Maintenance Diary

SR Performance replaced left-hand side front hub with new part sourced from USA. Repacked wheel bearings on both front wheels.

Installed new spark plug heat shields. Reinstalled v-shields for plug wires (1-3 and 2-4) with wire running through the engine mounts (as they did from the factory). Installed plug wire clips (using sump bolts) on both sides of engine.

Removed spare wheel tub, stripped paint from fiberglass and repainted metal frame (satin black) leaving silver rivets exposed.

Replaced complete exhaust system from manifold to exhaust tips with factory-correct 2½ inch Magnaflow system from Corvette Central. All mounting hardware was also replaced.

Renewed all suspension bushes in the rear of the car (every single one, no exceptions — even the trailing arms). Removed urethane engine, gearbox and diff mounts and replaced with quality, original-style rubber mounts.

SR Performance installed a diff drain plug in the diff housing. A flush-fitting hex-keyed plug was used to give a factory appearance.

Removed bellhousing, gearbox and driveshaft. Machined flywheel. Fitted Exidy clutch kit (clutch, pressure plate, throw-out bearing). Fitted shifter linkage rebuild kit and adjusted shifter. Fitted new transmission tunnel insulation (factory correct fiberglass). Fitted new universal joints to driveshaft. Fitted new (rubber) gearbox mount.

Removed spare wheel tub, rear suspension, diff and sub-frame. Repaired cracked welds on sub-frame mount brackets (both sides) including adding gussets for strength. Media-blast sub frame and powder coat (satin black). Clean and paint chassis, clean fiberglass. Rebuild diff with new bearings, seals and clutches. Add drain plug to diff housing, clean and repaint (cast grey). Fit new universal joints to drive shaft and both half shafts. Install new rubber bushings (strut rods, trailing arms, diff cushion, sub frame cushions, sway bar ends). Clean and paint sway bar (cast grey). Reinstall everything.

Removed rear blower motor and repainted blower housing and fan. Cleaned all the switches and electrical contacts and resealed the plastic ducting with a foam seal. Replaced radio antenna cable with correct cable. Replaced the antenna/wiring harness grommet (which was missing).

Removed rear blower motor carpet cover. Cardboard backing was brittle and broken in the middle. Made a new backing board using 3mm PVC foam board and reused the original metal eyelets to reinforce the mounting holes. Glued carpet to new board using 3M High Tack spray adhesive. Original wire mesh screen at rear of blower motor cover was missing, made a new one using zinc-plated wire mesh.

Measured diff ratio at S R Performance. Ratio confirmed as 4.11:1

Chassis dyno tuned at S R Performance. Confirmed air/fuel ratio correct throughout rev range.

Both headlights not opening. Removed right side headlight motor (suspected it was jammed). With right motor out, left motor works perfectly. Disassembled right motor and cleaned all parts. Tested armature with multi-meter (all OK). Cleaned armature and sanded contacts with 2000 grit. Greased gears, re-assembled and installed. Tested, motors now work correctly but right side still not closing completely. New drive gear required.

Upgraded PerTronix ignition module from original Ignitor to the latest Ignitor 3. Fitted matching Flame Thrower 3 45,000 volt coil.

S R Performance relocate tie-rods to rear hole on steering knuckles, grease all front end components and carry out wheel alignment. Steering improved significantly.

S R Performance fitted Wilwood D8-4 front caliper kit with DBA discs. 4mm spacer fitted to provide wheel clearance. New dust shields, dust caps and braided stainless lines fitted. New left side stainless brake line fitted. Bearings repacked. Old calipers and dust shields cleaned and stored.

Removed front sway bar, stripped to bare metal and repainted in Eastwood Steel Grey. Repainted brackets with Eastwood Chassis Black. Refitted with new rubber bushings (15/16") and new fasteners. Replaced end links with new links and rubbers.

Fitted new Mastercraft White Sidewall tyres. 205/75R15s on the front and 215/75R15s on the rear. Tyres are filled with Nitrogen to prevent leakage.

Heat Riser Valve removed and replaced with spacer (as used on FI cars).

Rebuilt engine reinstalled in the car.

Undertook complete restoration of engine bay.

Steering box reconditioned. New bearings and seals fitted, shaft machined and sleeved. Filled with correct grease (not oil). Relay rod rebuild kit fitted when steering box reinstalled.

Engine wiring loom replaced with new, reproduction loom made by Lectric Limited in the USA. Lectric loom is 100% exact match for original.

Engine rebuild completed.

Intake manifold vapour blasted by Sydney Vapour Blasting.

Cylinder 1 and 3 plugs oiling up and engine dropping cylinders. Engine idle very high (vacuum leak) and breathing very heavily (oil on intake manifold). Mastertouch remove left head and diagnose oil ring failure and possible valve issues. Decision taken to remove engine and rebuild. Engine disassembled and sent for machining.

One new, 'GM quality' valve cover hand finished, casting flaw removed. New cover and remaining original cover vapour blasted by Sydney Vapour Blasting. New 350 Horsepower decals applied.

Removed Delco radio. Thoroughly cleaned console area. Had radio checked and cleaned by SH Electronics. Reinstalled and tested (sounds great).

Removed fuel pump. Installed new 40083-style pump (correct style for 65 350hp engine). New fittings and stainless pump to filter line fitted.

Removed and disassembled Delco Remy 10DN alternator. Sent cases for vapour blasting, cleaned and painted stator, installed rebuild kit (bearings, diodes, posts). Repainted fan with Eastwood Clear Zinc. Polished pulley. Reassembled and tested.

Removed exhaust manifolds and sent out for ceramic coating (satin black). Finished result looks perfect.

Removed and wire-brushed cast iron exhaust manifolds. Repainted with Bill Hirsch Cast Iron Gray High Temp paint. After curing, refitted manifolds with new exhaust gaskets and road tested. Paint burnt off immediately, a total failure.

Repainted red-white-blue bands on wheel center caps. Bands are now correctly mirrored side-to-side.

Upgraded instrument cluster lighting using LED bulbs in 4 of the 9 globes.

Replaced power antenna with new, concours-correct antenna from Zip Corvette. Original antenna worked, but would fall apart when extended.

Replaced torn clutch rod boot with new part from Corvette Central.

Exterior paint work and chrome cleaned, clay blocked and polished by Complete Car Protection.

Replaced firewall grommet for speedo and tacho cables.

Replaced shifter boot (which was torn) with new boot from Zip Corvette. Added a layer of wool insulation under boot to reduce heat/noise in cabin. Replaced foam in armrest cushion.

Carpet replaced by Paul Nelson, the Corvette's first owner in Australia.

Tweaked the exhaust on the left side to create more clearance where it runs through the gearbox crossmember

After replacing the fuel pump, SR Performance ran the car on their dyno to check air/fuel ratio.

SR Performance installed new 40083-style pump (correct style for 65 350hp engine). Previous pump had torn diaphragm.

Replaced headlight bucket roll switch.

SR Performance install new steering box seals to solve leaking problem

Replacement Rear Blower Vent Cable from Zip Corvette broke the second time it was used. A replacement was supplied by Zip at no cost.

Cleaned white wall tyres using Steelo Stainless Steel Soap Pads

Fitted new Radio Antenna Cable

Replaced broken Rear Blower Vent Cable with new cable purchased from Zip Corvette

Set the Pertronix Ignitor Digital Rev-limit to 5000rpm

Fitted new drive gear to right-hand side headlight motor. Headlight now works 100% correctly, both headlights open and close in perfect sync.