Revision Corvette ZR-1 model year 1990 #125

[Thomas ZR-1]

I purchased the ZR-1 in Los Angeles from the previous owner (former member of this forum) in December 2018. The car only had 52000 miles on the odometer and was in quite a good and original condition. Carfax showed a little damage to the left hand side at the rear (no big thing...comments on this later). All the necessary documents such as the original dealer contract (09/22/1989) and the well-known ?pizza box? came with the car. After finishing the restoration the ZR-1 passed the regular technical and historical check at the German T?V for the official registration in Germany.

With more than 20 years experience with Corvettes C4 and ZR-1 I did all the restoration by myself. Only the paintwork, the saddler job and the total overhauling of the original rims were performed by expert companies.


Index:
1. Initial condition
2. Disassembling
3. Paintwork
4. Overhauling suspension, steering and brake system
5. Exhaust system
6. Saddler job
7. Overhauling BOSE sound system
8. Wheel rim restoration
9. Installation of axles, suspension, brakes and steering
10. Body and interior assembling
11. Assembling engine compartment
12. Engine rebuild
13. Installation powertrain
14. Wheel alignment, test drive, technical check and car dyno
15. Operating liquids

[Thomas ZR-1]

1. Initial condition

First some pics showing the car?s original condition on the arrival at my workshop.

[Thomas ZR-1]

The condition wasn?t bad for a 30 year old vehicle but not really important for my intention. The engine and the car ran smoothly and was in good condition, no parts were missing inside and outside the car. Only the California sun had worked hard on the paint and the weather strips over the years.

In preparation for the planned frame-off restoration everything had to be dismantled because the body would be sprayed in the original black color. At the end of the project the Corvette should be rebuilt almost to factory condition such as on the day of delivery plus some small and useful timely modifications.

[Thomas ZR-1]

2. Disassembling

First of all the engine and the complete powertrain had to be removed from the car, 30 years of dirt came out to the daylight.

[Thomas ZR-1]

The transmission tunnel was prepared and cleaned up for later on. Special heat protection foil should reduce the heating of the interior.

[Thomas ZR-1]

Body and interior were dismantled as well. The body painter should have all the parts delivered in raw condition. There should be no washer or nut left installed.

[Thomas ZR-1]

Much work...

[Thomas ZR-1]

Raw material:

[A26B]

Great work Thomas! You now have a beautiful, frame-on restored ZR-1, and the satisfaction of having done it all yourself. Well done! Congratulations!!

[Thomas ZR-1]

Thank you Jerry...I prepared a restoration report for the forum with lots of details...next steps will follow tomorrow...

[Prez1967]

Looks like a ton of fun! Looking forward to seeing the rest of your progress!

[Ccmano]

Nice work! I personally find a lot of satisfaction in doing the work myself. I've told people I probably enjoy working on it as much as driving it. One those (my case) Swabian traits. Enjoy driving it! Well done....
Hans
:cheers:

[richarde]

Great work Thomas - Hopefully, we'll be able to meet up at the Valkenburg 'vette show in 2021!


Sent from my iPad using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[conesare2seconds]

Nice work!

[Thomas ZR-1]

Thanx to all for the nice comments and yes Richard let`s hope for Valkenburg 2021...

[Thomas ZR-1]

3. Paintwork

This is the ZR-1 being transported to the body painter for the next 3 months?enough time for the preparation of the other parts.

[Thomas ZR-1]

The body painter could start immediately with the dismantled and cleaned parts. The small amount of damage to the rear (former listed at Carfax) was reworked too (no big issues). Finally the Corvette was sprayed in the original 1990 black Chevrolet color. The ugly gray body moldings and the hood scoop were sprayed in the Corvette C7 carbon black.

[Thomas ZR-1]

The carbon black scoop strip is lightly viewable in the daylight.

[Thomas ZR-1]

After the Spray job was finished the ZR-1 came back to my workshop with all the other parts carefully packed.

