In our aftermost installment, we covered the anatomy and suspension. Now we will abode the agent and its accessories, the drivetrain, and the braking systems.
Engine: Analysis Fit, Accessories, ECM, Dry Sump, Headers, Detailing, And InstallationSince the affair for our car is the aggregate of the aboriginal Z06 archetypal offered with the latest Z06 engine, our plan from the alpha has been to use the LS7 engine. We accept followed the development and availability of the GMPP agent and placed an adjustment with Dobles Chevrolet in Maner, New Hampshire, for one as anon as it was available. Afterwards some break from the aboriginal addition ambition date of August 2005, the agent was delivered in October 2005.
The agent comes assembled, forth with the burke body, injectors, flywheel, clutch, burden plate, starter, bankrupt manifolds, oil filter, atom plugs, and baptize pump. Several key apparatus are not included, such as the dry sump tank, oil lines, ECM, base harness, accent brackets, and alternator.
Test FitOur aboriginal footfall afterwards the accession of the agent was a analysis fit to see what issues we ability face for the chassis, motor mounts, and agent accessories. as you ability expect, we activate several issues. The aboriginal was the pilot address bare to be changed. Through 2004, a aggravate roller clamp pilot address (No. 14061685) was acclimated in the Y-Car. In 2005, a brawl address architecture (No. 12557583), which is acclimated on trucks, was appear on commuter cars and is the one acclimated on the LS7. This address is positioned about 10 mm added aft, and it doesn’t acquiesce the manual shaft to bench all the way. Fortunately, the crankshaft still has a accouterment for the earlier-type bearing, which works fine. It may booty a little accomplishing to get the address out, so be abiding to use a address puller advised for that purpose.
We additionally activate the anatomy cross-member beneath the agent bare to be adapted to bright the dry sump pan. The cross-member was cut, and a new allotment was anchored in place. The aftermost above change bare was to move the rack-and-pinion arise by a half-inch as the power-steering pump caster would baffle with the average council shaft.
The acceptable account was the agent fit able-bodied otherwise, as did the motor mounts and agent accent brackets. We additionally activated headers for approval of the anatomy application the LS1-style, street-rod-style units back there were no sources for LS7 specific headers at the time.
Engine AccessoriesAccessory Drive ::: Our accessories had to serve three purposes: function, fit, and appearance. There are several sources for serpentine-belt systems and brackets today. We chose Street & Performance (S&P) for the alternator, A/C compressor, ability steering, and idler brackets. We additionally acclimated the agent arise adapters from S&P for the motor mounts, which acquiesce the use of small-block mounts. We acclimated the mounts from Energy Abeyance to bout the added urethane bushings we’ve used.
Engine Systems ::: The LS7 is a bit added complex than added engines back it comes to setup, decidedly because of the 58x reluctor and the dry-sump system.
Computer And HarnessFor the agent management, we acclimated the reprogrammed ECM and agent accouter from Speartech, www.speartech.com. It’s able-bodied bogus and the chump abutment is top notch. John Spears bogus it to action with the fly-by-wire burke (we are application a C6 burke pedal), which eliminates the charge for a hard-wire cable.
Dry-Sump SystemSince we capital to advance as abundant acceptance as accessible with the new Z06, we chose to use the OEM dry-sump reservoir. It additionally has accoutrement for the dipstick and catchbasin aperture curve to the engine. However, the banal catchbasin is too alpine to fit aural the C2 agent compartment, and so we contacted Band Precision who makes the OEM tank. alive with them, we were able to absorb the aboriginal high and lower casting portions, forth with a new centermost breadth that was beneath and added in adjustment to advance the aboriginal 10.5-quart accommodation of the banal tank.
In researching the capacity of the dry-sump setup, we activate absolutely a few capacity on the banal system. There are two accessories on top of the tank. The rear applicable on the backlog runs to the “dirty-air” affiliation on the advanced commuter ancillary of the agent and to the PCV. The advanced applicable runs to the clean-air applicable advanced of the burke body. The catchbasin contains a aggregate of 10.5 quarts, which is the minimum appropriate to run an 8-quart account ample with the LS7 engine. Back 8 quarts are added to the tank, 1.2 quarts ample the curve and cored admission in the oil pan, abrogation 6.8 quarts of oil in the tank. The actual aggregate of the catchbasin is advised to accommodate for oil conditioning, de-aeration, and a fresh-air accouterment to anticipate sludging and PCV separation. If you use an aftermarket tank, it’s important that you actualize these accoutrement for crankcase burden equalization and PCV arrangement flow. The LS7 uses two oil pumps: the cruise pump pumps 25-percent added aggregate into the catchbasin than the accumulation pump draws out. This added aggregate is air, which will beset the catchbasin if you don’t accept a way to adjust the burden with the crankcase. It will additionally draw bottomward the burden on the crankcase to unacceptable levels, so there should be a band aing the catchbasin to the crankcase for burden equalization. It’s additionally recommended that you accommodate beginning air to the catchbasin and draw abhorrent air off the crankcase through the PCV system.
The oil curve from the agent to the oil backlog are altered fittings. If you can run the OEM lines, these will assignment fine. If not, or if you are application an aftermarket reservoir, such as that from Peterson Systems, you can get adaptors that catechumen the curve to an AN12 fitting. There are several sources for these fittings, such as Street & Performance.
To arise the tank, two lower brackets were bogus that fit into tabs anchored to the anatomy and one high bracket that mounts to the firewall.
To accretion amplitude for the oil reservoir, which was placed in the rear of the commuter ancillary of the agent compartment, the array breadth had to be moved. In some cars, the array could be placed in the block breadth (if we had one!) or the rear of the commuter compartment. However, we didn’t like the abstraction of a array in that breadth or active the cables that far from the engine. We absitively to assemble a new array arise on the driver-side framerails aloof abaft the close fender panel. For admission to the battery, a console originally acclimated on A/C-equipped, big-block midyears was acclimated in the rear of the close fender panel.
Exhaust HeadersYou may be able to use the banal bankrupt manifolds. They do accept a altered aperture though, which makes authoritative the blow of the arrangement added difficult. You may additionally run into approval issues with your anatomy or agent mounts. Street & Performance bogus a set of headers for us with beyond primary tubes, a border to bout the LS7 anchorage actualization and with the all-important clearance. Stainless collectors were used, which will be akin to the blow of the bankrupt arrangement that we will awning in a approaching installment.
Engine DetailingSince the car will be acclimated for shows, we capital to do article appropriate in account the engine. It was beatific to Street & Performance breadth Adam Gunn performed his work. The heads, burke body, and baptize pump were polished. To advice absorb their finish, they were coated with Zoops Seal. The advanced agent cover, oil pan, starter, braid mounts, and valve covers were chromed. Even admitting the block is aluminum and could be polished, we capital to accept a adverse to the able and chromed pieces, so the block was smoothed and corrective in our custom red paint. All the ascent ts were adapted to 12-point able ARP ts.
There will be several added custom pieces bogus for the final detailing; these will be apparent in a approaching installment. This will accommodate the cold-air assimilation system, the custom cooling-system radiator, and amplification catchbasin bogus by the Pro-Fab boutique at Be Cool. Mark Walkowiak from Mark VII Apparatus and Fred Militello from Be Cool accept formed from our diagrams to accomplish these units, and their assignment is outstanding.
Engine InstallationIn our aboriginal installment, we mentioned there would be some accessories you may not accept that would be accessible in the project, such as an agent elevate and leveler. We additionally activate a hydraulic table came in accessible back it was time to band up the transmission. some added calmly and eyes are consistently accessible back you are lining up the motor and manual mounts. Luckily for us, Frenchy Bernier and Ray Zisa from Corvette Centermost bogus a abode call.
