never posted pictures of the bead roller I made so here ya go.

the quick design I had done

https://static1.pt-content.com/images/pt/2013/04/beadroller_zps14c0745f-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/beadroller_zps14c0745f.jpg.html)

here it is, not totally done but functional. I still need to instal the motor and paint it. Started out as the Harbor Freight unit.

https://static1.pt-content.com/images/pt/2013/06/IMG_1768_zps6bce507a-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1768_zps6bce507a.jpg.html)

I made the main center surface with the shifter cutout. all the holes along the perimeter are mounting. I will be using allen bolts to give it the look I am going for. Here you can see the template for the armrest piece. I use some cardboard to get a template and then tape off the edges to get the exact shape and measurements I want.

https://static1.pt-content.com/images/pt/2013/06/IMG_1763_zpsf49c42e7-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1763_zpsf49c42e7.jpg.html)

armrest piece cut and bent into shape.

https://static1.pt-content.com/images/pt/2013/06/IMG_1765_zpse97f14b9-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1765_zpse97f14b9.jpg.html)
https://static1.pt-content.com/images/pt/2013/06/IMG_1766_zps9cfab2a7-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1766_zps9cfab2a7.jpg.html)


hole punched and dimpled the armrest. there will be a plate under the dimples and the armrest will be wrapped exposing bare aluminum openings.

https://static1.pt-content.com/images/pt/2013/06/IMG_1771_zpsab7170f0-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1771_zpsab7170f0.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1772_zps9293f4fc-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1772_zps9293f4fc.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1773_zpsa7191ed1-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1773_zpsa7191ed1.jpg.html)

and I now have usable center consol storage, something the c's always lacked. You can see in this photo the rails for the lid, I did the same thing for the center stack up all the way up which the allen bolts will screw in to.

https://static1.pt-content.com/images/pt/2013/06/IMG_1774_zps62ca19c7-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1774_zps62ca19c7.jpg.html)

[Motown 454]

Awesome job it looks great.

[User-C3]

thanks!!



I fixed my voltage drop issue, and have ditched the water to air setup. save some weight, and simplify some things. I ended up doing what I should have done in the first place when originally started to go A2A. I made a slim wide transition section to go over the radiator and maintain hood clearance. I am now going to be running an A2A in front of the radiator the same way I had the heat exchanger for the W2A setup V-Mounted. I refabed most of the piping leading up to the intercooler.

Here is the transition I made over the rad, much like the factory corvette units but not plastic.
https://static1.pt-content.com/images/pt/2013/06/IMG_1801_zpsbce07209-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1801_zpsbce07209.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1808_zps3e18dbfd-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1808_zps3e18dbfd.jpg.html)

The routing of the intercooler piping now is tucked up pretty close to the fender wells, and does a little up and over the filter to go down the side of the radiator.
https://static1.pt-content.com/images/pt/2013/06/IMG_1811_zps777d0981-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1811_zps777d0981.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1806_zps43072c64-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1806_zps43072c64.jpg.html)

here is where the piping routs to the side of the rad and through the radiotor support I orignially fabed for this reason. Its a super snug fit, but also a perfect fit and I'm using a coupler to give a cushion between the metal.
https://static1.pt-content.com/images/pt/2013/06/IMG_1807_zps9ab382e2-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1807_zps9ab382e2.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1809_zpsbb6ee4a6-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1809_zpsbb6ee4a6.jpg.html)

I also got a bit more work done on the interior center console. Still need to make the panels under the top pad, and my gauge panel area for the tach, install the gauges, wrap the center console arm rest, make a shifter boot, and figure out the hydro e-brake setup and where I want it located. After I start driving it around with this new interior I will figure out if I need to wrap more surface based on heat, and reflections. I also need to start finishing some of the surfaces smoothing and polishing a bit more as I am more concrete in the forms.
The insane amount of allen bolts will be either polished, or replaced with stainless button top allen heads.

https://static1.pt-content.com/images/noimg.gif (http://s1284.photobucket.com/user/TMantkus/media/IMG_1791_zps1537c6ad.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1792_zps255cc2d8-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1792_zps255cc2d8.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1793_zps1a48564e-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1793_zps1a48564e.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1794_zps1a34fbd2-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1794_zps1a34fbd2.jpg.html)


