62 Corvette rebuild

[don long]

Just chiming in to say congratulations, Don.

You're doing great work. For an old geezer (like me!) you still know how to get a LOT of great work done. I'm truly impressed. Best to you and yours, Dan

Thanks Dan

I'm not that far from you. You should plan a visit some time
(Old geezer is right)

Man Oh Man, I just adore your ride and what your doing to get it "pristine!"
I've see a very few of these, at car shows in my area and they almost always take the top, "Best Of Show" prize.
Being a convertible, is even sweeter....very impressive and your not even finished.
Thanks for sharing the built!

ambenz

My wife is starting to push on me a bit to get er' done.
It is the car we dated in, so it means a bit more to her than the others.

Thanks for the visit and sharing your kind thoughts with me!

Don

 

[don long]

We managed to make a little headway on the vette today
While Tom scratched on the bottom of the car, Paul worked on the front bumper opening gaps and I managed to finish block sanding and got a little primer sprayed on the door jambs and undersides of the hood, deck lid, and soft top cover.





I also made a groove in the left fender apron so the brake master cylinder fits cleaner

 

[BBChevro]

Another incredible build Don (I hadn't tuned in to this one before today), you're making great progress.

 

[mp_tx]

Wow, true talent. I can't get over how much you get done in what feels like a short time. You build a rotisserie, block sand, and prime in the same amount of time it takes for me to rotate tires!

 

[Zeke]

Wow, true talent. I can't get over how much you get done in what feels like a short time. You build a rotisserie, block sand, and prime in the same amount of time it takes for me to rotate tires!

He has help.

 

[don long]

Another incredible build Don (I hadn't tuned in to this one before today), you're making great progress.

Thanks BB

This one is getting exciting for me. I started the reconstruction project in the mid 90's. It's fun to see the changes and progress each day

Wow, true talent. I can't get over how much you get done in what feels like a short time. You build a rotisserie, block sand, and prime in the same amount of time it takes for me to rotate tires!

Thanks mp_tx

It helps to have most of the equipment needed to make it all happen.
I have too many project waiting to sit back and stare at what needs to get done, so I just keep plowing through the s--t until something happens

He has help.

Yes Zeke I do.
and you are welcome to come over and play any time too.

Thank you all for checking in

Don

 

[don long]

We spent the day playing in the shop with the vette
1st I glassed in the first section of the left front apron.



And while the glass was setting up I went into the booth and primed the 2 doors, hood, deck lid,and soft top cover.



Then after much discussion about the steering linkage and how it will fit with the new apron placement We took the body off the rotisserie and mounted it again on the chassis so we could mount the new steering column and hook up the linkage and figure out how much clearance we will have



Here is the right side apron after reconstructing it to close off the massive hole around the motor



Now if we can make the left side look that good with the steering and brake unit on this side.

 

[MP&C]

Nice work Don! You're becoming old hat with this fiberglass stuff. I never could get it to weld worth a darn..

 

[RickP]

Lookin' good so far - that fg work looks too nice for the engine compartment! You're doing a great job on it. I really want to see the final coat of paint - at the rate you're working, I won't have to wait too long...

Hey Don, have you thought about how the engine heat will affect the bondo inside the engine compartment? That stuff gets pretty soft in the heat, but it looks like those new fg panels aren't structural, so you should be okay. You might be able to protect them with some high temp paint or something like that.

 

[don long]

Nice work Don! You're becoming old hat with this fiberglass stuff. I never could get it to weld worth a darn..

Thanks Robert

Funny, That's the same problem that I'm having.
So I have resorted to making smaller pieces and glueing them together

Lookin' good so far - that fg work looks too nice for the engine compartment! You're doing a great job on it. I really want to see the final coat of paint - at the rate you're working, I won't have to wait too long...

Hey Don, have you thought about how the engine heat will affect the bondo inside the engine compartment? That stuff gets pretty soft in the heat, but it looks like those new fg panels aren't structural, so you should be okay. You might be able to protect them with some high temp paint or something like that.

Hi Rick

I'm working on finding just the right color for it right now. I'm anxious to see color on this beast too.