Gas TankThis is apparently a acceptable abode to acknowledgment the ammunition catchbasin . The stainless catchbasin is from Rock Valley and has a congenital ammunition pump. Agenda that this catchbasin has the capital and acknowledgment curve on the top instead of the basal as is accepted back we capital to accumulate the basal of the catchbasin chargeless of ammunition curve (photo 09). The catchbasin has been able (we’ve bogus a agenda that this is addition one of those jobs we never intend to do again). As we address this segment, we are attractive for the best breadth for the ammunition clarify (C5-style with a congenital regulator), and again we will avenue and arise the capital and acknowledgment curve with a aggregate of braided-stainless and hard-stainless lines.
TransmissionA Tremec T-56 manual from Keisler Engineering was chosen. We’ve had acceptable luck with that assemblage in our ’62, and like the bland alive and gearing. To advance its appearance, we absitively to bland and brightness the manual and bellhousing. That complex about seventy-five hours of cutting and is not article we’re acceptable to do again! The skip about-face solenoid was alone as was the advancement ablaze switch. The about-face lock-out assemblage was additionally polished, rear awning plates fabricated, and the brackets were painted. All the ts were adapted to 12-point ARP able stainless. To advice absorb the finish, the absolute assemblage was coated in POR 15 Glisten, which should angle up to the heat. The urethane manual arise is from Energy Suspension.
Flywheel/ Clutch/Pressure Bowl & Hydraulic UnitSince the agent comes with the flywheel, clutch, and burden plate, we saw no acumen to go with aftermarket units. To actuate the clutch, a hydraulic assemblage acclimated in the F-body cars was used, forth with a custom bracket arise from Alf Ebberoth of Performance Automotive.
DifferentialA Dana 44 cogwheel was called for its strength, forth with a accessory arrangement of 3:90 that works able-bodied with the bifold overdrive of the T-56 transmission. The assemblage was smoothed, and again corrective in our custom red blush for adverse to the chromed cogwheel carrier. A custom torque arm from SRIII Motorsports was used. The welds were smoothed, and the assemblage was chromed. Urethane bushings from Energy Abeyance were acclimated for both the cogwheel carrier and torque arm. They were army application six-point able stainless ts from Totally Stainless.
Drive & HalfshaftsDriveshaft ::: A custom driveshaft from Denny’s Driveshaft was used. The welds and yokes were smoothed, and the assemblage was chromed. Spicer universals were used. For added detailing, the accepted collective centers were powdercoated in red, the bearings were polished, and the accommodation rings were chromed. That bogus accumulation an absorbing exercise!
Halfshafts ::: The halfshafts were shortened. You may anamnesis from the aftermost chapter that we capital to absorb the banal anatomy profile, but still use added auto and tires; this appropriate absorption the halfshafts, cogwheel carrier, rear toe-rods, and camber rods. We capital to bland the welds and assuredly anticipation of a way to do that job added easily. We don’t accept a metal lathe, but do accept a copse lathe. We absitively to accomplish board dowels, which were angry to the bore of the yoke, to arise the shafts in the lathe. Then, axis at a apathetic speed, a alternation of files and grits of sandpaper was acclimated to bland the shafts (photo 13-shaft army in the lathe; photo 14-before and afterwards axis perspective). The shafts were again chromed, and the accepted joints advised to the aforementioned action of accomplishment as the driveshaft.
AssemblyIn the aftermost installment, we mentioned befitting the abeyance genitalia apart at that point. Back you activate to install the halfshafts, you won’t accept to alleviate as abounding ts as you accept to move the hubs outwards to accretion abundant amplitude to get the halfshaft universals into the cogwheel and arbor yokes. we activate that briefly removing the rear toe-rod at the hub and the camber rod at the cogwheel bracket can advice get abundant chargeless breadth to get the halfshafts in place.
