My 91 Z28 build. 17 years in the making... Finally going to do this right
#201
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Car: Building LS3, T56 Z28
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Axle/Gears: Moser/ 4.11
Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Fabric and fiberglass approach was massive failure. I am not good at all the contours. Had to rip off after applying resin and fiberglass. What a waste of time... life goes on.
Bezel made to angle gauges
lots of damage from undoing the glass.
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Car: Building LS3, T56 Z28
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Skim coat of bondo.
2 part glazing putty. Needs 1 more good application then final primer. Getting there.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Deciding what I am doing for the center console.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
PS hush panel modification
Fabricating DS hush panel and under column close out.
Bracing behind e brake close out. New ebrake will be electronic.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
DS coming along
Console has mid brace
Left side corner will be built up with fiberglass bondo
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Bracket to hold down front of console.
Covering concole is fleece. Fiberglass time.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Coming along
Close out panels for original belts. Car will have 4 point.
Fixing broken piece of rocker panel. So many smal pieces of board!
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Car: 1987 IROC-Z
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
tons of work. good stuff!
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Fiberglass going on
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Fiberglass done
Rundo laying down a base of filler. 2 parts fiberglass resin, 3 parts bondo.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Leveling out rundo
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Test fitting seats and console. Looks like everything fits well. Time to move onto glazing putty.
After a half dozen applications of bondo
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Fabricating heater brackets
Center console top coming along.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Decided I will have a center console cubby.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Some potetial button layouts. Billet buttons look and feel awsome.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Fabricated the center armrest/cubby door.
Final button layout can be seen here
Hinges are cabinet hinges. Wanted a hidden hinge system.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
3D printed a stencil to get the placement just right.
Holes for switches done. Onto the shifter hole and air ride contoler inlay. All other controls, heater, wipers, and headlights will all be hidden in the cubby. Designed and printed a mouthing plate for them in there.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Air ride tech kit layed out
Underside of console, test fit wiring
Black square is the 3D printed inlay for the ride tech touchscreen
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
From the top
In the car
Control center. 3D printed to ensure a close precise fit.
***** are Vintage air heater controls, usb in the middle to charge phone, upper right is Detroit Speed wiper module, lower right is headlights. (Car will have no radio)
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Checking fitment
Frenching in screen bezel after resin impregnating the MDF.
After 3 or 4 applications of filler, finally getting close.
Last edited by dennisbernal91z; 03-19-2023 at 04:40 PM.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
USB-C for screen. Allows screen to look inlayed but still able to pull out if needed.
Able to remove confirmed.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Where I want the air tank to live. Working alone means a lot of tape.
Tack welded brackets in place
Fabricating air ride control box mount.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Control box mounted
Valve block mounted
Air tank mounted. Working on battery mount.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Touching up before high build primer
Layer of rundo to smooth everything out.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Enough parts to make it worth shooting high build to seal off the filler
2 coats
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Test fit console post primer
How stock rear plastic can no longer fit
Trimmed to fit. Now to make close off panels.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Thanks for the kind words.
I believe you are referring to the second to last and last picture.
I removed a lot of material. In the second to last pic, the mounting screw on the back ear that attaches behind the rear seat back is like 5" away from connecting.
Also the seat belt pocket is in the way, so that had to be cut out as well.
I had to relocate the seat belt anchor inboard a bit since the old one was attached to the base of the stock tub. That area got absorbed into the new larger tub.
No amount of heating would get this to mount with the amount of mini-tubbing I did in this situation.
I will do the DS next and then make patch panels before covering the pieces in fleece, resin, fiberglass, rundo and high build primer.....ugh... lots of work, but worth it!
I believe you are referring to the second to last and last picture.
I removed a lot of material. In the second to last pic, the mounting screw on the back ear that attaches behind the rear seat back is like 5" away from connecting.
Also the seat belt pocket is in the way, so that had to be cut out as well.
I had to relocate the seat belt anchor inboard a bit since the old one was attached to the base of the stock tub. That area got absorbed into the new larger tub.
No amount of heating would get this to mount with the amount of mini-tubbing I did in this situation.
I will do the DS next and then make patch panels before covering the pieces in fleece, resin, fiberglass, rundo and high build primer.....ugh... lots of work, but worth it!
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Framing up passenger side
Anchor for fleece for rear panels
All I am using from stock panels. The edge mounting.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
DS fleece glued and stapled
Oversized piece of fleece so it can cover the entire panel in 1 piece.
After brushing on resin to basically turn the fleece into plastic, fiberglass pieces are cut to reinforce the entire unit.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Part around tube was designed and printed so I had someplace to attach fleece.
After fiberglass is resined on, it gets sanded 80grit to smooth out the bumps a bit.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Bondo and resin mixed to create Rundo. Basically self leveling body filler.
Coated and setting up
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Made a mistake appying filler with the panel off the car, fleece sagged. Starting repair. Chunks of material are filler to repair sag...
