Thread revival time!
Now that I have the engine test platform completed:
https://gmtnation.com/forums/threads/ll8-engine-test-platform-project.21715/#post-612919 and have a running, freshened 2006 engine (with 7x crank reluctor and P12 ECM) that can be used to get me started in racing, I will move on to the body preparation and chassis work.
The chassis is nearly complete. In addition to cutting out much of the inner box channel metal and deleting numerous weight adding brackets and features, I have fitted 4;11 gears into a larger differential sourced from the Rainier version, and have stripped out the parking brake mechanisms and trimmed the caliper mounts to an absolute minimum. As mentioned previously in this thread, I have converted to manual brakes and steering.
I have a stock 2008 transmission I could run as is, or I may crack it open and freshen it if needed??? Expenditures are vital: There is no endless pit of money to draw from, so it makes sense to run a stock transmission behind a stock engine, at least to put the car into operation!
The remaining chassis work entails selecting springs and shocks to set the ride height and reaction to power. Those component selections will have to come later, as they will be determined by the measurement of the lightened vehicle weight. Finally, I'll need to figure out a slick new method of attachment/detachment for the hood, grill and outer fenders! That should wrap up the chassis mods.
The body mount assemblies are surprisingly heavy, prolly 10 pounds each! I have eliminated a pair of mounts, back where the rear passenger seat belts coupled to the body. I will seek to lighten the remaining 8 mounts by using polyurethane pucks and lighter hardware.
On to the body mods. I am in the process of carving weight out of the robust GMT360 body.
The 5 doors are currently on the butchers block. I started with the rear doors, as they presented the clearest opportunity to pare them to a minimum. I have gutted them, reverted them to one piece glass, and will screw in 1/8" Lexan into a new mounting surface I welded in that will (hopefully) come out flush with the window framing. I just received the Lexan material and will post pictures of the first rear door when it's completed, if y'all want to see what your car could look like if you decided to carve it out like a pumpkin!
I'll tackle the rear hatch after I complete the rear doors. The hatch is a heavy and complicated structure, with the glass and hatch being independently operable. I'm gonna cut it waaaaay down to just a hatch operation with the same sized glass made immobile. The tools I'm using are an air driven reciprocating saw, metal bender and welder. I'm having some good times!
I'm saving the front doors for last. I want to simplify them as well, but am ambivalent about retaining the power operation and/or converting the glass to plastic. If you have or have seen any clever ideas on making lightweight operable roll up/down windows, please share!
I need to consider a roll cage. The dash (and entire interior) is gutted, so that huge, cast aluminum structure behind the plastic dash is gonzarella. I need a replacement hard structure to support the steering, and some beef to prevent excessive wadding of the body in case of roll over. I do not have a tubing bender, and don't have the coin for a single purpose tool. JEGS offers various weld up kits for other vehicle makes and models that may be suitable for adaptation to the GMT360 platform. They offer a 4 point kit for the GM C series truck of the same year model. I happen to have a 2005 GMC 1/2 ton Sierra that I can use for reference and measuring, so that will be my starting point in the search for a cage kit. I'll let you know what I find.
I will be purchasing a TIG welder for assembling the roll cage, and for the numerous aluminum welding projects that present themselves along the way. I'm looking to purchase a TIG set-up that is mid-priced, say $750 in total. If you guys have any recommendations, please post up.
Thank you for your interest and encouragement as I progress. I look forward to your questions or comments.
Rick