I know that with paint on a car in the Arizona sun, the bondo under is not affected, and with the electric fan pulling cooler air across the engine compartment I doubt the metal (bondo) temp will be much hotter, so it should be ok

(if it looks good does it still need to run??)

Thanks for checkin in guys

Don

 

[don long]

Today was only a half day of work due to the doctors wanting my money
(old age)

Here is what it looks like with the steering linkage hooked up.
I have to find a way to go around these obstacles



So I built a second panel for the left apron, using a 4" drain pipe for the form



Fitted it to the upper piece
And Paul cut up the matting and glassed the two pieces together



The final results

 

[don long]

We put the steering linkage and break master cylinder back on the car to get our final measurements for the bottom of the apron



Then we put the body back on the rotisserie to finish up the engine compartment

 

[don long]

I spent the day building fiber glass. First I built a mold from some left over foam block. I measured the mold against the steering knuckle in front of the tower support wanting a pocket in the apron for the knuckle to have room to spin without interference.
Once the mold was to my liking I cut the glass matting and wet it up with resin in the mold.
After that piece hardened I broke it out of the mold and glassed it to the existing left apron

View attachment 1701942

The rotisserie sure makes this job much easier. It offers so much more access to the insides of the car.

View attachment 1701943

 

[MattVette89]

Very impressive and I love following the process.

Here is a question I thought of (hard to judge clearance/distance from the photos): when you built the side aprons for the engine compartment, is there enough room on the side for maintenance, such as spark plugs, and for other routing such as wires and fuel lines?

 

[ihrescue]

What an intriguing thread. Its a huge project, how are you tracking all the planned tasks? Best of luck on the finished product.

 

[don long]

Very impressive and I love following the process.

Here is a question I thought of (hard to judge clearance/distance from the photos): when you built the side aprons for the engine compartment, is there enough room on the side for maintenance, such as spark plugs, and for other routing such as wires and fuel lines?

Thanks for checking in Matt

There is about 2 1/2 inches between the exhaust manifold and the apron
might need to remove the exhaust before pulling the plugs.
I'm not the mechanic I only make um look good lol.
Hadn't thought much about working on the engine just how to improve the looks of the engine compartment

Thanks Matt for bringing that to my attention

What an intriguing thread. Its a huge project, how are you tracking all the planned tasks? Best of luck on the finished product.

ihrescue
I'm glad to hear that you are interested in my project
We don't plan much we just keep hitting it day by day
I'm an old body man so the process kind of comes naturally

I started at the front of the car and we are working to get to the back.

 

[akdiesel]

Don

Lots of one step forward two steps back on a car build. That's what a custom perfection build takes though.
It is looking good. Thanks for sharing.

 

[56vette461]

Don that is amazing progress since I saw you in November. You and Paul are really making things happen. Since your getting so good at the fiberglass work, maybe I should bring my 56 down and have you perfect that new found skill. I am just finishing my sub frame for the rotisserie and hope to roll it over next week. Give our best to your lovely bride. aj

 

[RickP]

I spent the day building fiber glass. First I built a mold from some left over foam block. I measured the mold against the steering knuckle in front of the tower support wanting a pocket in the apron for the knuckle to have room to spin without interference.
Once the mold was to my liking I cut the glass matting and wet it up with resin in the mold.
After that piece hardened I broke it out of the mold and glassed it to the existing left apron

Beautiful work as usual Don. It looks like you really figured out how to make the molds work for you. And you're 10 times faster than I would be - I'll have to follow your method if I ever tackle some autobody glass work!

I like that metal bondo that you're using - I've never seen that before. I have a project coming up that will be perfect for that stuff - thanks!

 

[don long]

Don that is amazing progress since I saw you in November. You and Paul are really making things happen. Since your getting so good at the fiberglass work, maybe I should bring my 56 down and have you perfect that new found skill. I am just finishing my sub frame for the rotisserie and hope to roll it over next week. Give our best to your lovely bride. aj

AJ
It's nice hearing from you again.
I itch enough with my project don't want another for a while lol
but if you want to bring yours down I would watch while you worked on it.
I will admit that this f/g process is getting easier by the day.

the rotisserie has made life sooo much better for me, I can sit while I work rather than bending over or rolling around on the floor

Thank for the visit

Beautiful work as usual Don. It looks like you really figured out how to make the molds work for you. And you're 10 times faster than I would be - I'll have to follow your method if I ever tackle some autobody glass work!

