Roadkill's 1983 Chevy Z28 - (Work Starts on Page 5)

[Roadkill]

Not a bad idea . . . . .

I could call it weight saving, too.

Annnnyyywaaay . . .

Got a few bits ticked off the list on Saturday . . . . (cheers Ian).

Main job was to investigate the alternator (Ian will have to chip in here but I gather we're missing a connector thingy inside of the connector plug itself . . . ?)

Also to fit the seats . . . .

Here's a pic of the laser-cut mounting plate on the drivers side (FIA apparently like 3mm steel plates and mine are 6mm so I'm confident they'll be fine).



Both seats in and fixed into position (took a bit of fannying around but got there in the end . . . )



Finished fitting and adjusting the harnesses earlier today, too (another job off the list).



Also finished fitting the other exterior badges on the lower cill covers earlier . . . .



And fitted the final badge I bought in the interior.  That's all I'm doing though.  They're nice and subtle . . anymore would be too much, IMO.



Next I just need to do a little bit of paint touching up and re-POR15'ing around the seat fittings before dropping her back on 4 wheels and adjusting the steering, then start constructing the steering column.



EDIT -

After that she's - theoretically - drive-able . . . . Leaving only jobs relating to the two doors left !!!



I think.

[ianjpage]

Quoting: Roadkill

Main job was to investigate the alternator (Ian will have to chip in here but I gather we're missing a connector thingy inside of the connector plug itself . . . ?)

Yup - steve in the box of bits dean gave you, did you have the metal connector inserts for the altenator multi plug or not ?   typically the plug only has 1 metal connector in it - the one with teh thin wire coming out which is also a different size (so couldn't even borrow it) - if not are they buyable on their own or is it a new plug jobby ?

Quoting: Roadkill

After that she's - theoretically - drive-able . . . . Leaving only jobs relating to the two doors left !!!

Yeah bloody scary really!!! lol

[Titsy]

You'll be needing one of http://www.ebay.co.uk/itm/GM-Delco-CS130-Alternator-connector-plug-CS-130-/230751885098?_trksid=p5197.m1992&_trkparms=aid%3D111000%26algo%3DREC.CURRENT%26ao%3D1%26asc%3D14%26meid%3D5059183236688152687%26pid%3D100015%26prg%3D1006%26rk%3D1%26sd%3D230751885098%26\" target=\"_blank\" rel=\"nofollow\">these as neither the original nor the LT1 alternator connections are the same as the CS130

[Roadkill]

Quoting: Titsy

You'll be needing one of these as neither the original nor the LT1 alternator connections are the same as the CS130

Bought

[Roadkill]

Did some touching up here and there over the course of the week and started preparing stuff for the up-coming steering column battle . . .

Dropped her back down on 4 wheels today and took advantage of the sunny spells . . . got the main window rubber tracks and rubbers in.   Also re-fitted the rest of the interior trim around the windows.

Exhaust is low . . very low.  But no lower than I'd guessed it would be.

That said the plan is to remove the cross-over section next weekend and modify it the following week.   This should gain an extra inch, maybe a bit more.

Time is now running out, though.

I'll be battling the steering column this week and hoping that the alternator tail arrives so that can be sorted this coming weekend . . . .  

Some pics from this evening . . .





Thanks to Ian for assistance today.

[Cunning Plan]

Impressive dude!

Does it return home straight away when complete or off for an MOT first?

What about the white lettering on the tyres?






I jest, I jest!

[Roadkill]

Quoting: Cunning Plan

Does it return home straight away when complete or off for an MOT first?

I suppose I should actually send the V5 back to the DVLA with all the changes on it . . . . .

I also want to re-register it to get rid of the stupid Irish number plate so, no, not quite off to the MoT station . . . !

Quoting: Cunning Plan

What about the white lettering on the tyres?

The final (expensive) job will be to change the wheels as these are far too bling for the car, now . . . . the new wheels will (hopefully) get 4 new tyres but if cash is short I can re-use two of the old tyres (the rear wheels will need new tyres as they'll be a lot wider).

[Roadkill]

Spoke to an exhaust builder yesterday regarding the noise of the exhaust . . . Between the two of us we came up with a few ideas . . . (without completely changing the lay-out).

With the modifications to the "H" pipe I'll be introducing a different type of flexible pipe that'll both reduce vibration and noise a bit . . . That said it'll only be two short lengths so I don't expect it to do much on it's own.

The other plan is to add a 26" glass-pack type box to each of the side-pipes as far back as I can get them . . . this will reduce the noise a little but should get rid of a lot of the more aggressive "raspy" noise.

If it's still "too" loud I have the option to add another 18" glass-pack to the side-pipes as well !!

