Canadiangeek.net How do you know you can't do something if you haven't tried

6Mar/16

found some time to go out today.

Today was problem solving day.

1) i welded new transmission mounts the other day however its impossible to get the bolt in because the support was in the way. I welded two new braces on and moved the support forward 3" on the passenger side. Repainted everything and put it back on the car again. Problem solved.

2) I had a stupid moment and put the eccentric bolts in and mounted all of the suspension before i put the aluminum foot boxes in. I had not noticed that i had the bolt in the wrong way around so it can never be removed. It just so happens that the pieces i bought from Shane have to be welded to the bolt that now cant be removed. So....... I had to drill out a fair amount of rivets, removed the bolt, and then put them all back.

3) the brake line supports prevented me from installing the floor aluminum, had to drill out those rivets, mount the floor aluminum then put it all back.

4) the clutch master cylinder leaks where the reservoir plastic meets the metal cylinder.... I have tried to fix this 5 times with no luck before today. So today i took it all apart, hit the plastic with a heat gun like the instructions originally asked for until the plastic was softer. I then remounted it and cranked the crap out of the bolt that holds it on. Refilled and bled the system again. I then put a piece of paper under it for a few hours...... no drips yet.

We live and we learn.... today wasn't a step backwards but it sure as hell didn't get me any ways forward.

I ordered these parts today from Chev
- Another Starter bolt (I need two of the factory longer ones for the new starter)
- Metal mount for EVAP canister
- Bolts for exhaust manifold
- Exhaust studs for mounting headers GM dealership, GM# 12561310.
- Bracket that holds the brake light switch (forgot to take this off the donor)

Still have to find.
- transmission fluid (the gear oil everyone recommends on the Porsche forum's isn't available in Canada)

so by my calculations this is whats left before i can drive it around the block.

  1. check that i mounted down all steering bolts.
  2. find bolts that will fit though the new trans mount.
  3. finish front aluminum,
  4. rivet radiator down again.
  5. attach the heater lines again
  6. Fill with coolant
  7. Find a way to finish the emergency brake. (I will have to order a longer brake cable, its good enough for now.)
  8. Mount aluminum pieces that go beside the fuel tanks.
  9. Mount fuel tank (not going to use a 2x4)
  10. Mount pump+filters
  11. plumb fuel lines
  12. Fill engine with oil.
  13. Fill Trans with oil. (have to buy it first)
  14. grease all zerks
  15. install new plug wires. (i have them in a box.... somewhere)
  16. Mount Starter, (new bolt is on order)
  17. Mount clutch peddle stop (read the forum post where this caused damage when it was missed)
  18. Mount ECU, (I already modified the bracket)
  19. Run wiring harness. (I bought a premade one, this should be quick)
  20. Mount the seat (sliding rails are $250 each side locally... i might have to hit a junk yard to see what i can find.)
  21. Exhaust (just the factory/GTM stuff for now, I have to buy the kooks)
  22. Aircond, finish plumbing, fill AC lines.
22Feb/16

somewhat productive day.

I have everything between me and gokart in a checklist now, I made it though a small portion of that list today.

I had to remove the rad to get the drill to mount the grounding strap. (I should have mounted this earlier, whoops)
Click image for larger version. 

Name:	IMG_2599.JPG 
Views:	27 
Size:	160.7 KB 
ID:	50915

I mounted up the rear trans support cut the old brackets to fit the new transmission and tack welded them in place. This is where i ran into a problem that i am still scratching my head on how to fix. The bolts that need to go though the bracket and trans are now blocked by the square tube that runs down, I think my only option is to cut the square tube, weld in a smaller tube that fits inside and then drill a bolt hole though. This would allow the metal thats in the way to be removed, bolt put in, then reattached.
Click image for larger version. 

Name:	IMG_2602.JPG 
Views:	23 
Size:	186.0 KB 
ID:	50916Click image for larger version. 

Name:	IMG_2603.JPG 
Views:	19 
Size:	182.0 KB 
ID:	50917Click image for larger version. 

Name:	IMG_2605.JPG 
Views:	23 
Size:	131.1 KB 
ID:	50918

Gas tanks look great. I have been reading about how to mount these... i'm not a big fan of the 2x4 method, wood seems wrong somehow.
Click image for larger version. 

Name:	IMG_2607.JPG 
Views:	27 
Size:	174.5 KB 
ID:	50919

this is the clutch banjo and flexible line that i ended up with. Its all bled now.
Click image for larger version. 

Name:	IMG_2608.JPG 
Views:	28 
Size:	105.8 KB 
ID:	50920

I took apart the donor gas peddle, painted it black, mocked it up, drilled the holes, put in the rivnuts, now just waiting for the paint to dry before mounting one last time.
Click image for larger version. 

Name:	IMG_2611.JPG 
Views:	26 
Size:	218.3 KB 
ID:	50921

20Feb/16

Getting back into it.

so i have been off traveling for work for the last month... back now and ready to get back into it.

lots of parts arrived while i was gone,

  1. the aluminum fuel tanks from Boyd
  2. the heater bypass kit
  3. the rest of the fuel system fittings
  4. the M12 banjo bolt for the clutch

Tonight i went to a local car show then came home and finished the clutch plumbing and bleeding. I was shocked to see a GTM at the show. It was in about the same state as mine, not quite running but almost there. It looked like a twin turbo LS7 setup, its all being built by a local shop, doesn't look like the owner is doing anything himself. I grabbed the shops card so i can try and get a hold of the owner later.

I worked for a month straight without weekends or evenings so i have a few weeks of time off saved up, the current plan is to take a week off next month to focus on finishing the gokart.

 

this is the GTM i saw at the Calgary car show.

Click image for larger version. 

Name:	IMG_2583.JPG 
Views:	36 
Size:	203.3 KB 
ID:	50900Click image for larger version. 

Name:	IMG_2584.JPG 
Views:	35 
Size:	209.1 KB 
ID:	50901Click image for larger version. 

Name:	IMG_2585.JPG 
Views:	32 
Size:	204.4 KB 
ID:	50902Click image for larger version. 

Name:	IMG_2586.JPG 
Views:	33 
Size:	187.7 KB 
ID:	50903Click image for larger version. 

Name:	IMG_2587.JPG 
Views:	29 
Size:	180.4 KB 
ID:	50904Click image for larger version. 

Name:	IMG_2588.JPG 
Views:	32 
Size:	191.9 KB 
ID:	50905Click image for larger version. 

Name:	IMG_2589.JPG 
Views:	30 
Size:	175.1 KB 
ID:	50906Click image for larger version. 

Name:	IMG_2590.JPG 
Views:	32 
Size:	180.7 KB 
ID:	50907Click image for larger version. 

Name:	IMG_2591.JPG 
Views:	32 
Size:	190.5 KB 
ID:	50908Click image for larger version. 

Name:	IMG_2593.JPG 
Views:	27 
Size:	177.9 KB 
ID:	50909Click image for larger version. 

Name:	IMG_2594.JPG 
Views:	28 
Size:	141.2 KB 
ID:	50910Click image for larger version. 

Name:	IMG_2595.JPG 
Views:	30 
Size:	184.6 KB 
ID:	50911Click image for larger version. 

Name:	IMG_2596.JPG 
Views:	26 
Size:	145.7 KB 
ID:	50912

3Jan/16

Weekend well spent.

I started off the weekend by filling/bleeding the brakes. I had a 2 air leaks that took me a while to track down. The first was in the fitting at the top of the master cylinder which caused me to have to rerun the front brake line. Once the leaks were gone the lines bled easily.

I locktite'd, torqued and safety wired the axels. This process took no less then 6 hours. The drilling of the bolts took the majority of the time. Most of my drill bits are brand new and couldn't make a dint in the hard bolts using my drill press. I bought a set of BigDog bits a while back at tradeshow, they worked like MAGIC for about 3 bolts before the titanium ends broke off. They were able to drill through the bolts like butter. I bought safety wire pliers which made short work of actually getting everything wired up.

I then took the time to adjust the CableShift unit so i could get through all the gears without the shifter hitting sides or bottoming out the cables. I then spend the next 10 minutes or so sitting in the drivers seat shifting gears while making vroom vroom noises with my daughter, its a toss up for who had more fun.

I shifted focus to the ebrake, the one from the doner was covered in rust so i soaked it in rust remover
Click image for larger version. 

Name:	IMG_1771.JPG 
Views:	37 
Size:	131.6 KB 
ID:	49401

This is the after shot. (about 2 hours later)
Click image for larger version. 

Name:	IMG_1772.JPG 
Views:	33 
Size:	147.2 KB 
ID:	49402

It wouldn't fit because it was quite bent. I don't think this is factory, i think someone must have bent it by pulling WAY to hard.
Click image for larger version. 

Name:	IMG_1774.JPG 
Views:	31 
Size:	142.9 KB 
ID:	49403

I bent it back to flat and then a little bit more in the other direction so it clears the center console.
Click image for larger version. 

Name:	IMG_1780.JPG 
Views:	25 
Size:	115.0 KB 
ID:	49404

Connections to the rear went together as planned..
Click image for larger version. 

Name:	IMG_1791.JPG 
Views:	28 
Size:	113.0 KB 
ID:	49409

Where have people been mounting this piece. I saw that Shane has a kit but it wont fit because my starter is in the same mounting location.
Click image for larger version. 