Last but not least I have added a new project to the family. It will be an LS1 swap as well. This build will be a bit more extensive, caged, custom widebody I will be sculpting and pulling molds off of, and of course a custom interior. A build thread on this will be in the near future once I get the corvette to a happy stopping point to be comfortable driving it around and not doing much more major work.
https://static1.pt-content.com/images/pt/2013/06/IMG_1795_zpsec222020-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/1978%20Porsche%20911SC/IMG_1795_zpsec222020.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1796_zpsd3db1e23-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/1978%20Porsche%20911SC/IMG_1796_zpsd3db1e23.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1800_zps6fe7687e-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/1978%20Porsche%20911SC/IMG_1800_zps6fe7687e.jpg.html)

[Twin_Turbo]

nice fab work, I really like the dash you did

[BirdsThaWord]

MAAAAAAAN! Your console looks sick in there! Great work brother! Now, if you can just keep yourself from getting sidetracked by that whale tail. It'll be interesting to see what you do with that bad boy.

[User-C3]

Thanks guys, I can honestly say I never really know how my stuff is going to turn out until it starts really taking shape. I have thought about this interior for a long time, but honestly never thought I would do the entire thing out of aluminum.

The Porsche is going to be fun to build, I will most likely anger a lot of purists, but I'm not about the purist mentality, obviously!

[User-C3]

started placing the intercooler last night. I have chopped a large amount of material out of the front support sections to cut weight and also give clearances. The weight I took out of the vacume cylinder that was in front was almost equal to the weight of the turbo. This intercooler location is also going to give me a few more complications when I start fabing the headlight buckets. Still not sure completely how I am going to approach that.

https://static1.pt-content.com/images/pt/2013/06/IMG_1852_zps04442ddc-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1852_zps04442ddc.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1854_zpsa708d5ed-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1854_zpsa708d5ed.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1853_zps09eb4d2f-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1853_zps09eb4d2f.jpg.html)

https://static1.pt-content.com/images/pt/2013/06/IMG_1856_zps4ee5d55f-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1856_zps4ee5d55f.jpg.html)

[Aficionado]

Man, that center console is amazing! Love the storage!

[User-C3]

The car is back, and running. Drove it in to work today. Still having some boost issues. Boost comes on full at 3-3500 rpm and then falls off in the higher the rpms. I'm thinking its still an intercooler restriction which is frustrating. But at least its back on the road. Here is how the intercooler setup came out.
https://static1.pt-content.com/images/pt/2013/07/IMG_1869_zps46a062f7-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1869_zps46a062f7.jpg.html)

https://static1.pt-content.com/images/pt/2013/07/IMG_1877_zps214db837-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1877_zps214db837.jpg.html)


The mounts
https://static1.pt-content.com/images/pt/2013/07/IMG_1870_zpsc8f05a24-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1870_zpsc8f05a24.jpg.html)

I had to cut off the intercooler intake pipe and turn it and reweld it on so it came in the right direction. The intake side is 3" and my tubing is 2.5. This also shows the mounting
https://static1.pt-content.com/images/pt/2013/07/IMG_1871_zps716f9b47-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1871_zps716f9b47.jpg.html)

https://static1.pt-content.com/images/pt/2013/07/IMG_1873_zps99e95155-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1873_zps99e95155.jpg.html)

I had to do a bit of notching off the front structure to clear the intercooler. Its super tight for space trying to use the factory front structure, its going to make it even more difficult if the intercooler size is whats restricting flow.
https://static1.pt-content.com/images/pt/2013/07/IMG_1874_zps1b369816-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1874_zps1b369816.jpg.html)

I also made a little index book to show mee what fuses are for what
https://static1.pt-content.com/images/pt/2013/07/IMG_1905_zps227902f5-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1905_zps227902f5.jpg.html)

folds up like a nice clean book. I wrapped it in the same material I will be using on the console and dash and doors accented.
https://static1.pt-content.com/images/pt/2013/07/IMG_1904_zps3db7e456-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1904_zps3db7e456.jpg.html)

https://static1.pt-content.com/images/pt/2013/07/IMG_1909_zpsf66e2ef0-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1909_zpsf66e2ef0.jpg.html)

