The Build Phase (or my inner Frankenstein)

Once I made the decision to evaluate the GTM, I ordered a digital copy of the manual. It is a 700 page behemoth. I needed to determine whether or not there was anything I couldn't do. 

"A Man's got to know his limitations," Dirty Harry - Magnum Force 1973. 

There are things that still seem a bit hazy, but after tinkering on the Corvette and the Boxster these past couple of years, I think I can figure them out. Plus, I'm not going to build the engine or transmission, I am going to drop them into the GTM as finished modules and hook them up (easier said than done). After I digested the build manual, I broke it down to 144 major tasks. I can ignore the first 200 pages (as they deal with dissecting the donor). I purchased a donor parts get from Fparts.

Donor parts kit as it arrived on a single pallet (July 2011). My understanding and patient wife assigned me a corner  in the basement where I could store everything.

My initial analysis of 144 tasks does not take into account variances to the build that have been added since I started the planning phase. These include, but are not limited to:

• ISIS Power management replaces standard wiring.
• Paddle shift replaces stick shift.
• Ram Lift augmentation to Koni shocks.
• Additional sensors for parking, lane assist, tire pressure management.
• Digital gauges replace kit gauges.
• Kooks exhaust system replaces kit exhaust.
• The addition of roof scoop, splitter and rocker panels to standard body.
• Multifilament LED replacement for most lighting.
• Additional seat heaters.
• Carbon fiber wrap enhancement to various parts of the car.
• Sound deadening and heat shield enhancement to the build.
• Sway bar addition to standard suspension.

To facilitate these tasks in the build log, I am creating new index page for the build phase. Each major task will have a separate blog entry. Photos will be cataloged to the albums on the Super Car Build Facebook page.

Donor Parts Kit (Cataloged)

The donor parts kit was the most practical approach for this phase of the build. I do not have space for a donor C5, plus storage for GTM components. I had already decided that I was going with a bigger engine than the LS1, and I plan to purchase the big brake upgrade kit. Those decisions make a donor C5 impractical.  Photos are here.

I purchased the kit on Ebay from Fparts. Fparts is a salvage yard located in Bristol, PA. They specialize in Firebird, Camero and Corvette salvage. According to their banner, they put together more than 25 of these kits in 2008.

The first thing you need to understand is the kit is not sitting around on some skid, waiting for you to put your money down. These parts are still installed on existing vehicles. They even apologized that it took them a week to get things together. It would probably take me a month.

The second thing is this is going to come via freight. The shipping company provided a tracking number, and I was able to follow my skid from Pennsylvania to Minneapolis. The day before it was due into the Minneapolis terminal, I called and set up a delivery time. I did have to pay extra for a lift gate truck. If you have the means to pick it up yourself, you can save $50.

The third thing is the parts are used. However, you have to understand the Corvette mindset. Since I have a C5 and belong to Myrtle Beach Corvette Club, I get it. Most of these cars are driven on sunny days by older people. When I'm in South Carolina, my C5 is my daily driver except when it rains or I'm on my way to gun range. I'm hard pressed to put more than 3000 or 4000 miles per year on the car.

 Factory Five provides a GTM parts list. They even have a page with pictures of the parts. I make no claims that I know what everything looks like, and they look different sitting in your hand than they do attached to a vehicle.

Fparts uses this same list and provides everything except radiator, alternator, brake pads and brake lines. They print this stuff in red. Parts arrive on a pallet, steel banded and bubbled wrapped or bagged where appropriate. This means items like the steering column are bubble wrapped. Items like the O2 sensors are in bags labeled as such. Items like the fuel tanks, suspension are just sitting there, but these are pretty obvious. The suspension came in four pieces: left, right, front, rear. I don't have to think about putting all those parts together.

So you have the part numbers, description, photos (in some cases) and a list. What could go wrong? I broke things into the following groups:

• Suspension
• Fuel Tanks,
• Steering Column
• Transmission harness
• Engine harness
• Cooling system (e.g. hard pipes, condenser, fans)
• Doors (e.g. window motors, side view mirrors, handles, seat belts)
• Small items (e.g. sensors, bolts, tensioner, pulley, ignition)
• Electronics

I still ended up with a couple of things not on the list, and a couple of mystery pieces. I texted photos to my buddy Brian, who has forgotten more than I'll ever know about cars. He'll either have a good laugh or wish me luck.

