LS7 swap into a C4 ZR1
05-22-2020, 01:20 PM
#101
Staging Lane
Thread Starter
I'm starting the process of fitting the rear bumper cover together now...I finally heard back from Exotic Muscle as to what type of resin they used so I can be assured whatever I used bonds properly. I've ordered the carbon-fiber tape weave to re-bond it together and the correct resin, too.
The parts aren't right...as you can see the horizontal belt-line is off by about 3/8".
So...I'll have to section it between the belt-line molding and the tail-light openings, bond it back together, trim it on the centerline in back, piece it together with the other half and THEN cut the "CORVETTE" embossed lettering out and replace it with a new piece before making a mold of the finished product.
Once I have it pieced together...I'll be making my OWN mold of it and will make a new carbon-fiber piece using vacuum infusion. Lots of work...but drops a good bit of weight off the back.
I'm not thrilled with the cheap carbon fiber top either...and will address this at the same time. Places that "sold" them for C4's were simply a flat sheet of carbon-fiber cut to shape. when it was bonded to the frame it really looks like crap...it's wavy, flat in places and just looks like ****.
As you can see...they had to add a piece of bent aluminum U-channel to the middle to give it any "curve" at all.
I'll be taking my top off the '91 Z07 and making a mold from it and making a new top that's shaped correctly.
Once the hard part is done (making the molds) then recreating the items for others isn't a really big problem at all...time & materials.
My source for the carbon-fiber doors contacted me yesterday and there is STILL a chance I "might" be able to acquire them. I won't get my hopes up...but it's better than nill as it was before he sent me a message.
The parts aren't right...as you can see the horizontal belt-line is off by about 3/8".
So...I'll have to section it between the belt-line molding and the tail-light openings, bond it back together, trim it on the centerline in back, piece it together with the other half and THEN cut the "CORVETTE" embossed lettering out and replace it with a new piece before making a mold of the finished product.
Once I have it pieced together...I'll be making my OWN mold of it and will make a new carbon-fiber piece using vacuum infusion. Lots of work...but drops a good bit of weight off the back.
I'm not thrilled with the cheap carbon fiber top either...and will address this at the same time. Places that "sold" them for C4's were simply a flat sheet of carbon-fiber cut to shape. when it was bonded to the frame it really looks like crap...it's wavy, flat in places and just looks like ****.
As you can see...they had to add a piece of bent aluminum U-channel to the middle to give it any "curve" at all.
I'll be taking my top off the '91 Z07 and making a mold from it and making a new top that's shaped correctly.
Once the hard part is done (making the molds) then recreating the items for others isn't a really big problem at all...time & materials.
My source for the carbon-fiber doors contacted me yesterday and there is STILL a chance I "might" be able to acquire them. I won't get my hopes up...but it's better than nill as it was before he sent me a message.
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Project GatTagO (05-23-2020)
06-25-2020, 01:46 PM
#102
Staging Lane
Thread Starter
Some updates:
The carbon-fiber doors are on their way. They should be here end of July! After all this time it finally came together!
I've been piecing together the rear bumper...I am waiting on some additive for the CF resin that I didn't realize I needed. I've got the halves trimmed and need to get them patched before I can bond the entire rear together.
Engine is moving along now...finally got the pistons in for the motor on Tuesday. These things look like jewelry
First...here is the motor in the C6Z I bought it from.
And now...the jewelry...
Their new piston design come in @ 385 grams/ea. now...shaved over 35 grams off the previous design.
I just got word that there is a hiccup in the reassembly...it appears the prior owner had oil pressure drop and messed up a connecting rod. Instead of sending the motor back to HPR, some shop in Houston pulled it apart and they turned the crank and there are like 3 or 4 different journal diameters.
So HPR have sent the crank off to get everything right before they can put the bottom end together.
I'm sure glad I decided to get this thing refreshed BEFORE I stuck it in the car...**** like this just makes me scratch my head as to why people do it. I understand he needed to get the car back up & running for the next event, but if you have sponsors and you are going for winning a race series, you have a complete long block in reserve so if something goes sideways you can swap out the motor and send it back to be fixed properly.
Anyway...no pictures of the rear bumper right now...I should have some progress on it next week once my additive gets here.
The carbon-fiber doors are on their way. They should be here end of July! After all this time it finally came together!
I've been piecing together the rear bumper...I am waiting on some additive for the CF resin that I didn't realize I needed. I've got the halves trimmed and need to get them patched before I can bond the entire rear together.
Engine is moving along now...finally got the pistons in for the motor on Tuesday. These things look like jewelry
First...here is the motor in the C6Z I bought it from.
And now...the jewelry...
Their new piston design come in @ 385 grams/ea. now...shaved over 35 grams off the previous design.
I just got word that there is a hiccup in the reassembly...it appears the prior owner had oil pressure drop and messed up a connecting rod. Instead of sending the motor back to HPR, some shop in Houston pulled it apart and they turned the crank and there are like 3 or 4 different journal diameters.
So HPR have sent the crank off to get everything right before they can put the bottom end together.
I'm sure glad I decided to get this thing refreshed BEFORE I stuck it in the car...**** like this just makes me scratch my head as to why people do it. I understand he needed to get the car back up & running for the next event, but if you have sponsors and you are going for winning a race series, you have a complete long block in reserve so if something goes sideways you can swap out the motor and send it back to be fixed properly.
Anyway...no pictures of the rear bumper right now...I should have some progress on it next week once my additive gets here.
10-16-2020, 04:42 PM
#104
Staging Lane
Thread Starter
So...I've been swamped with work and have not had a lot of time to do what I wanted...but I HAVE made some progress on the rear clip!
The sequence of cuts, tacking together and then more cuts was a real pain in the ***...but it's looking pretty good now. Waiting on the gelcoat to get here so I can fill the holes and the seams, sand it smooth and then work on the outer corner reshape. The ZR1 has a more vertical rear fender than the base model, so the profile outside the lights isn't quite right. I'll be addressing it over the next few weeks.
14# 2 oz. complete so far...with what I have left...it'll still be under 15#, which saves me about 30# off the car.
The sequence of cuts, tacking together and then more cuts was a real pain in the ***...but it's looking pretty good now. Waiting on the gelcoat to get here so I can fill the holes and the seams, sand it smooth and then work on the outer corner reshape. The ZR1 has a more vertical rear fender than the base model, so the profile outside the lights isn't quite right. I'll be addressing it over the next few weeks.
14# 2 oz. complete so far...with what I have left...it'll still be under 15#, which saves me about 30# off the car.
10-17-2020, 07:05 AM
#105
TECH Veteran
This go be a bad MF!! 
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1991Z07 (10-19-2020)
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1991Z07 (11-05-2020)
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1991Z07 (11-05-2020)