I also upgraded to a 160 amp alternator. its getting pretty hot under the hood and I think the temps are affecting the voltage output.
https://static1.pt-content.com/images/pt/2013/07/IMG_1913_zpsbf28a6db-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1913_zpsbf28a6db.jpg.html)

https://static1.pt-content.com/images/pt/2013/07/IMG_1912_zpscd76f18c-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1912_zpscd76f18c.jpg.html)

[User-C3]

In trying to track down my lack of boost pressure I found out I had some major boost leaks. No one said this stuff was easy.
I put together a pretty simple and easy boost leak test. heres a little video I made. You can see how much air was blowing out of my throttle body. I also had to fix a couple spots on the piping where I smoothed out the welds and created some leaks.

http://www.youtube.com/watch?v=HLAK8fxpO1g

I found the seal on the shaft for throttle blade was not doing anything as far as holding in air pressure so I started trying to see if I could track one down or figure something out. Seems nobody has any knowledge about this, or seems to have had the same problem and you also cant purchase the seal. Either way I have had this thing apart and back on 2 or 3 times now
https://static1.pt-content.com/images/pt/2013/08/IMG_1928_zps095eff3b-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1928_zps095eff3b.jpg.html)

Here is the seal after I have made a couple modifications to it. I have added O-rings to both sides to creat more contact area as well as turned the seal around in the throttle body. The seal sort of flanged out to the outside and I think this allowed it to just let air escape out of it. My hope is by turning it around it puts pressure on it and creates a tighter seal. My hope!
Here you can see the now 3 layers of the seal

https://static1.pt-content.com/images/pt/2013/08/IMG_1929_zpsf76e08fc-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1929_zpsf76e08fc.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1930_zps6e45258f-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1930_zps6e45258f.jpg.html)

I also siliconed it into the housing to make sure it doesnt get blown out or let air escape out the sides

https://static1.pt-content.com/images/pt/2013/08/IMG_1932_zps43bd45a5-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1932_zps43bd45a5.jpg.html)

Its back together now and the blade opens and snaps shut just as it did before so I am almost 100% there will be no sticky situations....

I also found out from my multiple on offs of the TB that it hardly even covered the opening on the intake manifold. The manifold has a 92mm opening and stock TB's are 76mm. So I made a plate that will make up the difference.

https://static1.pt-content.com/images/pt/2013/08/IMG_1934_zps888b8f24-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1934_zps888b8f24.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1935_zps3f6993de-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1935_zps3f6993de.jpg.html)

Its back on now and waiting for another pressure test tonight. I am hoping it works or at least makes it a small enough leak to be tolerated.

[User-C3]

--old and new--


https://static1.pt-content.com/images/pt/2013/08/IMG_1924_zps9ec4937c-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1924_zps9ec4937c.jpg.html)

[vette427-sbc]

Love it! I actually like how the intercooler piping shows behind where the headlights should be.

[Supra510]

Nice work.

[User-C3]

Love it! I actually like how the intercooler piping shows behind where the headlights should be.

Thanks, the headlights will be addressed soon. I have had a set of projectors I was going to make assemblies for, but now that the intercooler is there I dont have the room. I'm thinking of using the LED 4x4 lights.
currently trying to sell the projectors though.

[User-C3]

Nice work.

Thanks, I allways appreciate the comments.

[User-C3]

Had the big yearly car show with work today for the woodward dream cruise. They had a couple of the new transformer trucks there, and the hotwheels camaro. We do a show in the morning around the lake in front of our building and then there is a sweet police escorted drive down to the event on woodward. It was a pretty fun day at work.

https://static1.pt-content.com/images/pt/2013/08/IMG_1991_zpsa6501879-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1991_zpsa6501879.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1990_zps0bb0c6a0-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1990_zps0bb0c6a0.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1973_zps5a90e1f0-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1973_zps5a90e1f0.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1970_zpsb0ec7b9f-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1970_zpsb0ec7b9f.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1986_zps68e9070c-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1986_zps68e9070c.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1988_zps9d1b9671-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1988_zps9d1b9671.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1977_zpsc63f43bb-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1977_zpsc63f43bb.jpg.html)

here are the transformer trucks. I think the black one is called dreadbot or something like that.