[Thomas ZR-1]

4. Overhauling suspension, steering and brake system

The Corvette went to the painter`s shop on a set of ?moving axles? so there was enough time to prepare a lot of parts for installing later with new PU bushings and ball joints. The cardan shaft and drive shafts received new u-joints and the cardan shaft was fine-balanced at ELBE Company in Cologne.

[Thomas ZR-1]

All forged aluminum suspension parts plus the rear axle carrier were thoroughly cleaned and rebuilt with PU bushings and ball joints. The following pics show the front lower control arms as an example.

[Thomas ZR-1]

Next the steering rack waited to be overhauled with new seals and checked on my test bench when I had finished the job.

[Thomas ZR-1]

The front and rear calipers came next. After disassembling, cleaning and painting black they were fitted with new seals and new brake pads. Later on the front discs came new, the ?old? rear discs (in good condition) were installed back into the car.

[Thomas ZR-1]

5. Exhaust system

I didn`t want to install the 30 year old exhaust system back into the car because I had a brand new original ZR-1 exhaust system in stock which I purchased 15 year ago when GM canceled the German main storage in Cologne. The system was for the 93-95 model so I had to adapt the couplers to the 90-92 exhaust gas manifolds flanges.

[Thomas ZR-1]

6. Saddler job

For the tagra roof a new headliner was prepared and covered with black Alcatara leather (same as the sun visors). The shift knob and the steering wheel got upholstered with smooth black leather.

[JThomas]

Keep up the great work. That is going to be an awesome car when completed! Keep the pictures coming. :thumbsup:

[BlueDevlC7z]

Wow, did I enjoy reading this post. What an amazing job so far. What meticulous detail to get it right. 5 stars all around. I'll be looking forward how this progresses. Glad to see the legend lives on the other side of the pond. Great job Thomas!!

Bill

[Thomas ZR-1]

7. Overhauling BOSE sound system

Meanwhile the four amplifiers from the speakers were overhauled. Over the years the capacitors on the boards lose their charge. The speaker turns down the sound and at the end there is only silence. The old capacitors were removed and the boards were cleaned up. New capacitors were soldered into the boards. Later the illumination of the head unit was checked to renew defective bulbs. In 2016 the previous owner of the car sent the head unit to a special company for a total overhauling so radio, CD and tape run perfectly.

[Thomas ZR-1]

8. Wheel rim restoration

When the tires were removed the four rims didn`t look very nice after cleaning. There was no damage or corrosion to see on the surface but the worn look wouldn`t be suitable for a newly sprayed car. The runout check showed hidden problems. This might be normal after 30 year in use.

[Thomas ZR-1]

A special company in M?nchengladbach removed the old paint from the rims and eliminated the runout problems. Afterwards the rims were completely power coated in a silver color. Next step was regrinding the inner rims surface and polishing of the rim wells. At the end all rims were finished in a powder coating in a clear color.

[Thomas ZR-1]

After tire fitting I realized they did a great job with the rims restoration. Only some little balance weights were required for the wheel balancing.

[Thomas ZR-1]

9. Installation of axles, suspension, brakes and steering

I installed temporary axles in the Corvette to keep the car rolling for the painter`s shop. Back in my workshop I could start assembling the car.

[Thomas ZR-1]

After cleaning up the engine compartment the axles were fitted including four new wheel bearings and hubs with new shock absorbers in the rear. The two front shock absorbers were overhauled by the manufacturer Bilstein. The transmission tunnel was covered with heat protection foil.

[Thomas ZR-1]

...and the front axle:

[Thomas ZR-1]

Instead of the original rubber brake hoses I installed black coated, stainless steel covered Teflon brake hoses and a new master cylinder on top.

[Thomas ZR-1]

The renewed steering rack was fitted into the car with new tie rod and ball joints

[Thomas ZR-1]

10. Body and interior assembling

When I started with the body the impact absorber bars and the bumpers were fitted in front and rear. The bare doors were fitted to the frame.

