[ProCycle]

Instrument clusters...

The new drivetrain needs a different combination of gauges. The original gauges are not functional due to age and corrosion. So, the plan includes a complete new set of VEI Systems digital gauges to be installed in new handmade panels in place of the original clusters. I removed the speedo and tach and took the cluster housing to the bandsaw and sliced off the rear of the meter housing.

I laid out the shape on the new gauge panel in AutoCad and cut it out in 1/8" ABS plastic.

With ABS pipe glue and epoxy I put the new panel into the front of the original housing.

I did the same with the center console gauge cluster. I removed the gauges.

Then I cut all the original gauge faces out of the panel leaving about a quarter inch border to bond the new panel to.

Here's the center cluster template done up in AutoCad:

I have the new gauge clusters temporarily connected to verify the wiring connections.

 

[ProCycle]

Fiero seats

The original Corvette seats leave a lot to be desired. They are narrow feeling (at least for me!) and do not have any adjustment for the angle of the seat back. Pontiac Fiero seats are a popular source for a seat swap so that's what I decided to try. The Fiero seats are much more comfortable and the seat back angle is easily adjusted. I just happened to find a pair in dark and light gray that match the new interior pretty well.

I made new seat brackets to bolt them to the original bolt pattern.

I had to make up a 'squaring jig' to ensure the brackets lined up with the holes in the floor.

 

[torqueofthetown]

Great project :thumb:

Have you ever checked the MPG?

 

[ProCycle]

:driver: Low 20s running around town having fun and showing off.

Mid 30s or better cruising sedately on 2-lane country roads.

 

[ProCycle]

Interior and gauges - done

In addition to the Fiero seats I installed a new gray carpet kit over the layer of 3/8 neoprene foam I had put down.
Also, new inner door panels and all the old wine colored interior parts were painted with vinyl paint.
I even made a 3D printed cup holder held in place by the park brake lever.

New seat belts, steering wheel. I made new panels for the sides of the transmission tunnel.

All the new gauges are installed in the ABS panels I made for the dash.

I have gauges for EGT, Boost, Speed, RPM, Fuel level, Water temperature, Fuel pressure, Oil pressure, Oil temperature, Voltage

 

[mannytranny]

Wow. Incredible craftsmanship!

Dare I ask the $ total?

 

[ProCycle]

Ahh... I learned a long time ago not to keep a $$ total on projects. If I know exactly what I've spent it can make it hard to justify getting it all the way finished. And that kind of thinking could stop the next project from happening.

I could take a wild ass guess. I'm into the car itself about $3500. There's another $10K - $15K in materials, parts, sublet work like the transmission, and other stuff that I'll be posting about soon like suspension and brakes, tires and wheels. Figure another $4K-$6K for paint later this year. All said and done I'll probably have spent $20K - $25K. And probably at least that much or more of my own labor.

See. this is why I learned not to add it all up. :Insane: :shootself: :ThrowUp:

 

[57diesel]

Are we caught up yet?

Do you finish a a car project before starting the next one?

 

[ProCycle]

Not caught up yet. My business has been getting super busy lately and I've been slow at getting to the next posting.

Do you finish a a car project before starting the next one?

Ha! It's more like I start a new one every time I run into a roadblock on a current project. Here are some concurrent projects - 65 Barracuda w/hotrod slant six, 1992 Lexus w/turbo-fuel injected slant six, big bore stroker (900cc single) DR650 adventure bike...
I have a sickness :cookoo:

 

[57diesel]

6's are a lot of fun. Dual exhaust headers will keep people guessing what is under the hood. Nothing sounds quite like em. I had a Mustang for a while with a 200 in it and at shows everyone was always around my car which was nothing special mostly stock except was the only 6. I almost bought a Pontiac with a OHC 6 in it last fall. That looked like an interesting engine. Always wanted to tinker with some of the straight 8's too. Seem em at shows but never heard one run or messed with one.