https://static1.pt-content.com/images/pt/2013/08/IMG_1993_zps09dbd891-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1993_zps09dbd891.jpg.html)

https://static1.pt-content.com/images/pt/2013/08/IMG_1979_zps80d34966-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1979_zps80d34966.jpg.html)

and here is the green chrome hotwheels camaro

https://static1.pt-content.com/images/pt/2013/08/IMG_1980_zps1467f9b5-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1980_zps1467f9b5.jpg.html)

[srh3trinity]

I am not sure how I missed this. I love the level of inventiveness and craftsmanship in this build. I love the C3's and these late 70's cars get the least respect.

[Z06killinSBF]

Very cool, I love these body Vettes. Amazing work you have done.

[cactuss4]

Who just goes to their bench and fabricates a new dash?? You guys make me so jealous!! love it!

[User-C3]

thanks guys, I do agree it seems nobody wants to put in work on the c3's much. Thats why I wanted a turbo LS c3 I havnt seen one yet, well I mean outside the one in my garage..lol

To the dash comment, that is pretty much what I did. Cant say I have built one before....


good news, boost is all straightened out and this thing pulls like a champ. I love every second im in the gas. I'm sure plenty of people have more HP than I do but its fun!!

[User-C3]

havnt been doing any real work on the car. went to a test and tune the other weekend and did some drifting. Here is a quick clip of one corner, ended up spinning on this one but who cares. does give a good sound clip of the car.

http://www.youtube.com/watch?v=vKYtQRvotHo

on the to do list.
-fix front spoiler that I ripped off and split in half drifting.
-make a mold of the spoiler so I can make multiples for the multiple spoilers I will be ripping off the car.
-finish interior
-fab and install hydro hand brake
-start designing for more steering angle and rack and pinion that is "not" steeroids!


In the meantime I just moved into a new house, lots of work to do on the house, and left my beautiful garage that I just built for an old crappy smaller one that needs to be completly rewired and new lighting. So theres where I sit.

[User-C3]

Been a long time since I've posted anything on here. Thought about selling the car, and had it up for sale for a little while, but once the weather got nice again and I started driving it again I remembered how awesome this car is. So It's staying for now. I have ben working on a headlight solution. Because of the intercooler the factory headlights are a no go anymore, so I started fabing some custom fixed headlights with LED light bars. The idea is a cross between the C5 fixed headlights and the L88 style.

https://static1.pt-content.com/images/noimg.gif (http://s1284.photobucket.com/user/TMantkus/media/0215161817_zpsxaltkfpv.jpg.html)

I started with a cardboard paper template.
https://static1.pt-content.com/images/pt/2016/08/0316162207_zpsbouvt30i-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0316162207_zpsbouvt30i.jpg.html)

Then started transferring to aluminum.
https://static1.pt-content.com/images/pt/2016/08/0316162207a_zpscthvkw2x-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0316162207a_zpscthvkw2x.jpg.html)

The buckets
https://static1.pt-content.com/images/pt/2016/08/0402162117_zpsf0evhhz4-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0402162117_zpsf0evhhz4.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0402162124_zpsshct0iay-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0402162124_zpsshct0iay.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0402162124b_zpsnwrsvwjb-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0402162124b_zpsnwrsvwjb.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0402162124c_zps1hl0x98w-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0402162124c_zps1hl0x98w.jpg.html)

With the light bars in place they stick above surface a bit. I debated between fixing the factory headlight covers with a slight open pop. While it does look better than the factory open position, this is just not the look I want all the time. If I could have them open and close to this position it would of been good, but there just isnt the space.

https://static1.pt-content.com/images/pt/2016/08/0402162127a_zpsfithj9zg-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0402162127a_zpsfithj9zg.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0402162127_zpsu8jjb37m-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0402162127_zpsu8jjb37m.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0402162127b_zpsfxtjwwsv-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0402162127b_zpsfxtjwwsv.jpg.html)