[Thomas ZR-1]

The old sun worn dashboard was changed into a nice looking different one and I also changed the leaky old heater core and replaced it with a new one.

[Thomas ZR-1]

After that the rear bumper was completely fitted including a new radio antenna.

[Thomas ZR-1]

The luggage department got covered with new noise-insulating material and was finished with the before cleaned carpet and the overhauled rear speaker units. The assembled rear hatch window was fitted as well.

[Thomas ZR-1]

New weather strips around the windshield and targa pillar were fitted together with the cover parts, the new Alcantara leather sun visors and rearview mirror.

[Thomas ZR-1]

Next the console with covers and the cleaned up carpets were fitted.

[Thomas ZR-1]

After that came the electrical seat consoles, safety belts, door sill trim plates and the center console storage cover.

[Thomas ZR-1]

At the end the reworked leather seats and renewed steering wheel were fitted back into the interior.

[Thomas ZR-1]

The targa roof was fitted with the new headliner and new weather strips, the spare wheel was fitted with a new tire in the required size T 155/70 R17 110M from Continental.

[Thomas ZR-1]

For the door, I fitted the door handles and the rearview mirrors were also fitted.

[Thomas ZR-1]

Both doors were assembled with new window seals and weather strips. After fitting the mirrors and door handles the wiring harness, the power door locks and the power windows went back in. Finally the cleaned door panels completed the door installation.

[Thomas ZR-1]

Now, for how the interior was finished.

[Z51JEFF]

Excellent restoration,nice to see one taken down to the bare shell and made new.

[-=Jeff=-]

nice.. Love the detailed info and pictures

[Thomas ZR-1]

Thank you guys...here are the next steps:

[Thomas ZR-1]

11. Assembling engine compartment

After cleaning all the engine periphery, the parts could be refitted. All wiring harnesses were cleaned up and all damaged electrical plugs were replaced.

[Thomas ZR-1]

...and some more:

[Thomas ZR-1]

Finally the large hood with new headlights and overhauled torque motors went back to cover the compartment.

[Thomas ZR-1]

12. Engine rebuild

Now it was time for the heart of the beast: the LT5 engine. As I told you I did the test drive with the ZR-1 before the project started. The engine ran pretty well but was in an ugly leaky condition?remember the basics:

[Thomas ZR-1]

The engine was developed at the LOTUS Company in Great Britain for the Corvette ZR-1. There was nothing in common with the standard C4 Corvette engines until the firing order (1-8-4-3-6-5-7-2) and the transmission flange. One of the main features is the four overhead camshafts. They drive the 32 valves via bucket tappets. The complex is driven by one primary and two secondary DUPLEX drive chains. The valve train is resistant until 8000 RPM. This construction is unique in the whole Corvette history until today. The camshaft timing is quite time-consuming and should be done very precisely to have the engine running smooth and powerful later on.

The engine was disassembled until it`s last screw and washer and all parts were cleaned up very well. At the fitting all seals and gaskets were new, the starter got new contacts, the alternator new carbo brushes and bearings, the belt tensioner a new main spring with base plate and new pulley. As a precaution I renewed both fuel pumps in the gas tank including the fuel filter.

Before fitting the engine some inner engine components had to be checked. I measured out the main and rod bearing sizes at the crankshaft. All diameters were good and got polished at the end. The NIKASIL coated cylinder liners and the pistons with piston rings (ring gaps) were checked as well, result: all sizes in perfect condition.

[Thomas ZR-1]

Next I started with the cylinder heads. All valve seats in the heads and on the valves were ground.

[Thomas ZR-1]

Unfortunately the 1990 LT5 engines don?t have valve stem seals on the exhaust side (only the old-school O-rings). This changed with the 1991 model to reduce the engine`s oil consumption. So we ground a fitting seat on every upper exhaust valve stem guide.

