dennisbernal91z

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Fabric and fiberglass approach was massive failure. I am not good at all the contours. Had to rip off after applying resin and fiberglass. What a waste of time... life goes on.

Bezel made to angle gauges

lots of damage from undoing the glass.

dennisbernal91z

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Skim coat of bondo.



2 part glazing putty. Needs 1 more good application then final primer. Getting there.

dennisbernal91z

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Deciding what I am doing for the center console.

dennisbernal91z

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PS hush panel modification

Fabricating DS hush panel and under column close out.

Bracing behind e brake close out. New ebrake will be electronic.

dennisbernal91z

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DS coming along

Console has mid brace

Left side corner will be built up with fiberglass bondo

dennisbernal91z

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Bracket to hold down front of console.


Covering concole is fleece. Fiberglass time.

dennisbernal91z

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Coming along

Close out panels for original belts. Car will have 4 point.

Fixing broken piece of rocker panel. So many smal pieces of board!

IROCZman15

iTrader: (25)

tons of work. good stuff!

dennisbernal91z

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Fiberglass going on

dennisbernal91z

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Fiberglass done

Rundo laying down a base of filler. 2 parts fiberglass resin, 3 parts bondo.

dennisbernal91z

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Leveling out rundo

dennisbernal91z

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Test fitting seats and console. Looks like everything fits well. Time to move onto glazing putty.

After a half dozen applications of bondo

Abubaca

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I'm enjoying this thread! Nice job.

dennisbernal91z

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Fabricating heater brackets

Center console top coming along.

dennisbernal91z

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Decided I will have a center console cubby.

dennisbernal91z

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Some potetial button layouts. Billet buttons look and feel awsome.

dennisbernal91z

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Fabricated the center armrest/cubby door.

Final button layout can be seen here

Hinges are cabinet hinges. Wanted a hidden hinge system.

dennisbernal91z

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3D printed a stencil to get the placement just right.

Holes for switches done. Onto the shifter hole and air ride contoler inlay. All other controls, heater, wipers, and headlights will all be hidden in the cubby. Designed and printed a mouthing plate for them in there.

dennisbernal91z

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Air ride tech kit layed out

Underside of console, test fit wiring

Black square is the 3D printed inlay for the ride tech touchscreen

dennisbernal91z

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From the top

In the car

Control center. 3D printed to ensure a close precise fit.
***** are Vintage air heater controls, usb in the middle to charge phone, upper right is Detroit Speed wiper module, lower right is headlights. (Car will have no radio)

dennisbernal91z

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Checking fitment

Frenching in screen bezel after resin impregnating the MDF.

After 3 or 4 applications of filler, finally getting close.

dennisbernal91z

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USB-C for screen. Allows screen to look inlayed but still able to pull out if needed.

Able to remove confirmed.

dennisbernal91z

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Where I want the air tank to live. Working alone means a lot of tape.

Tack welded brackets in place

Fabricating air ride control box mount.

dennisbernal91z

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Control box mounted

Valve block mounted

Air tank mounted. Working on battery mount.

dennisbernal91z

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Touching up before high build primer

Layer of rundo to smooth everything out.

dennisbernal91z

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Enough parts to make it worth shooting high build to seal off the filler

2 coats

dennisbernal91z

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Test fit console post primer

How stock rear plastic can no longer fit

Trimmed to fit. Now to make close off panels.

tylercamaro

iTrader: (1)

was there too much showing through on the tub to try and heat gun and remold it? looks real close from that last picture but doable? awesome progress, I admire the skill and dedication!

dennisbernal91z

iTrader: (2)

Thanks for the kind words.

I believe you are referring to the second to last and last picture.

I removed a lot of material. In the second to last pic, the mounting screw on the back ear that attaches behind the rear seat back is like 5" away from connecting.
Also the seat belt pocket is in the way, so that had to be cut out as well.

I had to relocate the seat belt anchor inboard a bit since the old one was attached to the base of the stock tub. That area got absorbed into the new larger tub.

No amount of heating would get this to mount with the amount of mini-tubbing I did in this situation.

I will do the DS next and then make patch panels before covering the pieces in fleece, resin, fiberglass, rundo and high build primer.....ugh... lots of work, but worth it!

dennisbernal91z

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Framing up passenger side

Anchor for fleece for rear panels

All I am using from stock panels. The edge mounting.

dennisbernal91z

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DS fleece glued and stapled

Oversized piece of fleece so it can cover the entire panel in 1 piece.

