Steering Rack Installation

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Major System Category: Steering
Task: Install steering rack to chassis
Parts: Steering Rack Assembly
Prerequisite Tasks: Kit Disassembly
Additional Costs: N/A
Time Requirement: 90 minutes
Date Started: July 1, 2012
Date Completed: July 1, 2012

Many have told me that build manual is like the code in Pirates of the Caribbean -  more suggestion than rule. The manual references two part numbers, but I could only find one in the detailed inventory. I figured everything I needed for the steering rack would be in the same box. So I hopped in the Boxster, rambled down to the storage locker and retrieved the box.

Steering rack assembly sealed in plastic.

The assembly is a single piece that requires you to install some bushings and sleeves, then bolt it to the chassis. The steering column orientation is self explanatory.

Bushings and sleeves.

Bushings and sleeves installed on the assembly.

Orientation is looking at the chassis from the front. The blue tape indicates where the assembly is attached.

Assembly attached to the chassis. Torque to spec (see Appendix A of the manual).

Issues: This is a very straight forward task. A couple bushings, a couple of bolts and tighten everything to torque specification. It pretty much went that way on one side. These are the issues I ran into.

1. The powder coating was bit thicker on one side. I took the die grinder and opened up the hole. 
2. The sleeve was too tight for the bolt. I mounted a 1/2 inch drill bit and opened up the interior of the sleeve.

After Market Goodies

The GTM has been around long enough to spur an after market. Rather than wait for the car to be fully finished before deciding on enhancements, I intend to add enhancements into the initial build.

Sway Bars:
Quick Racing Products makes a sway bar kit for the front suspension.

LED Lighting:
Quick racing Products makes some interior LED lighting strips ready to plug into the electrical system.

Big Brakes:
West Coast Corvettes sells the big brake upgrade for C5/C6. This does require the 18 inch wheels.

Instrument Panel:
I'm still thinking about this one. The kit currently comes with these Auto Meter gauges. They look kind of ugly. The gauge set sits on a beautiful carbon fiber panel, and white clunky looking gauges just don't make the grade. One problem I have run across is that many gauge sets have speedometers that only go 160 mph. The Revenge Design folks produce a luxury GTM starting at $145K, and they appear to be using a Dakota Digital display.

Exhaust System:

Vraptor Speed Works offers a stainless steel cross over pipe exhaust system that looks way better than the H pipe supplied in the kit. All I can say is, "Now that's an X pipe!" Regardless, which exhaust makes into the initial build, I am going to have a ceramic heat coating applied to the pipes.

LED Exterior Lights:
There are a couple of places that do a great job with Corvette replacement of bulb with LEDs. I am considering contacting them about a core replacement on the kit supplied lights.

Fuzz Buster:
The Passport 9500ci is an integrated system built into the car. The build seems like the perfect time to get this installed.

GPS/BT/Backup Camera:
Escort also makes a product called Smart Mirror. This replaces the donor rear view mirror with a unit that has GPS, Blue Tooth and an integrated backup camera. I am pretty sure the GTM does not offer the best sight picture. It will definitely need a backup camera, especially since all of my sports cars are backed into their parking spots.

HUD Display and Home-Link:
I really like the HUD in my Corvette. The after market HUDs that I have looked at to date are very primitive in execution. Although, Pioneer and Microvision are working on some things due out in 2012 that look quite interesting. For Home-Link, I think the easiest thing is to have it integrated into the driver's side sun visor.

Powder Coating:
As I understand it, there 34 sheet metal pieces that are visible on the GTM. Several builders have powder coated these black. This is mostly for aesthetics. Powder Coating Technologies is just down the road. I'll probably use them for the ceramic heating coating on the exhausts as well.

AM/FM/XM/MP3 Player:
I though that I would need something that integrated all the functionality of the smart mirror into this unit. Now I have the option to simplify this aspect of the build. I think I'll still go with some 2 DIN unit just so I have allocated space for a 7 inch screen. Who knows my passenger might want to watch a movie or something.