Rundo knocked down
Of course still not perfect. Detail work.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Here is how far the sag moved. Only way to get the mounting point to line up was slice the sag. Lost some time filling the sag. Oh well.
Glazing putty to fill in small imperfections.
Kicker panel with fleece filler stapled to it.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
No fiberglass here, just straight to fiberglass reinforced bondo to keep the stack up low.
Finally got a vented battery mounted into the trunk. Summit universal mount.
Will be mounted below the AirRide 3 gallon air tank.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
DS looking sort of done (in primer)
Starting PS
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Starting rear piece. Fleece time. Using stock top rail to mount upper section.
Trimmed and soaked in resin
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Fiberglass time
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
That is one impressive build !!!
I like the vette too
I like the vette too
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#241
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
What calipers are you using for the electronic parking brake? I started making a center console from scratch and halfway finished it but I couldn't find a way of getting it in and out because the ebrake was in the way. I hadn't considered and electronic unit, good thinking. I also wanted to caution you about doing too much fitment without the carpet in. Carpet can raise the console up to 1/2".
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Thanks for the heads up about the carpet thickness. The base of my "from scratch" center console is still the oem unit. It does have extensions toward the dash, but I did maintain the oem gap with the floor.
As for calipers, I have been playing with ideas for sooo long. Looking into Baer brakes (eventually). Internal drum ebrake. This will be activated by an electronic E-Stopp. Just need to confirm if these will fit on my c-clip eliminator Moser 12 bolt rear end.
I like Willwood solutions but I don't like the size of their front calipers. For a show car like this, looks are a big deal for me.
As for calipers, I have been playing with ideas for sooo long. Looking into Baer brakes (eventually). Internal drum ebrake. This will be activated by an electronic E-Stopp. Just need to confirm if these will fit on my c-clip eliminator Moser 12 bolt rear end.
I like Willwood solutions but I don't like the size of their front calipers. For a show car like this, looks are a big deal for me.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
https://www.estopp.com/product-page/...p-standard-kit
This is the unit that will convert basically any manual ebrake into electronic. Not cheap, but clean solutions rarely are.
This is the unit that will convert basically any manual ebrake into electronic. Not cheap, but clean solutions rarely are.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Main issue was that Baer rear brakes don't have kits that fit c-clip eliminator rear ends.
After emailing them, they got back to to me saying for an additional $200 they can machine the rear retainer plate to accommodate.
Only other option was Willwood's electronic parking brake, but they don't offer that for third gens.
Their e-brake is a manual option for these cars, so I would still need the E-Stopp.
Looks like I am going to use 100% Baer components for the braking system.
E-Stopp for the elimination of the e-brake lever. Will mount the unit someplace near the back seats most likely since the center console can't fit it since I made a custom center cubby, sort of like stock.
The unit is long though, so it will be tricky. Maybe transverse above the fuel cell area. Basically where people put the "trap door".
After emailing them, they got back to to me saying for an additional $200 they can machine the rear retainer plate to accommodate.
Only other option was Willwood's electronic parking brake, but they don't offer that for third gens.
Their e-brake is a manual option for these cars, so I would still need the E-Stopp.
Looks like I am going to use 100% Baer components for the braking system.
E-Stopp for the elimination of the e-brake lever. Will mount the unit someplace near the back seats most likely since the center console can't fit it since I made a custom center cubby, sort of like stock.
The unit is long though, so it will be tricky. Maybe transverse above the fuel cell area. Basically where people put the "trap door".
#246
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Have you wondered around d a junkyard for ideas? Mazda uses a caliper that has the electronic brake as part of. It's not a third part, perse. Finding a caliper like that and making a mount might be much cheaper.
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Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
I have considered that. I read Telsa's also have an electronic ebrake.
Decided I would go with supported systems for this build. Regardless of expense.
Decided I would go with supported systems for this build. Regardless of expense.
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Transmission: T-56
Axle/Gears: Moser/ 4.11
Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Rear most piece fiberglass done and started to mooth out with body filler
Time to rebuild rear hatch pull down. Parts from Hawks.
A bit more work on passenger side
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DynoDave43 (01-20-2023)
#249
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Join Date: Feb 2005
Location: West Warwick RI, postal code: 02893
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Car: Building LS3, T56 Z28
Engine: LS3
Transmission: T-56
Axle/Gears: Moser/ 4.11
Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
First time seing all three pieces in.
Sail panels didnt fit right. Adjustments made.
The following users liked this post:
DynoDave43 (01-20-2023)
#250
Supreme Member
Thread Starter
iTrader: (2)
Join Date: Feb 2005
Location: West Warwick RI, postal code: 02893
Posts: 4,355
Received 61 Likes
on
46 Posts
Car: Building LS3, T56 Z28
Engine: LS3
Transmission: T-56
Axle/Gears: Moser/ 4.11
Re: My 91 Z28 build. 17 years in the making... Finally going to do this right
Rebuild done!
Adjusting PS sail panel fitment
Smoothing PS with body filler
The following users liked this post:
DynoDave43 (01-20-2023)