After brushing on resin to basically turn the fleece into plastic, fiberglass pieces are cut to reinforce the entire unit.

dennisbernal91z

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Part around tube was designed and printed so I had someplace to attach fleece.


After fiberglass is resined on, it gets sanded 80grit to smooth out the bumps a bit.

dennisbernal91z

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Bondo and resin mixed to create Rundo. Basically self leveling body filler.

Coated and setting up

dennisbernal91z

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Made a mistake appying filler with the panel off the car, fleece sagged. Starting repair. Chunks of material are filler to repair sag...

Rundo knocked down

Of course still not perfect. Detail work.

dennisbernal91z

iTrader: (2)

Here is how far the sag moved. Only way to get the mounting point to line up was slice the sag. Lost some time filling the sag. Oh well.

Glazing putty to fill in small imperfections.

Kicker panel with fleece filler stapled to it.

dennisbernal91z

iTrader: (2)

No fiberglass here, just straight to fiberglass reinforced bondo to keep the stack up low.

Finally got a vented battery mounted into the trunk. Summit universal mount.

Will be mounted below the AirRide 3 gallon air tank.

dennisbernal91z

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DS looking sort of done (in primer)


Starting PS

dennisbernal91z

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Starting rear piece. Fleece time. Using stock top rail to mount upper section.

Trimmed and soaked in resin

dennisbernal91z

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Fiberglass time

BizJetTech

iTrader: (3)

That is one impressive build !!!

I like the vette too

Tibo

iTrader: (15)

What calipers are you using for the electronic parking brake? I started making a center console from scratch and halfway finished it but I couldn't find a way of getting it in and out because the ebrake was in the way. I hadn't considered and electronic unit, good thinking. I also wanted to caution you about doing too much fitment without the carpet in. Carpet can raise the console up to 1/2".

dennisbernal91z

iTrader: (2)

Thanks for the heads up about the carpet thickness. The base of my "from scratch" center console is still the oem unit. It does have extensions toward the dash, but I did maintain the oem gap with the floor.

As for calipers, I have been playing with ideas for sooo long. Looking into Baer brakes (eventually). Internal drum ebrake. This will be activated by an electronic E-Stopp. Just need to confirm if these will fit on my c-clip eliminator Moser 12 bolt rear end.

I like Willwood solutions but I don't like the size of their front calipers. For a show car like this, looks are a big deal for me.

Tibo

iTrader: (15)

Can you post a link to the solutions/products you've looked at for the electronic parking brake? I'm really interested in this again.

dennisbernal91z

iTrader: (2)

https://www.estopp.com/product-page/...p-standard-kit

This is the unit that will convert basically any manual ebrake into electronic. Not cheap, but clean solutions rarely are.

dennisbernal91z

iTrader: (2)

Main issue was that Baer rear brakes don't have kits that fit c-clip eliminator rear ends.
After emailing them, they got back to to me saying for an additional $200 they can machine the rear retainer plate to accommodate.

Only other option was Willwood's electronic parking brake, but they don't offer that for third gens.
Their e-brake is a manual option for these cars, so I would still need the E-Stopp.

Looks like I am going to use 100% Baer components for the braking system.
E-Stopp for the elimination of the e-brake lever. Will mount the unit someplace near the back seats most likely since the center console can't fit it since I made a custom center cubby, sort of like stock.

The unit is long though, so it will be tricky. Maybe transverse above the fuel cell area. Basically where people put the "trap door".

Tibo

iTrader: (15)

Have you wondered around d a junkyard for ideas? Mazda uses a caliper that has the electronic brake as part of. It's not a third part, perse. Finding a caliper like that and making a mount might be much cheaper.

dennisbernal91z

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I have considered that. I read Telsa's also have an electronic ebrake.

Decided I would go with supported systems for this build. Regardless of expense.

dennisbernal91z

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Rear most piece fiberglass done and started to mooth out with body filler

Time to rebuild rear hatch pull down. Parts from Hawks.

A bit more work on passenger side

dennisbernal91z

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First time seing all three pieces in.

Sail panels didnt fit right. Adjustments made.

dennisbernal91z

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Rebuild done!

Adjusting PS sail panel fitment

Smoothing PS with body filler