Name:	IMG_1792.JPG 
Views:	25 
Size:	127.6 KB 
ID:	49410

I shifted my attention to the AC lines. I started by putting in all the lines loosely (heater/AC)
Click image for larger version. 

Name:	IMG_1784.JPG 
Views:	23 
Size:	132.4 KB 
ID:	49406

I could not get the evap unit to sit where the manual says. Upon further investigation (by watching FastThings videos) i saw that it mounts better just behind the coolant tank. The reason i couldn't get the unit to fit there was because i used the 6" extension as the manual stated.... i will be removing that 6" piece, which is a shame because it was a ***** to get it in there in the first place.
Click image for larger version. 

Name:	IMG_1788.JPG 
Views:	28 
Size:	132.4 KB 
ID:	49407

The heater lines come with fittings that turn 90 degrees. why? it seems this would be easier to plumb if they were straight fittings.
Click image for larger version. 

Name:	IMG_1789.JPG 
Views:	28 
Size:	94.1 KB 
ID:	49408

These seals were in the box with the AC pieces... what are they?
were they supposed to go on the AC compressor fitting?
Does anyone know what these are for.
Click image for larger version. 

Name:	IMG_1783.JPG 
Views:	26 
Size:	139.9 KB 
ID:	49405

I also have a few parts on order
1) I ordered the heater bypass solenoid from Crash's website today.
2) Fuel tanks should be finished this week and shipped out (they are being custom made by Boyd's). They have AN fittings and a fuel pickup in the drivers side and a sending unit on the passenger side.
3) Aeromotive fuel rails should be here next week
4) M12 banjo bolt and fitting for the clutch

I head out to CES (Tradeshow) on Tuesday, back for a few days then off to Bett in London (Another Tradeshow), back for a few days then off to ISE in Amsterdam (yet another Tradeshow)..... so it might be a while before i post another update. 🙂 I do plan on getting some Traction control planning done in my other thread while traveling.

25Dec/15

Laws

For anyone in Alberta Canada like me, I have found the basic rules for what needs to be completed before being certified to run on the road.

There might be a more recent version of this but i couldn't find one.
http://www.qp.alberta.ca/documents/Regs/2009_122.pdf

20Dec/15

Progress, progress, progress…

First the current road blocks... The Medeola slave cylinder uses an M10 banjo bolt and banjo fitting that came with the GTM. I used G96 transmission that seems to use an M12-1 banjo bolt and fitting. I visited 6 automotive stores none carry M12... all carry M10.. I guess M12 is not common. I ended up ordering an M12-1 bolt from Vancouver if it fits I will pick up the fitting from the internet somewhere.

Safety wire was hard to find but i finally found a shop that carried it. I also bought the fancy spinning pliers because i can never pass up an excuse to buy a new tool.... I also bought 3 new torque wrenches and 3 new ratchets.

I picked up almost all of the required fluids like coolant, Dot 3 brake fluid, engine oil. However i still have to pickup transmission fluid, seems most people on line are very picky about what they use.... I think i might pick up transmission fluid directly from Porsche.

Click image for larger version. 

Name:	IMG_1713.JPG 
Views:	44 
Size:	151.6 KB 
ID:	48780Click image for larger version. 

Name:	IMG_1714.JPG 
Views:	45 
Size:	141.9 KB 
ID:	48781
I bought my fuel pump/filters/mounts/regulator/rails and most of the required fittings for the fuel system.

I have ordered some new parts
Sway bar: http://quickracingproducts.com/html/chassis.html
Fuel Tanks: http://quickracingproducts.com/html/fuel_system.html
Door Switches http://quickracingproducts.com/html/electrical.html

All in all this week cost about $4000... the value of the Canadian dollar is killing me.

Still enjoying it though 🙂

15Dec/15

Another day another issue to work through

Click image for larger version.  Name: IMG_1665.JPG  Views: 48  Size: 138.3 KB  ID: 48610
The shifter mounted a little different then the images on the vspeedworks site http://vraptorspeedworks.com/cable-s...g-bracket-kit/. My shifter ends about 1" more forward then the images on that site. Not exactly sure why but I am tall, that comes with long arms so 1" further away from the seat might be a good thing.

Click image for larger version.  Name: IMG_1668.JPG  Views: 36  Size: 80.4 KB  ID: 48613
This banjo fitting doesn't have a bolt so i will need to buy one. The manual simply says "use the supplied bolt"... not sure what it was supposed to be included with. (I have two slave cylinders, i didn't get a bolt with either)

Click image for larger version.  Name: IMG_1670.JPG  Views: 42  Size: 127.6 KB  ID: 48615 Click image for larger version.  Name: IMG_1671.JPG  Views: 38  Size: 124.1 KB  ID: 48616
Axles fit right in, I just need to put some thread lock on the bolts and get them locked down.