 

[ProCycle]

Suspension rebuild

As expected it looks like all the suspension bushings, ball joints, shocks and springs are original 1980 stuff. Not in bad shape considering the age but still in need of freshening up or upgrading.
Pull everything apart

Upper and lower control arms, steering spindles, etc. ready for powder coating

Rear end with new fiberglass spring, new calipers, shocks, re-ground brake rotors

 

[Nastybuzzard]

Subscribing!

 

[ProCycle]

DIY 4 wheel alignment

There's a pretty nice writeup and explaination to do DIY 4 wheel alignment that I found through one of the Corvette forums.
You need some big bearing plates, a good digital carpenter's level and a tape measure.

Here's a link to the PDF --> https://dl.dropboxusercontent.com/u/1634366/align.pdf

The write up is specifically made for a newer generation Vette so the actual number calculations are a little off.
That doesn't matter to me as I'm not trying to set it up exactly to factory specs.

I made some 'bearing plates' to make it easier to check and set the alignment adjustments.
They are made from 8x16 pieces of 1/4" steel flat bar. The 3/8" ball bearings are contained by a cage made from 1/4" MDF.

This works very nicely. Set the car down on the plates and the suspension can move freely.
I can turn the steering easily with almost no friction.
Don't accidentally lean against the car or it will slide right off the bearings!

 

[57diesel]

I just used 2 greased pieces of 14 gauge. Was fun the first time I pulled on em, sounds kinda like when you leaned on yours. Guess that is why the 'real' ones have a locking pin. I like the bearings and retainer.

 

[ProCycle]

So the Diesel Corvette is finally on the road and I've run it around enough to burn through several tanks of fuel. Pretty damn entertaining. :coolnana: The 6.5 motivates a 3400 lb car very well. It's a lot more fun than when it had the anemic low compression gasser. Of course when it comes to power more is always better. It’s time to start dialing it up.

The original setup: DB2831-4911 of unknown age. The go-fast screw has been turned all the way in then backed off a hair so it is not bottomed out hard. Turbo is a CKO HX40W-II. Wastegate is set around 20 psi. Full throttle acceleration leaves a nice light haze behind the car. 70 on the freeway is 1700 rpm and takes about 3/4 lb of boost with EGTs around 320-350. It gets around 35 mpg on the highway and 24 in town having fun.

But...

The governor starts de-fueling way too early. The specs say max HP should happen at 3400 rpm but I can feel power drop off pretty rapidly after 2800. I haven't seen much over 3200 on the tach. It could benefit from another 500-600 rpm. I don't really want to spin its guts out but I know it could do more than it does now.

I experimented with swapping out the governor spring and that helped a lot with the RPMs. With it revving higher I was able to recalibrate all the shift points in the transmission controller.

Inside the governor. A stiffer spring here helps it rev much better.

 

[ProCycle]

More fuel for the Corvette

Getting some more revs out of it is nice but not nearly what I want it to be.

So…

I bought a marine injection pump from Kennedy. They advertise this as 250-300 HP

The number on the pump is one I have not run across before.
I assume it is a replacement for the discontinued DB2833-4974

To go along with it I got a set of injectors from the good guys in Canada fully infused with Turbonator Magic.

Now I just have to put the damn thing back together.
Sometimes I envy you guys with your cavernous engine compartments.

 

[6.5 NOVA]

nice to see all works out so good. With my Chevy Nova 6.5 diesel max fuel mpg i had was 32. When you have your new injectionpump and injectors in it can you check 0-60 time and mpg numbers? verry good work on this project!:thumb:

 

[ProCycle]

Thanks Nova, At some point I'll take it to the race track and get some 0-60 and 1/4 mile times.
There's still more story to tell before I get there.

 

[chevy410]

awesome work. does the shop make or cost you money? im slowly working on mine

 

[ProCycle]

Over the long run the shop has done me well in the money department. But it's not a 'working' shop. I don't do any work for customers but use the shop for prototyping new products and some small production runs of a few items we sell.

Mostly though, the shop is my personal playground :clap: