I'm getting ready to do the Z06 rear brake duct mod to my 01' vert. I think I've read enough about the job and am confident that I can do this mod myself. However, I thought I would solicit any tips or ideas from those of you who have already done the job to see if there are some ideas floating around out there that may not have made it to print.

This is how I'm planning to go about the job:

Remove the rear wheels and inner fender liner.

I've printed the template and have cut my pattern from a piece of cardboard. I plan to use the same one for both sides.

I am going to tape off the area with painters blue tape and then trace my pattern onto the taped area with a sharpie marker.

Could use some pointers on how to line up the template to ensure it is in the proper place.

I will then drill a starter hole in the area to be removed and then plan to use my jig saw with a fine tooth metal cutting blade to cut the hole. I considered using my Dremel as many here have done. I think I would have more control with the jig saw. Recommendations?

I was planning to use a pair of metal shears to cut the inner fender liner. I have an 01' so the fender liners should have the markings to trim the area for the ducts to fit through. Recommendations?

That's the meat and potatoes of the job, put it all together and life will be good!

 

sounds like you have it covered pretty well

 

I'd say you have! I used a skil saw on the inner fender.

 

if you are really nervous, try using a non power saw with some nice new blades to cut it.
it will be harder, and take longer. but the chances of screwing up is slim to none

 

I agree that slower may be better.

Good Luck

 

I did my 03, A starting hole, then a dremel works great with the carbide cutting bit, then a small drum sander attachment in dremel, (about 1/2 inch in dia), to smooth all out to a nice contour. For aligning the templates, I actually measured the distance from door contour to duct in three or four places from a Z06, and put my template at same location. Your idea of using metal shears is what I used as well, worked nicely. Take your time, measure twice...

 

When I worked at Flowmaster we always used to tell people "measure twice cut once".

I plan on doing this later down the road, so if you could post some pics, I'd appreciate it

 

Thanks for the info. I live by your quote "measure twice, cut once". It's just that I have found sometimes I can misread the tape measure twice, so I've started measuring three sometimes four times to ensure I've got it right. This would definitely be a time to get it right. There are no "do overs" here.

I plan to put some pictures up after the project is done.

You have a beautiful car. I love the Nassau blue. It's on my top five list with the top three all being blue. Thanks

 

Run shop vac with floor attachment pointed up at the work area. You will make a ton of dust.
I did the rotor cutting bit and it worked great. I couldnt imagine using a jigsaw at that angle and making a nice cut while the panel is vibrating.

 

I'll keep that in mind. I read a thread by a CF member who mentioned this idea in his thread. I couldn't believe how much dust was generated during the cutting.

I picked up a bit for my Dremel today. Think I will give the Dremel a try first.

 

it's not a bad job, not too hard, was going to do mine, but stopped by Manny's and he ended up wizzing through it before I knew it:

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

the list you posted on how you're going to do it is exactly correct

 

Out of curiousity, what are the widest wheels you can go with before interfering with the ducting?

 

Anything that will fit a C5 Z06 will fit no problem.... I can't see how these ducts would interfere with any tire size - big fat tires/wheels will rub elsewhere before they ever touched the ducts....

 

Maybe I just have the wrong mental image of how the ducting is routed around the wheel to the braking area. I plan on doing this mod and have 295 tires in the back that I would like to eventually switch to 305s. Just want to make sure nothing rubs

 

Nice...when you do yours be sure and post some pics!