Click image for larger version.  Name: IMG_1678.JPG  Views: 43  Size: 111.4 KB  ID: 48619
The rear bump steer kit just arrived, postmarked from last Tuesday (3 weeks after i was told it was shipped...) regardless its here and looks great! Now i just need to get all the bolts locked down.
Brake lines are now 100% complete, I will pick up some brake fluid on the way home from work tomorrow.

13Dec/15

I mounted the battery tray and washer fluid bottle. I will use a small piece of tube with a bolt though it to secure the top of the washer bottle. That will ensure that it doesn't move at all. I drove all over town looking for the last fittings for the brakes, turns out no one carry's brake line fittings anymore because "there is no money in it". I went to 5 automotive stores and received the same response at each one. (I ordered them off Amazon, should be here soon). In the meanwhile i used the fitting that came with the master cylinder and the T that was supposed to be used at the back of the car. Works great.
Click image for larger version.  Name: IMG_1656.JPG  Views: 62  Size: 147.3 KB  ID: 48547

Robb was over, he welded in the VSpeedworks cable shift mount kit that i bought. Fit perfect, was short one bolt (kit comes with 6 bolts, requires 7 if you follow the pictures on the site).
Click image for larger version.  Name: IMG_1661.JPG  Views: 63  Size: 143.7 KB  ID: 48548

This is the welder that i had to wire into the garage, works amazing.
Click image for larger version.  Name: IMG_1664.JPG  Views: 68  Size: 143.0 KB  ID: 48549

Shifter installed
Click image for larger version.  Name: IMG_1665.JPG  Views: 68  Size: 166.0 KB  ID: 48550

I finally figured out how to mount the shifter cables to the trans. Turns out the bracket that came with the trans is a perfect fit. I just had to remove the bracket flip it over 180 degrees and put it back together. Not sure how i didn't see that before.
Click image for larger version.  Name: IMG_1666.JPG  Views: 66  Size: 131.5 KB  ID: 48551

the rear bump steer kit that i bought 2 months ago still isn't here yet. I was told it shipped over a month ago, I have called the company that I ordered it from 5 times, they seem to have no idea where it is. I might have to cancel the Visa payment on it and cut ties with that company to get my money back.... ARRGGG.

I started putting on the front bump steer kit. I don't quite understand how its supposed to go together or how it would help with bump steer. It mounts in the same way the factory unit mounts and has almost the same clearance. I also don't see how it would be adjustable... is that what all the washers are for? is that how it adjusts? If so it doesn't adjust by much.

I finished putting the axles together and got stuck on the Porsche side clips. Only one C Clip was in the box... I needed one more 1" clip, once again i hit every automotive store around me and turned up nothing. I had to order a kit containing 300 clips for $8 off the internet, that should be here soon as well.

I think i'm going to have to install the AC lines next before the coolant system because its easier to climb in the front without the radiator.

21Nov/15

Pretty productive day

Pretty productive day, I will try and post some photos tomorrow (I have a few hours tomorrow to work on the car as well).

Brake lines and clutch lines are in although I need to buy a few new fittings because I stripped out the T that goes on the front brake master. The ones from FFR seem a little cheap, I will pick up a better quality one. The kit also didn't come with enough brake line to finish the clutch and brakes. The manual mentions different lengths of brake line however I only received 60" lengths. So I will have to go to the store to pick up another couple of feet to finish the last rear brake tomorrow.

I disassembled both corvette axels and cleaned all the axel components of all grease. I mocked everything up so tomorrow should be smooth sailing. I still don't have the banding clamp pliers that I ordered so I wont be able to do up the CV boots (that's the tool I was talking about)

The radiator rubber bushings came in today, Once the brakes are all bled and tested and the windshield washer fluid container is in tomorrow I can get that all mounted.

So for tomorrow:
Washer fluid tank install
radiator install
Mount axels in car (assuming I can find the tool locally)
Ebrake lines
Shifter mount (I bought the Vraptor pieces, I just need to weld them in)

This leaves:
Coolant lines
Fuel system
(rear bump steer kit still hasn't arrived)
Rear mount for transmission (have to weld something up)
Attaching the wiring harness (premade)
Wheel alignment

Then I can gocart... I am getting excited about gocarting 🙂

8Nov/15

Waiting.

Waiting on Orders to come in isnt a ton of fun.

Almost a month in and the Bump steer kit hasn't even been shipped yet.
New rubber bushings for the radiator have been over 3 weeks without being shipped.
I bought some new tools to assemble the CV's, those are MIA. (couldn't find the tool locally)

hope some orders will be here soon so i can resume progress.