[Thomas ZR-1]

Of course both cylinder head sealing surfaces got ground as well to have perfectly tight cylinder head gaskets later on.

[Thomas ZR-1]

At the end the heads were fitted with 32 new valve stem seals and two new actuators for the eight secondary port throttle flaps.

[Thomas ZR-1]

As usual the assembling started with the empty crank case on the engine stand.

[Thomas ZR-1]

Crankshaft, base frame and the new main bearings were ready for the installation.

[Thomas ZR-1]

...and installed:

[Thomas ZR-1]

The eight pistons with rods and a set of new rod bearings followed.

[Thomas ZR-1]

Following that the oil pan unit and the engine mounts were fitted next.

[Thomas ZR-1]

Next followed the oil pump installation including new O-rings.

[Thomas ZR-1]

An important detail of the LT5 is the chain guide drive facings. They had worn out a lot during the past 30 years (and they love to break away sometimes). All the facings were not so bad at all but were fitted in new regardless. The reused chains were only stretched minimal (normally they are good for 150 miles).

[Thomas ZR-1]

Now the cylinder heads could be installed. The cylinder head bolts (in size M14x1.5) were used again (final torque specification: 160 Nm).

[Thomas ZR-1]

Next the 4 camshafts and the bucket tappets were installed.

[Thomas ZR-1]

Special measuring tools were installed for the camshaft timing.

[Thomas ZR-1]

Therefore the cam lobes maximum lift was timed to: intake 114? after TDC, exhaust 110? bevor TDC.

[Thomas ZR-1]

Now the valve covers, the engine front cover, the new water pump, the oil filter adapter with new sensors and the injector housings could be fitted.

[Thomas ZR-1]

At the beginning I told you that the car and the engine would be rebuild in absolutely OEM condition. But the intake system consisting of the injector housings and the plenum could not stay original. The design of the intake ducts is really unfavorably for the flow (especially the area where the fuel injectors ends in the ducts). Partially nearly 50% of the sectional area is covered. This throttles at higher RPM, the engines cylinder charging could be better. So much engine power gets lost. So I did my standard porting for the LT5. All reductions were removed and the channel diameters got enlarged a little bit.

[Thomas ZR-1]

The belt drive could be completed with a new alternator, AC compressor, steering pump and overhauled belt tensioner.

[Thomas ZR-1]

The fuel rail was assembled with new stainless steel injectors (ACCEL 150821).

[Thomas ZR-1]

The plenum was completed with the throttle body and the air horn.

[Thomas ZR-1]

Rebuild finished: assembled LT5 on the engine stand.

[DRM500RUBYZR-1]

Incredibly beautiful work!!!

The restoration of ZR-1's will continue to pick up speed.
The lines are blurring between the cost of a no/low mile original and the cost to return a used one back to as built day one quality.

Others have done it here, and this is just another example and a superb one at that.

Congratulations!

Very well done!

:cheers:
Marty

[tgonyaw]

Very nice!
Top notch treatment for a top notch car!

[Z51JEFF]

I have a new GM part, not sure what it's called maybe the baffle that goes under the radiator your welcome to it free,you pay shipping. This offer is only for this project. I bought this for an 84 years ago it should be the same for 90.

[Thomas ZR-1]

Thank you for the offer but I`m not sure what you are talking about...can you post a picture of that item?

[Thomas ZR-1]

13. Installation powertrain

Before the engine could be fitted back into the car the transmission tunnel was covered with heat protection foil to reduce the temperature level inside the car caused by the exhaust gas system.

[Thomas ZR-1]

The assembled engine was pre-lubricated with engine oil by the oil pressure sensor hole with an electric pump.

[Thomas ZR-1]

After 6 months the engine was finally back where it belonged.

[Thomas ZR-1]

Flywheel, clutch with a new disc, a new clutch bearing and the bell housing with a new slave cylinder were installed.