I use the same list that Factory Five provides, and Fparts uses to define the donor parts kit. I cataloged everything so I know where I put all these parts. I intend to matched these parts up with the build task list that I developed. I also plan to integrate the Factory Five Parts into the task list. This is my method of knowing where to go find something, when it is time to put it into the build. There are a lot of smart people out there, so you probably have a better way to do this.

Tool List

I finished acquiring the tools on the required tool list.

• Storage shelves for kit and running gear parts
• Body storage area (can be outside)
• SAE and metric socket set, a 52-piece set that includes an 18mm is a good choice
• Deep sockets for some common sizes are helpful.
• SAE Combination wrench set (3/8” – 15/16”)
• Metric combination wrench set (10mm – 18mm)
• Full set of standard and Phillips head screwdrivers
• Standard Hex key set
• Long nose pliers, 4.5”
• Snap ring pliers
• Pop rivet tool with 1/8” and 3/16” heads
• Drill
• Drill bits (3/32”, 1/8”, 9/64”, 3/16”, 7/32”, 5/16 ”, 7/16”, ½”)
• Caulk gun
• 24 oz. Plastic Dead Blow hammer
• Razor knife
• Wire stripper/crimping tool
• ⅞”, 1¼” and 2¼” hole saws (Body cut outs)
• Bench top vise
• Tape measure or straight edge ruler/T-square
• Hydraulic floor jack
• Work Bench or 2 Saw horses with 4’x 8’ ¾” Plywood Top
• Engine hoist
• 6’ 5/16” chain (to lift engine)
• 4 Jack stands
• Hack saw (metal blade)
• ¼” & 5/16”Fuel/brake line bender (hand held)
• Jig saw (Body cut outs)
• Torque wrench (Click style, ⅜” drive)
• Eye protection
• Gloves
• The thing between your ears

Body storage is listed in red. I haven't figured this one out yet. Most likely the body will have to be stored off site, then retrieved for painting and body work when I get to that part of the build (probably in 2013).

Engine hoist and chain is listed in green. These can be rented from Highway 55 Rental, which is just down the road from the house at the intersection of Highway 55 and 101. The actual dropping the engine into the car and securing it to the mounts shouldn't take more than a couple of hours. This will probably be towards the end of 2012.

So many of the things discussed in the build manual and the jobs that need to be done would have made perfect sense to my dad. I know I am going to struggle on some of these issues. The entire point of going through the build manual and breaking it down into a 142 tasks is to help simplify the build in my mind. Not one task was beyond my abilities. I think if I keep that in mind then the build becomes a doable project that results in unique car.

Finally, I know I have some friends who will help, and eight grand-kids to turn a bolt or two.

The Build Task List

The idea of a kit car build is daunting. Professionally, I am a database administrator. I wrench on my Corvette and Boxster as a hobby. The idea of a tubular chassis, boxes full of parts, an engine and transaxle getting dropped off by the Fed Ex guy should be enough to make me reconsider. Let's start with some givens:

1. The GTM will probably cost more than the Ferrari 355.
2. There will be times of great frustration.
3. Things will break or get messed up during the build.
4. It will take time.
5. It will cost more than I think.

So how do I figure out if this is even possible? Buy the build manual. For $10 Factory Five will sell you the GTM Build Manual in PDF format. There are lots of pictures. The first 200 pages deal with salvaging parts from a donor C5 (more on this later). The next 500 pages explains how to build the GTM. Here is the break down:

1. There are 142 tasks defined.
2. Some tasks are much more involved than others.
3. They cover everything from attaching the suspension, mounting the engine, running the brakes lines and wiring the car.
4. Less clear is the build order for these tasks, and dependencies between tasks.
5. There are no considerations provided (e.g. LED lighting options, dash board gauge packages, powder coating exposed parts).

There are many things listed in the build manual I have never done. There is nothing in the 142 tasks that I think are beyond my modest capabilities. Here are my conclusions:

1. The wiring, drilling, riveting and wrenching are straight forward enough.
2. I don't have to build the engine or transaxle. I just need to purchase them, get an extra pair of hands and mount them in the chassis.
3. The GTM is based on a Corvette C5. I already have a C5. Many of the parts are familiar to me. I get how they attach to the car.
4. My familiarity with the C5 makes the GTM seem much more accessible. I get the technology, and I understand how to maintain it.

There is one other thing, it will cost more than I think.