I've also invested in 5m of heat wrap and stainless ties for the pipe that runs under the gearbox to stop that from cooking !!

[Jamieg285]

Have you seen SuperTrapps.  They do a relatively compact muffler, that bolts on the end of the pipe, and can be tuned by adding/removing plates. You can even buy just the plates kit and attach it direct to the exhaust.

[Andy]

Quoting: Jamieg285

Have you seen SuperTrapps. They do a relatively compact muffler, that bolts on the end of the pipe, and can be tuned by adding/removing plates. You can even buy just the plates kit and attach it direct to the exhaust.

Are they the things VW Beetle guys use? They do look really interesting!

[Roadkill]

Quoting: Jamieg285

Have you seen SuperTrapps

No I hadn't.  Interesting stuff . . . and not cheap !

There's a seller selling stainless glass packs for £55 each so will start with them . . . If they don't work at least I've got something I can re-use or sell on.

Update on the steering . . . .

Quoting: Roadkill

I'll be battling the steering column this week

Weeeeelll . . . . some bad . . some not so bad.  

Not so bad news :  I think I've found somewhere to mount the steering heim, now . . and I think I know roughly how I'm going to do it.



Bad news : After a 4th attempt with all new rods I'm still drawing the same conclusion . . . and that is that it is IMPOSSIBLE to construct a steering column which will not bind using the U-Joints Spohn provide in their kit.

I had this belief after the 3rd attempt but it's now very clear.

The critical angle is on the U-J between the two main rods . . . . the best I can get is about 135* . . . the U-J's bind at anything smaller than 145*.

The only way around this is to introduce a double-U-J where this one is now to spread the angle over two joints.

The problem is the joints I'm using aren't available over here, they're super expensive from the manufacturer, jegs don't sell them and Summit will take 2 weeks to get a double-U-J in stock !!!!

However, Summit do have another single U-J ready to ship so I've ordered another single one, to connect directly to my existing single joint to make a slightly longer double.

Make sense ?

No ?

Thought not.

Long story short, the steering is dead in the water - again - until the U-J arrives from the U.S . . .

[Roadkill]

BTW - I've had the Camaro for 8 years today !!!  

[Titsy]

have a look at UJ's here: http://www.ondrives.com/c/460/universal-joints\" target=\"_blank\" rel=\"nofollow\">http://www.ondrives.com/c/460/universal-joints

they don't show double joint on the page I've linked to but they are in each sub category.

[Roadkill]

The needle roller double U-J's are on a 21 day lead time and the bore is 1/4" too small.

The rest of the UJ's are pin and block which aren't as durable.

I've bitten another bullet and ordered a single from summit for $75+shipping . . . . We'll see if it gets here in time.

[ianjpage]

Quoting: Roadkill

Spoke to an exhaust builder yesterday regarding the noise of the exhaust . . . Between the two of us we came up with a few ideas . . . (without completely changing the lay-out).

With the modifications to the "H" pipe I'll be introducing a different type of flexible pipe that'll both reduce vibration and noise a bit . . . That said it'll only be two short lengths so I don't expect it to do much on it's own.

The other plan is to add a 26" glass-pack type box to each of the side-pipes as far back as I can get them . . . this will reduce the noise a little but should get rid of a lot of the more aggressive "raspy" noise.

If it's still "too" loud I have the option to add another 18" glass-pack to the side-pipes as well !!

I've also invested in 5m of heat wrap and stainless ties for the pipe that runs under the gearbox to stop that from cooking !!

Sounds good when they arrive then lol

Quoting: Roadkill

Long story short, the steering is dead in the water - again - until the U-J arrives from the U.S . . .

bummer

Quoting: Roadkill

BTW - I've had the Camaro for 8 years today !!!

Happy 8th anniversary lol!

Quoting: Roadkill

ordered a single from summit for $75+shipping . . . . We'll see if it gets here in time.

WOW they really arn't cheap!!

Have you managed to persuade any more time out of work ?

[Roadkill]

Quoting: ianjpage

Sounds good  when they arrive then lol

Once I've sold some stuff on eBay !!!

EDIT - I do have something else in the box with the U-J coming from the states, though . . . . . . . Seemed a shame to waste a box on just one thing !

Quoting: ianjpage

Have you managed to persuade any more time out of work ?

Not yet . . . . I'm waiting until next week for that . . . .

[Roadkill]

Well.  The progress on Saturday was less than good.  

They kept telling me that a dual exhaust system was impossible on a Third Gen . . . . !

Anything's possible with the right amount of engineering is my answer  . . . . and I still believe it  . . . . . I've just not applied the right amount of engineering to it yet, it seems.



