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.
Replaced complete exhaust system from manifold to exhaust tips with factory-correct 2 1/2" 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 original-style rubber mounts.
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.
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.
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.
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.
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.
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.
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 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 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.
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.