So I've been working on the fixed lenses. Currently making the shape/form of the lens which I will pull a mold off of and then have molds to slump or vacuform plexy into to have a final clear plexy cover.
I started with some simple wood forms to get the general rail surfaces to clear the light bars.
https://static1.pt-content.com/images/pt/2016/08/0426161854_zpsg9rjvyrm-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0426161854_zpsg9rjvyrm.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0426161853a_zpshza0bpup-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0426161853a_zpshza0bpup.jpg.html)

I covered the aluminum buckets with foil to make sure no fiberglass would adhere to it.
https://static1.pt-content.com/images/pt/2016/08/0426161912_zps5fjgyqe0-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0426161912_zps5fjgyqe0.jpg.html)

I used some cotton to stretch over the entire form to get a rough main shape to start with. Installed them back on the car to maintain the flats and then started the resin and a couple layers of fiberglass. I now have a rough start to the shapes and will fill and shape the rest to get the final forms of the covers.

https://static1.pt-content.com/images/pt/2016/08/0503162159_zps0gyofffc-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0503162159_zps0gyofffc.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0505162149_zps5jr6qcto-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0505162149_zps5jr6qcto.jpg.html)

[User-C3]

I've also chopped off the exhaust so it is now just a dump out the fender. Surprisingly not any louder at lower rpms and average cruising, but does bark pretty good wide open.

https://static1.pt-content.com/images/pt/2016/08/0215161826_zpsfxnba5bh-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0215161826_zpsfxnba5bh.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0215161819_zpsz2hkndua-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0215161819_zpsz2hkndua.jpg.html)

I've also started making a hydraulic hand brake. I've got the handle sorted out. I started with a 1/2 piece of aluminum.

https://static1.pt-content.com/images/pt/2016/08/0505162029a_zpsscqdliho-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0505162029a_zpsscqdliho.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0505162133a_zpsrdcrer6o-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0505162133a_zpsrdcrer6o.jpg.html)

- - - Updated - - -

Progress on the headlights has been continuing but slow. I have gone a little further into the process to be able to make positive casts to make multiples of the lenses down the road.

The lens forms
https://static1.pt-content.com/images/pt/2016/08/0618161657_zpsxquofiub-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0618161657_zpsxquofiub.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0614162032_HDR_zpsko9vumb7-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0614162032_HDR_zpsko9vumb7.jpg.html)

After the forms were done I covered them in box tape and then 3 or 4 coats of wax
https://static1.pt-content.com/images/pt/2016/08/0629161944a_zpsnlnaujny-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0629161944a_zpsnlnaujny.jpg.html)

Here are the molds of the forms before I have removed them from the car. Hopefully they pop off fairly easily. The wood is a simple support structure for them and also create a nice flat surface for them to sit on while using them.
https://static1.pt-content.com/images/pt/2016/08/0712162138a_zps0alcxeez-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0712162138a_zps0alcxeez.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0712162138b_zpsmxha0dw2-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0712162138b_zpsmxha0dw2.jpg.html)

[User-C3]

I have also taken the plunge to go flared. Always loved the look but didnt want to spend the money. Had previously refurbished some work mesh 3 piece wheels, 17x14 rear and 17x11 for another project but decided on a different direction with that one. Found some flares on ebay for cheap so on they are going.

https://static1.pt-content.com/images/pt/2016/08/IMG_1923_zpsa4perxo8-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1923_zpsa4perxo8.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/030415072422_zpsis07xmof-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/030415072422_zpsis07xmof.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/ewingamptires_zpsa0txhfd4-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/ewingamptires_zpsa0txhfd4.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0712162138_zps3xy4rar1-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0712162138_zps3xy4rar1.jpg.html)

Quick little mockup
https://static1.pt-content.com/images/pt/2016/08/0712162137b_zpsp15eksvf-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0712162137b_zpsp15eksvf.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0712162139_zpsyjhp0sw4-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0712162139_zpsyjhp0sw4.jpg.html)

[User-C3]