Brakes: Calipers, Rotors, & BoostCalipers ::: As they say, “once you accept affluence of power, you will additionally charge affluence of endlessly force.” There are abounding choices for brakes these days, alignment from the banal Corvette units to Wilwood and Baer aftermarket components. Back we are aggravating to use as abounding accepted Corvette genitalia as possible, we absitively to use the banal C5 Z06 calipers up front. Back we are application the C5 front-suspension components, these t appropriate up after the charge for adapters. We advised application the C6 Z06 calipers, however, we were anxious they ability not assignment as able-bodied in aggregate with the C4 rears. We were additionally anxious there was not abundant approval with the 17-inch advanced auto we are using. In the rear, we acclimated the calipers from the ’96 C4 Corvette. One acumen for application these calipers is they accept an basic parking brake. Braided-stainless curve to the calipers were used, forth with stainless adamantine lines. These were able and coated with Zoops Seal.
To add added detail to the calipers, the “fins” were smoothed and polished; the calipers were corrective in red, and again clearcoated. The anchor brackets were smoothed and chromed, as able-bodied as the emergency-brake parts. We additionally had able stainless plates bogus to awning the anchor pads for a final touch.
Rotors ::: We like the attending of the two-piece Baer EradiSpeed rotors, which are slotted and drilled. To add added detail, the rotor hats were chromed, and stainless ts were used. Also, the alfresco bend and abdomen of the cooling vanes were powdercoated in red by Anvil Ability Stryke powdercoatings, a analysis of Har-Conn Chrome in Newington, Connecticut, for actualization and to accumulate any blight from forming.
Boost Arrangement ::: We’ve acclimated vacuum-boost systems in the past, but capital to try article altered this time. We had heard of a new arrangement from ABS Ability Brake, www.abspowerbrake.com. It’s an electric/hydraulic unit, and the ability assemblage mounts accidentally on the frame, which allows added amplitude on the firewall. The amalgamation comes with a batten adept reservoir, able booster pump, accumulator, and a hydraulic stop-light switch. The accumulator food ability should the assemblage fail.
For ascent it to the frame, a bowl was bogus and anchored in abode low on the disciplinarian side. Curve were run to the advanced and rear brakes, and the burden band runs from the pump to the adept unit. The electrical access are beeline forward: battery, ignition, and arena wires.
Parking BrakeSince we are aggravating to absorb as abundant of the aboriginal actualization as possible, we chose to accumulate the original, pull-style, parking-brake lever. To do this, we had to acclimate it to the ’96 C4 rear-brake calipers, which accept an basic parking-brake apparatus in the caliper. We acclimated the underdash parking-brake apartment from a ’64 Vette because we like the way it mounts, and its caster apparatus allows the cable to run afterpiece to the firewall. A banal parking-brake arm arise was anchored to the new anatomy in the aforementioned breadth as the banal unit. A stainless-braided cable from Lokar was acclimated to accomplish the affiliation from the parking-brake handle to the arm on the chassis. From that point, Lokar braided-stainless cables were acclimated to run to the calipers.
So Here We ArePhoto 20 will accord you a acceptable abstraction of breadth we are at this point in the project. We couldn’t abide ascent the auto from Mid America Motorworks on the anatomy for a look. There are additionally abounding added things activity on simultaneously, such as the bodywork at Corvette Center, autogenous assignment at Autogenous Motives, apparatus assignment at Mark’s Machine, bankrupt assignment at Patten Cycles, and the circadian UPS commitment of endless parts.
Next TimeIn accessible installments, we will get into added detail on several systems (exhaust, cooling, heating/air, and so on), as able-bodied as the anatomy and interior. Back we are autograph the accessories as the car is actuality built, there will be a few month’s break while we complete added assignment on the car. Architecture a car is agnate to architecture a house-the anatomy seems to go up quickly, but it’s the autogenous plumbing, electrical, fixtures, and so on that booty the majority of the time.
We achievement what you accept apparent so far has been of absorption and advice if you are because a agnate project. In the meantime, you can acquisition added photos and links to sources on our web armpit at www.corvetteforum.net/c5/richs7/.
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