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Project Procrastination '91Z LS1/T56/currie 9" w/PICS This might get lengthy, but I'll do my best to make this as readable as possible. I bought an '86Z in 2009. This is it at a car show: https://cimg1.ibsrv.net/gimg/www.thi...2d782cfd97.jpg It had a well-built 355, 700R4, 3" fiberglass cowl hood, and ran very well. I did a T56 swap a few months after buying it. Also built a Currie 9" for it. Here's a thread I made of installing the gears: https://www.thirdgen.org/forums/tran...-your-9-a.html Then I noticed how bad the floors were. Around this time I found a complete '99Z LS1/T56 car: https://cimg0.ibsrv.net/gimg/www.thi...fece1c99ca.jpg So I sold the engine/trans from the '86, to pay for the '99. I pulled the LS1/T56/fuel tank, and sold the '99 as a roller. So at this point the '86 had no engine/trans, just the Currie 9". I also now had a complete LS1/T56/plastic fuel tank.........but no car to put all these parts into. So one night I'm trolling craigslist and I found a '91Z shell that had been mini-tubbed. It was bare, but had FAR less rust to contend with (compared with the '86) had already been mini-tubbed, and only cost me $200. There ended up being more rust to deal with than I had anticipated, but it's been dealt with. It was a chore to get it home, but I made it happen. Here's a thread I made about the car: https://www.thirdgen.org/forums/body...tub-shell.html First thing I did was tackle the rust in the floor. Here's the thread of that repair: https://www.thirdgen.org/forums/body...tub-shell.html After I fixed the rust the car just sat in my garage...... Until last year when I decided to build a rotisserie for the body. Some of you may have seen the thread, but here it is anyway: https://www.thirdgen.org/forums/body...otisserie.html After I built the rotisserie I cleaned/degreased the bottom, then it sat. Again...... So now to the present! I finally decided to do some real work on the car, and I'm happy to say that the bottom/floor is FINISHED. Let me walk you through what I did over the last week and a half. I started by patching the 7 body plugs. There's also 2 more above the fuel tank, but they're seam-sealed and I didn't feel it was necessary to do them. First I pulled the plugs: https://cimg5.ibsrv.net/gimg/www.thi...453d01b3d6.jpg Then scrapped away the sealer from the inside: https://cimg8.ibsrv.net/gimg/www.thi...754ec76a7e.jpg Then cut out the entire area so that the patch would extend over the entire area: https://cimg9.ibsrv.net/gimg/www.thi...2f0f7df89e.jpg Cut out the patch: https://cimg1.ibsrv.net/gimg/www.thi...62e45bb0b2.jpg And welded it in: https://cimg2.ibsrv.net/gimg/www.thi...cb6a649076.jpg Here's one of the round plugs underneath the passenger seats: https://cimg4.ibsrv.net/gimg/www.thi...de6bcae06a.jpg Also, it looks like the car hit something that tore up this area: https://cimg5.ibsrv.net/gimg/www.thi...29233179d8.jpg So I worked the metal back into place and welded it: https://cimg6.ibsrv.net/gimg/www.thi...a5e99472cd.jpg Then I had more work to do on the floors. Cutting out ANY rust and replacing it with new metal: https://cimg8.ibsrv.net/gimg/www.thi...bfe7b43a53.jpg https://cimg9.ibsrv.net/gimg/www.thi...86b28fd444.jpg |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 8 Attachment(s) After that I went back and sandblasted all of the areas of previous metalwork to get rid of any rust that had accumulated: Attachment 335282 Once all that was done, it was time to prep for paint. POR15, followed up by Rust-oleum undercoating: Attachment 335283 I cleaned then etched the entire bottom of the car: Attachment 335284 The painted with POR15: Attachment 335285 Attachment 335286 Attachment 335287 I did 2 coats, then finished with a the Rust-oleum undercoating: Attachment 335288 Attachment 335289 And that's where she sits right now. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Very nice! I love the home made rotisserie too. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Thanks. This much floor work wouldn't have been possible without that rotisserie! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Yesterday I bought some Lizard Skin sound-deadening insulation (2-gallons) along with the accessory kit from Summit. Should be here tomorrow. https://static.summitracing.com/glob...iz-50115_w.jpg https://static.summitracing.com/glob...Z-50125_xl.jpg I'd also like to provide some details about the work done so far since I kind of skimmed over a lot yesterday. First, the body/floor drain plugs - From what I understand they were only designed into the cars floor so that liquid would drain from the car during manufacturing. You'll notice that they're sealed with some kind of sealer from the inside which also holds the carpet in place. I saw these as just unnecessary holes in the floor, which is why I patched them. Patching holes - Because you're welding thin sheet metal you have to make your patch almost perfectly contoured to the hole it's covering. When welding, staying in one spot too long will cause burn-through so move around to avoid this. You can also cool the weld with compressed air or a damp rag. POR15 - This stuff is no joke. WEAR GLOVES. If you get it on your skin, you can easily clean it off with mineral spirits. I used gasoline too. However, if it dries on your skin it is NOT coming off! I had some dry on my fingers last week, and it's almost completely worn off by now. So if it happens to you don't sweat it, it'll wear off. I applied the POR with a $3 3" paint brush. This stuff drips too, and if it gets on your concrete it's NEVER coming off! 2 coats is a must. 1 coat looked fine, but after I did a second it was clear that 2 was the way to go. I cannot imagine working with this stuff with the car above me. Just having my car sideways on the rotisserie was somewhat challenging. Last thing, you must prep your surface properly. Clean/degrease then etch before painting. I etched the entire bottom of the car for over 30 minutes keeping the metal wet by continuously spraying in different areas. 1 quart was enough for 2 coats. I now have a second quart that I haven't touched. http://cdn.mscdirect.com/global/imag...5950536-23.jpg Rust-oleum rubberized undercoating paint - This stuff cannot be sprayed from a paint gun! The can says to use a hopper style gun, but that's a lie.........I tried and it won't even spray. Simply too thick. This stuff is like thick chunky peanut butter. I used it to protect the POR (which will breakdown over time if not top-coated) and for it sound-deadening properties. While I only used POR on the floor, this stuff was used on every surface that faces the ground. Also unlike the POR I had to use 2 quarts for 1 coat. First thing I did after the POR dried was apply a dust coating of this product in its spray can form. 2 cans did the trick. http://cloudfront.zoro.com/product/large/4YLC9_AS01.JPG Followed by 1 coat (using 2 quarts) in paint can form. I also brushed this product on using a 3' brush. It's very thick and covers well. https://static.summitracing.com/glob...-254864_xl.jpg Sandblasting - I bought a small sandblaster a few years ago and haven't touched it until now. Since some of my previous metal repairs had rusted a little I decided to remove as much with my grinder and abrasive wheel as I could, then sandblast the rest. This thing worked very well, but sand gets EVERYWHERE! From the track of your garage door to the crack of your *** I mean EVERYWHERE! Wear a hood and ling sleeves too. I bought a cheap sandblasting hood a while back that helped. http://img1.r10.io/PIC/27173261/0/1/500/27173261.jpg |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Subscribed!! Followed your rotiserrie build! Nice work bud!! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Thanks. I'd love to see someone build another one. The goal of course is to get the car off the rotisserie and possibly sell it to another member. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Subscribed! Take two! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 5 Attachment(s) Ok Lizard Skin is on. The discoloration is just because I took the pictures as it was still drying. Attachment 335067 Attachment 335068 Attachment 335069 Attachment 335070 Attachment 335071 Good product. Went on easily, covered well, and cleans up with just water. I still need to do the doors with it so I might buy another gallon. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS No progress last weekend. I'll be making my own outer subframe connectors, and emailed Alro for a quote. http://www.alro.com/ BMR said they could sell me the material bare and un-welded, but it wasn't exactly cheap. So I emailed Alro in Melrose Park (I'm in Chicago) for a quote on 24' of 2"x1.24" .120" wall rectangular tubing. Quote was around $150 picked up. Is that fair? Cheap? Expensive? I know it's more than I need but I'll be using some of it to brace in other areas too. I also cut the inner subframe connectors (Alstons) off of the '86 (the first pic in this thread) intending to use them on this build, but now I'm second guessing myself. I planned to connect them to the outers I'm building, but I'm worried they'll become a problem with the car lowered. Also, I'll be using a crossmember mounted torque arm (like the BMR Trac Pak) that mounts a crossmember between outer subframe connectors. I've never seen that crossmember mounted to INNER SFC's......has anyone else? |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Keep it up man looks good! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS
Originally Posted by propaintball96
(Post 5783197)
Keep it up man looks good! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Today I bought 2 12" sections of 2"X1.25" rectangular steel from Alro in Melrose Park. $80 picked up. I'll be building my outer subframe connectors with this. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 8 Attachment(s) Started on the outer SFC's yesterday. Here's what I started with: Attachment 334282 Starting with the passenger side I decided to keep them tucked close to the floor which meant making 2 sections so that the front will line up with the front subframe: Attachment 334283 Attachment 334284 Attachment 334285 They won't hang below the floor which is why I went with outers VS inners: Attachment 334286 Attachment 334287 Drivers side. The drivers side is one solid piece running the length of the rocker. Attachment 334288 Attachment 334289 I still need to make angled mounting points for both side to connect the the front subframe. I'm still not sure If I should make a piece to fit around the control arms, or just weld it as-is. What do you think? |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS How heavy is that steel? I like the potential that those have. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS I haven't weighed anything, but it's the same material that UMI uses for their SFC's. I believe BMR too. I should have gotten a lot more done yesterday, but it was hot and I was feeling lazy. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 7 Attachment(s) Got some more done on the subframe connectors this weekend. Still need to get a trans crossmember bolted up before I make the angle piece that'll weld near it. Attachment 334104 Attachment 334105 Attachment 334106 Attachment 334107 Attachment 334108 Attachment 334109 Attachment 334110 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 6 Attachment(s) I also spent some time making the garage nicer to work in. Since parts for this build are split between the garage and shed, I decided to add shelving to my shed so I could store everything in there. This way I have more room to move around in the garage. From the garage I was able to remove: - 700R4 (great trans and need to sell. Only pulled it for a T56 swap years ago) - 4l60E (picked it up for $50. couldn't pass it up) - T56 (LS1) - Both 91 Formula doors. (got them for $50 at a discount weekend at the local parts yard) - Plastic fuel tank - Heads - radiator/fans Went from this: Attachment 334097 Attachment 334098 To this: Attachment 334099 Attachment 334100 Attachment 334101 Attachment 334102 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 9 Attachment(s) Slight detour. I found a Trans Am part-out local and couldn't resist. I picked up the engine/seats/fuel tank. Then I had to build another engine stand/dolly/cradle. Bought a SBC one off ebay then moved the front mounts back a few inches. Here's the pics: Attachment 333409 Attachment 333410 Attachment 333411 Attachment 333412 Attachment 333413 Attachment 333414 Attachment 333415 Attachment 333416 Attachment 333417 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 11 Attachment(s) |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 6 Attachment(s) Got some work done on the subframe connectors today. Finish welded the passenger side, just need to add one more tube, clean, paint, and weld in. Attachment 333178 Attachment 333179 Attachment 333180 Attachment 333181 I Tig welded this so the bead wouldn't push the tubing away from the cars subframe. First time I've ever Tig welded on a project. Practiced a little before hand, and didn't come out half bad. Attachment 333182 Attachment 333183 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Nice welds! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Thanks. Tig isn't hard either. Just a little practice is all it takes. It's just soldering on a larger scale. I've been putting off adding the last tubes to the crossmembers because I don't have the trans crossmember in place yet. I'm also on the fence about using my inner connectors and connecting them to the outers with tubing. I'm concerned they'll bottom out on a lowered car. However, this car won't be slammed so I'm just not sure yet. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Would you mind posting a close up picture of the Rustoleum Undercoating? I am debating whether to use Rustoleum, EZ Liner, or Al's Truck bed liner for the bottom of my IROC... Thanks! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Sure I'll take one later. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 3 Attachment(s) |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 11 Attachment(s) Ok the subframe connectors are done.....well as done as I can currently make them without the plate steel I need to finish the rear sections. Denny from thirdgenranch hooked me up with a stock transmission crossmember that I used to make sure my design wouldn't hit it. I'll be using the stock crossmember to build my own for my T56. I'll link to that thread whenever I get to making it. Attachment 332920 Attachment 332921 Attachment 332922 Attachment 332923 Attachment 332924 Attachment 332925 Attachment 332926 Attachment 332927 Attachment 332928 Attachment 332929 Attachment 332930 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 7 Attachment(s) Little update. I started sanding on the engine bay to prep for primer/paint, and get rid of some lizard skin over-spray. I've been sanding with 60, 80, and 100 grit. Attachment 332343 Attachment 332344 Attachment 332345 Attachment 332346 Attachment 332347 Attachment 332348 A few areas had small amounts of rust that I couldn't sand off so I used some rust treatment. It did an excellent job. Attachment 332349 The epoxy primer and primer surfacer are almost ready to go on. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 12 Attachment(s) Got a minor update. Since i got a few questions about how I initially got the car onto the rotisserie, I thought I'd document how I got it off. Since winter is here and will snow soon, I decided to take the car off the rotisserie so I could stack cars and park my 4runner in the garage. All of the work that I needed the rotisserie for is done too, so I might as well get it off and move on. I kept everything of course since you never know when I'll want to put the car back on it. First I raised the lift to the level of the car and back it up to the edge of the lift. Attachment 329970 Attachment 329971 Attachment 329972 Then I put my trans jack where the fuel tank goes: Attachment 329973 Attachment 329974 Then I started taking the rotisserie apart and backing the car over the lift Attachment 329975 Attachment 329976 Attachment 329977 Attachment 329978 Attachment 329979 Then lift the car off the ground with the lift Attachment 329980 Attachment 329981 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 2 Attachment(s) |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Very nice job.. I just did just about a complete tear down like this. I like your subframe connectors. I went with jegster bolt in kit and bolted and fully welded them. I did notice that they metal off the back of the connectors that went through the control arm bolt. Might be worth welding a flat piece of metal on the back of each connector so the control bolt goes through your connector. I see you brushed on the bedlinder. I have had good luck using a shultzs gun at higher pressure with that brand. Comes out textured and very even. But yea great build. Only way to do them. You know every bolt of the car and what is done. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Looking good. Make sure if you weld the subframe connectors on while the car is on the rotisserie that there is no body twist in the car. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS
Originally Posted by racerkilla
(Post 5854243)
Very nice job.. I just did just about a complete tear down like this. I like your subframe connectors. I went with jegster bolt in kit and bolted and fully welded them. I did notice that they metal off the back of the connectors that went through the control arm bolt. Might be worth welding a flat piece of metal on the back of each connector so the control bolt goes through your connector. I see you brushed on the bedlinder. I have had good luck using a shultzs gun at higher pressure with that brand. Comes out textured and very even. But yea great build. Only way to do them. You know every bolt of the car and what is done. I was thinking about what position to mount the connectors in, and I think on the rotisserie will be fine considering the car is literally broken down as far as it possibly could be. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Nice work... I cant wait to see how it turns out.. keep us updated |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS look forward to the progress |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS What are you gonna do with the 86's body? And sweet rotisserie! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Coming along great! Good Luck! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS
Originally Posted by Mr.ChevyStroker
(Post 5865834)