Got the headlight molds pulled off, they turned out pretty well for the quick layup job I did and use of box tape and wax as the mold release. I didnt need them to be perfect as I will now be pouring plaster positives to vacuform over and I can do final finish work to the those.

https://static1.pt-content.com/images/pt/2016/08/0714161951a_zpslaryih6f-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0714161951a_zpslaryih6f.jpg.html)

I finished getting the flares mounted. Just needed to remove them and trim back the original fenders in this photo. The rear fitment is on point, wheel sticks out from the flare a bit and the stretch on the tires tuck up in the flare nicely. I wish the fronts where a bit more of the same but they sit inside the flare. I'm not complaining for having the wheels for a different purpose originally.

https://static1.pt-content.com/images/pt/2016/08/0719162032_HDR_zpsvmbwd0xv-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0719162032_HDR_zpsvmbwd0xv.jpg.html)

[User-C3]

when I was finishing the turbo and redoing the electrical panel and harness I realized I never really did it up to my standards. I was in a bit of a rush to get it tuned and running so I could be able to have it driveable for the move we were about to do. Since moving I have finally been able to spend some time working on the car again and realized I needed to damn near completely start over on the wiring. I got new fuse blocks and dove in.

Here is the jumble of wiring mess that I never loomed and organized.

https://static1.pt-content.com/images/pt/2016/08/0728162110_zpsh92faftj-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0728162110_zpsh92faftj.jpg.html)

what the previous fuse blocks consisted of, can also be seen in previous posts

https://static1.pt-content.com/images/pt/2013/07/IMG_1909_zpsf66e2ef0-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/IMG_1909_zpsf66e2ef0.jpg.html)

New fuse blocks and panel layout.

https://static1.pt-content.com/images/pt/2016/08/0804162132b_zpsxzwzympx-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0804162132b_zpsxzwzympx.jpg.html)

This is basically the entire interior harness. I purchased some weather proof 6 pin connectors so every connection has a factory style easily removable connector. This photo shows before the last connectors where installed, I wanted to do that in the car so I knew exact length the wires needed to be.

https://static1.pt-content.com/images/pt/2016/08/aac285dc9b6d426ca2d2ac45200cf357_zpsmxqw-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/aac285dc-9b6d-426c-a2d2-ac45200cf357_zpsmxqwn55n.jpg.html)

- - - Updated - - -

No going back now

https://static1.pt-content.com/images/pt/2016/08/0720162101a_zpsdzjcz60c-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0720162101a_zpsdzjcz60c.jpg.html)

Got it outside for the first time since doing the wheels and flares. I also got the rear lowerd an extra 2" which made a huge difference in the stance. Didnt really take any photos except for the booty. :)

https://static1.pt-content.com/images/pt/2016/08/0806161439_zps2eawnyxn-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0806161439_zps2eawnyxn.jpg.html)

- - - Updated - - -

I finally started on wrapping some of the interior aluminum pieces. I still want to build some knee bolsters and door panels but in the meantime it's getting closer to my end vision. Should help cut down the glare onto the windshield, it was pretty bad under direct sunlight. I also have a plexy cover for the recessed gauges that I want to tint so you will only see them when the car is on and their lit up, thats why the holes are there.
Def the Bomber feel I wanted.

https://static1.pt-content.com/images/pt/2016/08/0811162202b2_zpshqmng3wy-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0811162202b2_zpshqmng3wy.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/08111622012_zps5siwmbra-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/08111622012_zps5siwmbra.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/08111622022_zpsqkawo6oz-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/08111622022_zpsqkawo6oz.jpg.html)

https://static1.pt-content.com/images/pt/2016/08/0811162200_HDR22_zpsicbxl9ff-1.jpg (http://s1284.photobucket.com/user/TMantkus/media/0811162200_HDR22_zpsicbxl9ff.jpg.html)

[Guyt699]

That was a hell of an update and I have to say thanks. You just gave me an idea of a panel for my fuses and relays. Looks like a fun ride!

[cbpldc]

Love the material contrast, and that you're making both the Corvette and the Porsche communities mad. You do great work, and I always enjoy an update to your thread.

Chris

[rohrt]

subscribing.

[andrewb70]

Tell me more about that wrap!

Andrew