I like that metal bondo that you're using - I've never seen that before. I have a project coming up that will be perfect for that stuff - thanks!

Hi Rick
Yes it is like other jobs that I have done, once you figure out what tools you need and get set up, the work gets easier.

Bondo is easier than glass

Good luck

Don

 

[404]

Um so you have a full size paint booth in your shop?



Were you one of the founders of Microsoft?

 

[don long]

Nope
But you got to luv craigslist

 

[don long]

I'm almost done with the fiberglass creations.
Today was spent building and glassing the last panel to the left apron



After the glass cured we pulled the body back off the rotisserie and mounted it back on the frame to see if my calcs were close.
I put the steering column and linkage back together to check out the clearance before smoothing the apron with bondo.
I didn't like the lines on the apron so I cut them down so I can build them straighter.

Tomorrow the car will go back on the rotisserie again and the apron will be finished up. The wiper motor will be remounted under the dash rather than in the stock spot in the engine compartment on the firewall and the air conditioning plumbing will be sorted out.

Then I can close off the firewall and work on the hood locks.

 

[don long]

Corvette is back on the rotisserie today and the left apron is ready for bondo.

Next will be the center of the firewall

 

[-Brent-]

http://www.ksl.com/index.php?nid=218&ad=32715667

Don, saw this fiberglass project and thought of you. If it were a skill I posessed, I'd be all over this thing.

 

[don long]

http://www.ksl.com/index.php?nid=218&ad=32715667

Don, saw this fiberglass project and thought of you. If it were a skill I posessed, I'd be all over this thing.

Hi Brent
Thats a wild dune buggy.Go for it.
You can learn as you go any mistakes can be cut out and redone That was my additude when I started glassing the vette (I had never worked with fiber glass before)
Thanks for thinking of me

Don

 

[MattVette89]

I put the steering column and linkage back together to check out the clearance before smoothing the apron with bondo.

How close is that to the header?

And tell us more about the truck in the background of the other pics

 

[BBChevro]

...And tell us more about the truck in the background of the other pics

Here is Don's COE thread Matt...

http://www.garagejournal.com/forum/showthread.php?t=221122

Nice progress on the 'vette Don.

 

[don long]

How close is that to the header?

And tell us more about the truck in the background of the other pics

Matt
The steering shaft is about 1/2" from the header and the apron is about 3 1/2"
away

The truck is a project I started a year ago and the vette seemed to be a quick build so the truck took a back seat. it will be a tow rig with a 429 ford motor.

Here is Don's COE thread Matt...

http://www.garagejournal.com/forum/showthread.php?t=221122

Nice progress on the 'vette Don.

Thanks for the help BB

Some days seam to better than others. Today we figured out the windshield wiper motor placement under the dash rather than in the engine compartment.

I plan on building up the area where the wiper motor was and make the fire wall smooth all the way across I'm also changing the hood locks out to be incorporated into the top of the firewall All to be done by next week

Thanks for checking in.

 

[don long]

Here is an example of what I have in mind

 

[56vette461]

Hi Don, That vette resto is looking better with every photo. Can't let my bride see what your up to or I'ma gonna catch ?$^$%#&

Just checking to see if you experienced any flex in the rotisserie sub frame you built from the square tube. I'm going to the supplier this weekend to pickup material for mine and was curious how rigid yours was using the upright positioning arms versus welding the connection points across the entire sub-frame. (If that makes sense)

I like the ideal of having some working room clearance between the frame cross members and the bottom of the body. In the pictures it looks like the uprights are 2"x2" square tube with 1" x 2" rectangular pads for the hard points?

Any suggestions are appreciated. AJ

 

[MattVette89]

Love the COE thread, Don.