Looking at multiple ways of increasing the ground clearance as my first second third fourth fifth plan didn't work.

The critical thing is to maintain sufficient cross-sectional area of the pipe(s) . . . . I've been researching ideal exhaust diameter formulas today and the utter minimum I dare go to is 2 1/4" duals.  

Based on that I can achieve a 15mm  angled notch in the top of the current 2 1/2" pipes which will reduce the internal area to 2396mm2 . . . . compared to 2303mm2 for a 2 1/4" pipe.

Not ideal but it should give me at least an extra 10mm ground clearance and in the process locate the cross-over closer to the front wheels and further away from the middle of the car.



We'll get there . . . .

EDIT

I've also looked at using oval pipes but they're rare as rocking horse $hit in the U.K . . .

My other option is to "press" the round pipes oval to maintain (theoretically) 100% flow but still get extra clearance . . . . Not sure how the pipe would crush, though, without doing some experiments . . . .

[F Body]

Quoting: Roadkill

I've also looked at using oval pipes but they're rare as rocking horse $hit in the U.K . . .

My other option is to "press" the round pipes oval to maintain (theoretically) 100% flow but still get extra clearance . . . . Not sure how the pipe would crush, though, without doing some experiments . . . .

The V8 4th Gens have exhaust pipes sections from the cats very flat to increase the ground clearance, I see if I can find a picture

[F Body]

Quoting: F Body

I'll see if I can find a picture

[Roadkill]

Yeah, the "flat" oval pipe from what I've seen over here is only available in limited sizes.

Plus everyone wants £££ for it !!

The standard oval pipe is uber rare here . . . very popular in the states, though.

Considering I need a 2m length the shipping to get a piece here would be epic !!

[F Body]

Quoting: Roadkill

The standard oval pipe is uber rare here . .

Don't know the prices but might be worth a phone call

http://www.eliptec.co.uk/\" target=\"_blank\" rel=\"nofollow\">http://www.eliptec.co.uk/

http://www.smithshp.com/metals/stainless-steel-tube.htm#\" target=\"_blank\" rel=\"nofollow\">http://www.smithshp.com/metals/stainless-steel-tube.htm#

[Roadkill]

Quoting: F Body

http://www.eliptec.co.uk/

Have put an enquiry to them.

Quoting: F Body

http://www.smithshp.com/metals/stainless-steel-tube.htm#

No mention of oval tube, limited info, plus it was very aerospace orientated.

[Roadkill]

I've been thinking outside of the box . . . . I currently have two headers, each with 3" collectors.  I opted to reduce the pipes down to 2.5" diameter based on previous research . . .

2 x 2.5" pipes, then is the minimum cross section I should maintain . . .

So a 2.5" pipe (with 1.5mm wall thickness) = 2874mm2

Doubled is 5748mm2 which is the maximum my headers will feed (with the reducers) so this is the minimum I intend to maintain . . . .

I've sketched up a solution where both headers immediately feed into their reducers, then immediately into a short section of flexi-pipe (to reduce vibration), then these connect to modified elbows welded onto a flat-oval "box" that also forms the cross-over.

This box's section measures 40mm x 170mm overall and is unbaffled.

It won't require further notching as it's already 28mm more slender than the existing arrangement . . . .

The downside is that this section doesn't exist so I'm having it custom formed and TIG welded together.

Once I get the section back I need to start modifying various bits of my existing set up to connect to it . . .

CONS : It's a lot of work.  Will take a lot of time and will look a little odd.

PROS : It'll be unique, 100% custom designed and fabricated (always a bonus IMHO) and will actually mix the gases better than the last set-up while maintaining 100% cross-sectional area.

Just hope it fits when I get the first bit back . . .

EDIT -

Still no sign of the Alternator tail, yet . . . .

Also the Steering elbow is now in the country but it's looking unlikely that I'll get it for this weekend.

[Roadkill]

I've done a 7-day, 60+ hours week this week so progress has been a tad slow . . . I have got some pictures, though . . . I'll upload later on.

Camaro must be out by the end of the month - long story but that's all I can wangle.

[Roadkill]

Here's the "test" section . . . Tack TIGed . . . When the final piece was full seam welded it flattened down about 4mm and the length grew about 6mm with the distortion.

Good news is that it stayed straight, and even with the distortion I still maintain the cross-sectional area as I'd allowed a little extra in the first place . . . I also gain ANOTHER 4mm of ground clearance !!!





Next I started pillaging bits off of the current exhaust to make the new cross over (I'll sort this out later) . . .

Before :



After :



With about an hour of fettling and test fitting . . . . Almost got the first of 4 contoured !