Rear Quarter Floor (R, L)

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Major System Category: Body (Undercarriage)
Task: Install floor plates
Parts: Rear quarter floor panels
Prerequisite Tasks: Rear Tunnel Aluminum
Additional Costs: N/A
Time Requirement: 2 hours
Date Started: October 4, 2012
Date Completed: October 4, 2012
One of the items I have held off completing are the floor panels. It has been convenient to reach up through the floor and get some things done. When I was working on the original fuel tanks, there was no requirement to install the floor panels beneath the tanks. The Corvette tanks just kind of were there. I found this to be a good arrangement, because it provided access to everything around the tanks.

Rear quarter panels under the tanks. These panels are on the engine  side of the fire wall.. Orientation:  Center line of the undercarriage on driver's side.

The rear tunnel aluminum needs to be installed for the Corvette tanks. Once the tanks are in place, these areas become inaccessible for the purpose of installation. I upgraded the fuel system to use aluminum tanks, and these tanks require the floor to be installed. I was quite excited to install the tanks, bur first things first.

I sound proofed the panel closest to the cockpit, as it technically resides inside the same body shell area as the cockpit. The more triangular shaped piece resides adjacent to the engine. Since the tanks rest atop wooden blocks and camper mount tape is used to minimize rattles, these new tanks should ride pretty quiet.

Anything being installed from the underside of the car requires that the item be drilled and riveted straight up. There is nothing very complicated about getting this done, it just takes time and grunt work. Every rivet is into a cross member on the chassis. There are no easy holes to drill and some of the areas can be awkward. I had to take the rear axle off the jacks, because they interfered with my access. A right hand drill comes in very handy.

GTM AC Compressor Shield

<< Cockpit/Tunnel Aluminum (Rear)   Front/Center Undercarriage Aluminum >>

Major System Category: AC & Cooling System
Task: Install AC Compressor Shield
Parts:
Prerequisite Tasks: Sound Proof  Rear Tunnel
Additional Costs: N/A
Time Requirement: 30 Minutes
Date Started: August 25, 2012
Date Completed: August 25, 2012

This is the cut out as delivered with the kit. Orientation: Passenger side, behind the firewall.

The compressor shield is thick chunk of metal that covers the hole in the panel facing the passenger side fuel tank. This really simple. Drill five holes and set five rivets. The important thing is to get this finished before mounting the fuel tanks. No one wants to undo the fuel tanks once they are installed. I also sound proofed the area.

Same area with the sound proofing and shield installed.

Cockpit/Tunnel Aluminum (rear)

<< Coolant Line Routing            Front/Center Undercarriage Aluminum >>
                                                 Rear Quarter Floor (R, L) >>
                                                 GTM AC Compressor Shield >>

Major System Category: Chassis
Task: Install rear tunnel aluminum
Parts: Tunnel Aluminum - Rear (4 pieces)
Prerequisite Tasks: Run all lines inside tunnel (less an issue if you have a lift)
Additional Costs: N/A
Time Requirement: 90 minutes
Date Started: August 24, 2012
Date Completed: August 24, 2012
I started the preliminary fit for the Corvette fuel tanks. These mount behind the seats and ahead of the fuel tank finish panels. I figured out how things fit together and wondered a bit about the lines coming off the bottom of the tanks. About this point I noticed the tunnel panels would be impossible to install after the tanks are mounted.

Driver's side rear tunnel aluminum. I performed a light test looking for leaks in the seams. I found  a couple of places were  air can get through. I used my seam sealer and a spreader to close up gaps along the bottom of the pamels where there is no overlap.

I pulled the fuel tanks out of the car. I need a few things before these tanks are prepped for install. I am a bit reluctant to close up the tunnel, since there are so many things running though there. I also have come tot he conclusion that the AC hoses are too short to comfortably reach the compressor. I read on another blog (I apologize I don't have the link) that another builder ran into the same problem. He found a place that could extend the hose length.

Passenger side rear tunnel panels riveted into place.. I can still access the tunnel from above and below the tunnel.

I decided to sound proof all panels on the cockpit tunnel. I am doing this even though the firewall intersects the tunnel panels. My reasoning is that this is a common panel that could easily transmit heat and sound into the cockpit.I probably will run the heat shield the entire length as well.

Driver's side installed. When the fuel tanks are mounted, all the rivet lines are hidden by the  fuel tank.

Coolant Line Routing

<< Radiator Install                       GTM A/C Evaporator Kit  >>
<< Clutch Line Routing                Cockpit/Tunnel Aluminum (rear) >>

Major System Category: AC & Cooling System
Task: Run the hard coolant pipes through the tunnel
Parts:

• Hard coolant pipes
• Corrugated flex pipe
• Spectre 7810 pipe adapter
• Corvette lower radiator hose (to adapt for upper radiator hose)

Prerequisite Tasks: Mount the radiator
Additional Costs: Insulated pipe wrap ($50)
Time Requirement: 60 - 90 minutes
Date Started: August 1, 2012
Date Completed: August 1, 2012
My strategy for the build is to do as much as I can prior to engine install. This is also part of my budget and cash flow strategy. I am 12 to 14 months out from my engine purchase, this means I am going to a number of tasks that terminate with the engine, but will remain incomplete until the engine and accessories are installed. The coolant lines are an example.

This is one of the hard coolant lines wrapped in insulator tape. I zip tied the ends and attached the appropriate connect sleeves. 

Consideration: The hard coolant lines are the main supply and return for engine coolant. This is going to run  through the tunnel. Consider insulating the pipes. I used a wrap that is rated to 1500 degrees. This is probably overkill, but heat is a problem with these cars.

Both wrapped hard coolant lines resting inside the tunnel. Orientation: the engine bay looking forward.

I wrapped the hard coolant lines and zip tied the ends. These pipes take up a fair amount of room in the tunnel. There are a number of other lines that run through the tunnel, including emergency brake cable, soft coolant lines, wiring, cable shift (or control lines for the paddle shift). I have not permanently tied anything down. I want to see how everything lays before installing the insulated clamps.

The 1/2 and 1/4 inch lines connecting into the radiator. This area will get more  crowded as  the AC lines get run.

After the coolant lines are in place, I installed the Spectre 7810 hose adapters on both ends of both pipes. If you don't have a lift, then I suggest installing these prior to placing them in the tunnel.

Lower radiator hose clamped to the radiator and uncut at this point.

The manual specifies the lengths for the front end corrugated flex tubing. I basically, gave myself an extra inch on the front end. There is some wiggle room here. The length requirements on the rear are shorter. I ran the flex tubing through the half moon shapes in the radiator aluminum. 

Coolant line run from the upper radiator to the hard line below.

Consideration: Ensure everything remains below the line of side on the inner wheel wells. The bulb seal for the hood goes on top of the wheel wells.

The item I am missing is the Corvette donor lower radiator hose needed to make an elbow from the driver's side upper radiator connection. A quick couple of clicks on my mouse, and found what I needed at Corvette Salvage. This part showed up a couple of days later. I went ahead and used a Spectre 7810 hose adapter to connect both ends.