Build quality
Racer
Joined: Feb 2026
Posts: 288
Likes: 245
From: PNW
This seems questionable to me too. Wouldn't that be considered a factory defect and covered by the 3/36?
Melting Slicks
Joined: Apr 2021
Posts: 2,594
Likes: 2,651
From: Texas
As someone who has OCD (about certain things, not everything) I am torn by this post because I generally agree with the comments that perfection is not a realistic expectation with a mass produced GM vehicle, however, the OP can do whatever he wants. I spent $4000 on an aftermarket exhaust system for my Z06 because the interior exhaust did not align perfectly with the fake exterior exhaust tips (I consider them fake since they aren't connected directly to the exhaust, but that's just me). It was a small thing, something nobody would notice unless they bent down and stared at it, but it bothered me enough to put a new exhaust in (AWE Switchpath). Rational? No, of course not, but like I said I have OCD so I did it. Funny enough, it took a bit of playing with the AWE tips to get them perfectly aligned with the exterior rear panel. To each their own.
Racer
Joined: Jan 2026
Posts: 438
Likes: 322
I've had 6 C8s and they're all bad... GM owns this price point and you have to pay double for a Porsche to get it any better or almost double for a Mercedes with nowhere near the performance.
I'm very picky, but I've come to terms that I have to ignore it if I'm going to own one.
I'm very picky, but I've come to terms that I have to ignore it if I'm going to own one.
Pro
Joined: Feb 2018
Posts: 611
Likes: 415
From: Texas
I've had 6 C8s and they're all bad... GM owns this price point and you have to pay double for a Porsche to get it any better or almost double for a Mercedes with nowhere near the performance.
I'm very picky, but I've come to terms that I have to ignore it if I'm going to own one.
I'm very picky, but I've come to terms that I have to ignore it if I'm going to own one.
Racer
Joined: Jan 2026
Posts: 438
Likes: 322
Anyone who says they have excellent panel gaps/assembly doesn't know how to look at a car. OP's concern is how these cars are... even $200K ZR1s have door beak alignment issues.
Pro
Joined: Feb 2018
Posts: 611
Likes: 415
From: Texas
Pro
Joined: Apr 2019
Posts: 698
Likes: 421
From: Armonk, NY
How have you made it this far in life?
I GUARANTEE the person who bought your "rejected" E-Ray is enjoying every moment of driving it instead of spending time worrying about panels being a mm off.
I remember when the GT350R came out and all the "serious" waxers complained about panel gaps😂, meanwhile the people who actually bought them to DRIVE were too busy enjoying...you know DRIVING them as opposed to worry about panels being gaps.
I am far more OCD than 99% of the population but if you'll drive yourself crazy looking for the perfect car. Mass produced cars are just that. As soon as you actually use a powerful car on the street or track, pebbles and road debris are going to start making a mess of things anyway--PPF or not.
The thing about perfection is it never ends. As soon as the panel gaps are perfect you might latch on to a squeak or start concentrating on interior panel misalignment. The rabbit hole is deep and never ending. Corvettes appeal is that it gives you performance unmatched for the money, if you are looking for higher standards--spend $100K more and get a Porsche--I bet you it won't be as fun though.
I GUARANTEE the person who bought your "rejected" E-Ray is enjoying every moment of driving it instead of spending time worrying about panels being a mm off.
I remember when the GT350R came out and all the "serious" waxers complained about panel gaps😂, meanwhile the people who actually bought them to DRIVE were too busy enjoying...you know DRIVING them as opposed to worry about panels being gaps.
I am far more OCD than 99% of the population but if you'll drive yourself crazy looking for the perfect car. Mass produced cars are just that. As soon as you actually use a powerful car on the street or track, pebbles and road debris are going to start making a mess of things anyway--PPF or not.
The thing about perfection is it never ends. As soon as the panel gaps are perfect you might latch on to a squeak or start concentrating on interior panel misalignment. The rabbit hole is deep and never ending. Corvettes appeal is that it gives you performance unmatched for the money, if you are looking for higher standards--spend $100K more and get a Porsche--I bet you it won't be as fun though.
Thread Starter
Pro
Joined: Oct 2013
Posts: 648
Likes: 355
For $136000 panels should align and drivers door should not crunch when opened because it is aligned incorrectly. And dealer PDI should fix these. It isn't OCD.
If more buyers rejected poorly made cars I guarantee the build would become better.
If more buyers rejected poorly made cars I guarantee the build would become better.
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Racer
Joined: Feb 2026
Posts: 288
Likes: 245
From: PNW
If buyers rejected buying homes in any areas that have floods, earthquakes, fires, hurricanes, tornadoes, rock slides, trees, etc. insurance prices would be lower. My point is it’s never gonna happen because most people accept imperfection. You do you, but as a recovered perfectionist I can report that life is a lot happier and enjoyable when I’m not fixated on the small stuff.
Advanced
Joined: Jun 2006
Posts: 55
Likes: 60
Its not a $136,000 car, its a 70k car with a lot of options running it up to 136k. Strange that the dealer didn't try to please you though. Mine had the bumpers and roof a little off. I didn't ask the dealer to fix it cause I learned long ago that they will likely make it worse. You did the right thing to reject it. I would move on to another brand cause if you order another one it will likely be the same.
Instructor
Joined: Nov 2022
Posts: 115
Likes: 79
The Red car is not that bad and if it's the worst example on that car and it bugged me enough, I would just fix it myself. The Green car definitely needs some adjustments, and a warranty repair order should to be created so the dealer can make the correct repairs.
5th Gear
Joined: May 2026
Posts: 5
Likes: 2
From: S. Florida
If buyers rejected buying homes in any areas that have floods, earthquakes, fires, hurricanes, tornadoes, rock slides, trees, etc. insurance prices would be lower. My point is it’s never gonna happen because most people accept imperfection. You do you, but as a recovered perfectionist I can report that life is a lot happier and enjoyable when I’m not fixated on the small stuff.
Last edited by BGT3; May 12, 2026 at 03:27 PM.
Le Mans Master
Joined: Nov 2001
Posts: 6,904
Likes: 205
From: Kern County CA
Isn't "hand built" also a hit or miss, depending on that particular assembler?
Don't humans have more variations than robots?
I have no dog in this "fight", just curious, because I don't believe that just because a car is "hand built" makes it automatically "better" than a robot-assembled car.
Burning Brakes
Joined: May 2025
Posts: 796
Likes: 601
From: Bucks County, PA
The Red car is not that bad and if it's the worst example on that car and it bugged me enough, I would just fix it myself. The Green car definitely needs some adjustments, and a warranty repair order should to be created so the dealer can make the correct repairs.
Racer
Joined: Apr 2018
Posts: 469
Likes: 215
Agree with others this is a 80k car with options or performance models. You’re paying for the additional performance not quality.
it’s hard to tell how bad those pictures are becuase they are close. I would be curious if you took a picture for 5 feet away if they would even be noticeable.
it’s hard to tell how bad those pictures are becuase they are close. I would be curious if you took a picture for 5 feet away if they would even be noticeable.
Instructor
Joined: Apr 2017
Posts: 249
Likes: 194
That green car is badly misaligned. That shouldn't have gotten past quality control. It makes one wonder what the standards are in the factory and how gaps and panel alignment are examined? If anyone from the factory can chime in, I'd love to hear more about the process of panel alignment and quality control.
My '24 C8 HTC Z51 3LT has close to perfect gaps and alignment, and it was a clear step up from my '16 C7 3LT, where alignment on the hood, for example, was clearly off-- the gaps on each side between the hood and the fenders were of different widths. Not so on the C8. The frunk and beaks are perfectly aligned, as is the trunk. When I saw it, I was very pleased, but this should be the standard on all the C8s. How widespread (no pun intended) is this problem of gap/misalignment?
I would think dealers would fix this during PDI, but apparently not.
My '24 C8 HTC Z51 3LT has close to perfect gaps and alignment, and it was a clear step up from my '16 C7 3LT, where alignment on the hood, for example, was clearly off-- the gaps on each side between the hood and the fenders were of different widths. Not so on the C8. The frunk and beaks are perfectly aligned, as is the trunk. When I saw it, I was very pleased, but this should be the standard on all the C8s. How widespread (no pun intended) is this problem of gap/misalignment?
I would think dealers would fix this during PDI, but apparently not.
Last edited by PDXC7; May 16, 2026 at 01:03 PM.
Instructor
Joined: Nov 2022
Posts: 115
Likes: 79
Panel alignment repair is not part of the PDI process. Instead, what the tech is supposed to do is make a note of it, and then a warranty ticket is created for a panel alignment concern. Then the dealer gets paid to address the problem, additionally GM see's that there is a warranty claim on that VIN and then becomes aware if there is an assembly line quality control concern.
Racer
Joined: Jan 2026
Posts: 438
Likes: 322
Panel alignment repair is not part of the PDI process. Instead, what the tech is supposed to do is make a note of it, and then a warranty ticket is created for a panel alignment concern. Then the dealer gets paid to address the problem, additionally GM see's that there is a warranty claim on that VIN and then becomes aware if there is an assembly line quality control concern.