What are you gonna do with the 86's body? And sweet rotisserie! I hope to sell the rotisserie once I know I'll never need to put the car on it again. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 6 Attachment(s) Finally got back to work on the car. Bodywork is fully underway now! Right now I'm finished sanding the engine bay, roof and quarters. One dent to pound out in the passengers quarter, and a small area in the drivers wheel well to cut and replace. I decided to sand down the existing paint and not completely strip everything down to bare metal. Too time consuming and not necessary. I'm constantly fighting myself on this car. I just don't know how far to go.....Once I think I'm done sanding somewhere I just keep finding more and more and MORE to do! I need to keep reminding myself that this isn't a show car. It's going to be driven and enjoyed and it doesn't need to be perfect. If I keep trying to make things perfect I'll simply never finish it. Also put the sandblaster to good use: Attachment 326628 Attachment 326629 Somebody previously cut a hole in the drivers battery tray so I finished smoothing it out. Was very jagged before. Attachment 326630 Also pull all the weatherstripping and molding off: Attachment 326631 Attachment 326632 Drivers door striker hole is jacked up so I'll have to pound/weld that back into shape: Attachment 326633 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 2 Attachment(s) So as of now: Fenders, hood, bumpers - coming off of the car in the very first pic of this thread. Doors - Came got off of a '91 Firebird (not pictured yet) from a Victory Auto Wreckers free parts weekend ($50 as much as you can carry) Ground FX - Have a pair from a parts yard that need some work. Not sure if I'll use them or find another set. Paint will go like this: Grey epoxy primer Grey high-build primer White sealer White paint Still not sure about black stripes pr accents.....opinions? Here's where the engine bay is now. Not doing any more sanding on it. Attachment 326626 Attachment 326627 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS SUBSCRIBED! Damn, I wish I had a third gen again! |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 7 Attachment(s) Finally pulled the windshield today. NEVER want to do that again! The tool I bought was garbage so I ended up just smashing it out then coming back with a razor and getting as much old sealant off as I could. Then I used a SUPER aggressive wire wheel on my angle grinder. After all that I'm very happy with the results. No rust, but there were quite a few gnarly places under that windshield sealant in the form of welding slag and sharp metal points near the spot welds. I ground them all down of course. Kinda satisfying. After coming this far I'm not going to puss out now! I'd like to have to do this only once! Attachment 326543 Attachment 326544 Attachment 326545 Attachment 326546 Attachment 326547 Attachment 326548 Attachment 326549 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 9 Attachment(s) Today I sanded the windshield channel since I didn't get to it yesterday. I also finally tore apart the doors (only got to 1 today) that I got from a parts yard years ago. I'm glad I grabbed them because they're about as clean as a midwest car door could get. They came from a '90 or '91 Firebird so I'll have to weld 2 or 3 ground effect mounting holes and eventually drill the correct ones. Since I still need to spray lizard skin on the inside of the doors I decided to gut them. Not very hard at all and since I know what I'm doing now the second door will be very easy. To remove the glass you have to drill/cut 3 rivets. This one: Attachment 326530 And these 2: Attachment 326531 After then the window just pulls out: Attachment 326532 And because I'm pulling the glass I'm sure I'll just replace it. Here's the rest: Attachment 326533 Attachment 326534 Attachment 326535 Attachment 326536 Attachment 326537 Attachment 326538 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS No rust! :thumbsup: |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS
Originally Posted by DynoDave43
(Post 5911253)
No rust! :thumbsup: |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 3 Attachment(s) I finished up some prep on the first door (Passenger) Popped out the spring and took apart the bottom hinge for sandblasting. Attachment 326500 Attachment 326501 Attachment 326502 |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS 2 Attachment(s) |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS The drivers door hasn't been touched yet but I looked it over and appears to be in even better shape than the passenger side. I've also been trying how to adjust my Nikon cameras setting to take better pics. Some seem too dark to me. I also need help..........This has been a one-man project until now. Without some bodywork help it'll simply take too long so and skilled hands feel free to contact me. My goal is to have the car assembled and painted one month from now. |
Re: Project Procrastination '91Z LS1/T56/currie 9" w/PICS Looking good Rob! If you weren't so far away i'd come by and help you with the body. Keep us posted! |
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