aussieross01

Plan on using a C6 interior but more upmarket with quality leather dash, door trims, plus a smattering of carbon fiber

aussieross01

Decided to run with C6 style interior with this build. It fits with our build plan, and by the time we finish, it should look pretty cool with our goals of using leather and carbon fibre in the finishing process.
We sourced a local RHD fibreglass dash shell, and cut it up to suit the fitment with the widened C3 windshield frame. Chopped off most of the front of it:- of course the C6 windscreen rake is huge when compared to the C3 we are using.
Pic 1 shows the fitting on the bare cut down dash, pic 2 shows the start of the process building with urethane foan. Real easy to shape this foam, and you can fibreglass right over the top.

aussieross01

Yes, lot of hours, sometimes think a man is mad, but I'm retired, love the challenge, and can't think of anything else I'd prefer to be doing. It is also true there are some days, I hate the bloody car.
Good opportunity to spend time with your friends as well.

Certainly not a commercially viable build, and if you paid retail shop rates down here, it's better than $100 per hour. Must concede also, we're pretty darn slow these days.

derekderek

8500 hrs times 100 bucks/hour. Just think how much that car will be worth!!

aussieross01

Hmm! Cost is one thing:- worth is something else entirely. We get it right, perhaps it will be worth a reasonable amount. On the other hand, if we get it wrong, it's worth the sum of the parts.

aussieross01

Dash taking shape.
took a 'quicky' mold from the front edge of a C3 dash pad at base of windshiled, and used that as a reference point to pick up the C6 RHD dash, styled it with foam, then bogged and smoothed to shape.
We will now give it one layer of glass, smooth out, then take a mold from it.

aussieross01

Pic showing metal fabrication for new front:-

1. internal metal front bumper support now a new custom unit
2. Front bumper is a cut and shut original
3. Grille surrounds, thou the same length are now 2" higher
4. Bumper over riders now also 2" taller
5. Grilles now all custom fabricated from flat aluminium bar

While it all looks reasonably stock in configuration, every thing is custom

doorgunner

NICE........very NICE!

aussieross01

Showing custom hood sub structure. Used original C6 rear hood subframe to pick up original rear hood latches. Raised outer front sections to pickup hinges for custom tilt front. This whole front section made from foam, the glassed over, and we use lots of plastic filler in this mock up process. Once completed mold will be taken off, for production of the 5 copies we need. Whole process, quite a 'mission'.

Rear mock up near completion. Originally going to run C3 LED tail lights, but given we widened the rear 9.5", they looked like 'peep holes in the snow'. Very happy with the C6 tail lights. Original 'corvette' script between lights gave way to C6 centre emblem. Original C3 bumpers had some surgery to fit. and mount close to the body. Lower valance modded from a glass copy of the original. Pretty happy with it, almost ready to flop a mold from this

Priya

This is an amazing thread, I'm glad I found it!

Renatopazperu

Awesome thread! Makes me want to go home and start creating something different on my C3. I quickly remember I could never get it to look that good. Great Job!

Rescue Rogers

thanks for the update

naramlee

this is FANTASTIC!!!!

aussieross01

Challenge here is to get front hinge assembly to come immediately up and then forward to clear front valance which stays in place like the C4. First time we are having to use a non corvette part. Scouring the salvage yards we found some hinges from a volvo p70, which so far, look like they will do the job. To make this easier, I just flopped a quicky short front from our mold. Plan on using linear actuators to open the hood. So far so good, will post operation when complete.

munro 2446

Looking good Ross.

aussieross01

9.5" wider, and 4" higher than a stock C3 at the rear. Surprisingly we thought the C6 tail lights looked a heap better than the new LED C3 tail lights I had bought. Modded original C3 bumpers. C6 cross flags emblem used instead of original 'corvette' lettering. C6 inspired license plate surround, as is the lower modded valance with exhaust cut outs, and reversing lamps. Used the 'corvette' logo found on the C6 rear bumper cover

Much surgery needed to get C3 body to work with the C6 frame. Clearly the most obvious thing is the rear wheel arch which had to be pushed back nearly 7". Uses Z06 rear brake ducts, C6 side marker lamps, 'bullits' behind the seats, plus you can see the paring seams of the tilt front. Sill panels still under design/construction stage.

Every square inch of this body has been modified and is hand made. Trying hard to make it look like a chrome bumper C3, but really nothing is the same. The very front is only 2" wider, but it changes quickly and is 7.5" wider at base of windshield. Modded original front bumper. All grilles custom made, the 2" extra in width is found in the centre grille. Side grilles are standard in length but 2" deeper. Modded original C3 pop up lights to be retained. Car is taking shape npw.

emccomas

Reminds me of the guy that put 1961/1962 body panels on a 1990-1995 ZR-1. Nice work guys.

loup68

I just found this thread, otherwise I would have asked this question sooner. I hope that you somehow treated the aluminum frame to the steel C-3 windshield pillers. Otherwise you will
get the steel eating the aluminum. Did you use some kind of a plastic barrier? Lou.

aussieross01

If you look earlier in the thread, you'll see where we boxed and plated the original aluminium 'A' pillar of the C6, We then fabricated a plate, and re enforcing system on the widened C3 metal windscreen frame. Then used a special bonding compound to glue and bolt together, so the glue is a barrier. 9 bolts were used each side for securing. We put them all in just past finger tight, waited for the glue to nearly set, then nipped the bolts down. We had to get this process signed off by our certified engineer.


The metal birdcage was also treated to a 2 pack quality sealing undercoat with superior adhesion qualities, so pretty happy with the process this end. Sent a couple of pics

aussieross01

If you look earlier in the thread, you'll see where we boxed and plated the original aluminium 'A' pillar of the C6, We then fabricated a plate, and re enforcing system on the widened C3 metal windscreen frame. Then used a special bonding compound to glue and bolt together, so the glue is a barrier. 9 bolts were used each side for securing. We put them all in just past finger tight, waited for the glue to nearly set, then nipped the bolts down. We had to get this process signed off by our certified engineer.


The metal birdcage was also treated to a 2 pack quality sealing undercoat with superior adhesion qualities, so pretty happy with the process this end. Sent a couple of pics