Also, I reread my post and I'm not trying to sound negative in any of them, I'm just trying to prevent future problems down the road if I see something that looks like it might have interference issues. Hope you understand that.

 

[don long]

Hi Don, That vette resto is looking better with every photo. Can't let my bride see what your up to or I'ma gonna catch ?$^$%#&

Just checking to see if you experienced any flex in the rotisserie sub frame you built from the square tube. I'm going to the supplier this weekend to pickup material for mine and was curious how rigid yours was using the upright positioning arms versus welding the connection points across the entire sub-frame. (If that makes sense)

I like the ideal of having some working room clearance between the frame cross members and the bottom of the body. In the pictures it looks like the uprights are 2"x2" square tube with 1" x 2" rectangular pads for the hard points?

Any suggestions are appreciated. AJ

Hi AJ

Thanks man it's good to hear from you again
Not much swaying other than from the welding.
Tomorrow I will take some good pic.s of the rotisserie bed and post them for you. As you know the body weighs very little.
The uprights are 1" square with 2x1 box for the feet
I ran 2&1/2 angle under the tork box mount area and the main frame is 3" x.120 tubing.
I really didn't know how handy the connecting tubes were going to be but they make changing the body on and off a snap

Love the COE thread, Don.

Also, I reread my post and I'm not trying to sound negative in any of them, I'm just trying to prevent future problems down the road if I see something that looks like it might have interference issues. Hope you understand that.

Thanks Matt

No offence taken. I appreciate your concern it makes me stop and think about what has been pointed out. I'm not a pro and am always looking for help so ask away

The C.O.E is begging for some of my time but it seems that the party garage gets any free time i might have. I do want to stay focused on the vette til it is a driver again

Don

 

[don long]

Here is an update on the progress made last few days

1. finished out the left engine compartment apron
2. put the windshield wiper motor inside under the dash
3. started molding in the firewall where the wiper motor was originally mounted

I picked up another block of styrofoam and shaved it down to fit what I wanted the firewall to look like



Then I molded the fiberglass around the foam



With the fresh piece of f/g I molded it to the car

 

[RickP]

That's good looking glass work Don. Your engine compartment is going to end up looking better than a lot of fiberglass jobs I've seen!

 

[don long]

Thanks Rick
You have been very supportive and helpful

Here is where the engine compartment sits as of tonite
It's been an *** kicker due to the way I started it but it is turning out to be what I first envisioned it to be.



Now on to the tire well.
We had to remove about 6 inches of the back of the tire well to accommodate the rear end stabilizer bars.





I kept the piece that I had removed several years ago, modified it and am in the process of rebuilding the tire well by moving that piece 6" forward and glassing it back in
Sorry for the poor photo!!

 

[8man]

Enjoying your build.

 

[don long]

Enjoying your build.

Thanks 8man
I get up every morning excited to get out in the shop and play with my tools and hope to get something done on the vette every day.

Today I blocked out the right engine apron and finished the trunk mod.
Hopefully the car will go in for the 2nd coat of primer next week.

Pic taken before the mud was final sanded


I left the small window in the pop out to be sure the rear end will fit when the body is lowered down onto the frame

 

[src60]

Don, great project and workmanship. I have a similar project. Mine is a '60. Paul did the frame in 1997 and I have had many 'issues' to deal with and the car is sitting neglected in my garage. I really need to get back on it. Mine also has a LT1/6-speed and I had it running and driving many years ago. Anyway, what are you planning for your cars VIN tag? The original is spot welded on the steering column which you have replaced with a newer one.
Steve

 

[don long]

Don, great project and workmanship. I have a similar project. Mine is a '60. Paul did the frame in 1997 and I have had many 'issues' to deal with and the car is sitting neglected in my garage. I really need to get back on it. Mine also has a LT1/6-speed and I had it running and driving many years ago. Anyway, what are you planning for your cars VIN tag? The original is spot welded on the steering column which you have replaced with a newer one.
Steve

src60

I didn't realize that I had a vin problem. What did you do to fix yours??

Thanks for the heads up, and for following my project. It's a lot of fun for me
and a lot of work at the same time. I can't wait to drive it around town again.

Don