[Thomas ZR-1]

The old connecting pipe between the clutch master and slave cylinder was replaced with a new stainless steel covered Teflon hose. The slave cylinder bleeder was exchanged for a further stainless steel covered Teflon hose ending at the hood lock on the driver side for an easier fluid change.

[Thomas ZR-1]

The 6-speed transmission with cardan shaft and transaxle C-beam followed.

[Thomas ZR-1]

Wiring harness, diverse pipes and hoses were connected.

[Thomas ZR-1]

The OEM exhaust gas manifolds and catalytic converters were installed.

[Thomas ZR-1]

The engine was covered with the plenum.

[Thomas ZR-1]

The radiators for cooling water and engine oil were fitted back into the shroud housing as well as the AC condenser.

[Thomas ZR-1]

The cooling water system was connected with a new set of black silicone hoses.

At the end the air filter case was equipped with a new K&N filter element and the AC pipe system was installed with adapters for the modern R134a refrigerant. A custom calibration chip from Marc Haibeck (Haibeck Automotive) for an OEM engine was installed into the engine control module to make the engine run perfectly and smoothly.

[Thomas ZR-1]

What a shame, nobody cares...regardless: the story goes on....

[Thomas ZR-1]

14. Wheel alignment, test drive, technical check and car dyno

The engine installation was followed by the wheel alignment to adjust the overhauled front and rear axle. The following data was adjusted:

Front axle: Caster angle 4??6?
Camber angle -0.15??-0.25-?
Toe angle 0.15?
Rear axle: Camber angle -0.5?
Toe angle 0.15?

The following under car view was without complaint.

[Thomas ZR-1]

With the new and adjusted suspension I did a 1000 km test drive on the German Autobahn (Highway) to find and solve possible hidden problems and mistakes?but there was nothing. The engine was run in (new bearings) at once. The 1000 km were divided in 3 thirds while driving 2000, 2500 and 3000 RPM engine speed. At the end I changed the oil to have the engine full load qualified. This check was successful as well.

[Thomas ZR-1]

After the test drive it was time for the official technical check at the German T?V. The ZR-1 passed the required tests including the special check for getting registered as a classic vehicle in Germany.

Based on the porting of the injector housings and the plenum the engine seemed to be really powerful. So I checked the engine power on a car dyno in Cologne with 406.5 PS (401 HP) as result. This was over 25 PS (24.7 HP) more than stock. It?s justified on the better air flow into the engine by the ported intake.

[Thomas ZR-1]

15. Operating liquids

Engine oil: Mobil Delvac MX 15W40 9,0L (incl. filter PF 970C)
Transmission oil: Castrol Edge 10W60 2,1L
Differential: Castrol Limited Slip 75W140 1,25L
Power steering: AC-Delco 105074 0,7L
Air conditioning: R134a 820g refrigerant + 20g comp. oil
Brake fluid: ATE DOT 3 0,7L
Clutch fluid: ATE DOT 3 0,15L
Anti-freeze coolant: C11 14L (incl. 50% water)

[Thomas ZR-1]

That`s all folks! 1000 hours of work in 10 month and much money for a brand new car.

[dredgeguy]

Thomas you have done an incredible job bringing your Z back to like new condition. Congratulations! One day we should get a group over to Germany and drive the Autobahn all together...on my bucket list but that is for another thread. Thanks for sharing.

[DRM500RUBYZR-1]

What a shame, nobody cares...regardless: the story goes on....

Thomas,
While it may seem like nobody cares, I doubt this to be the case.

Heretofore, the majority of "restorative efforts, concerned hoses, radios, starters, wheels, exhausts and paint correction.
While there are a number of examples of those who do a "deep-dive" into mechanical upgrades, improvements, repairs, and full blown restorations, they are comparatively few.

This not only holds true for ZR-1's, but C-4's in general.

Using Corvette Forum as an example, If you review the C1, C2 and even the C-3 sections, you will find the bulk of the posts lean towards restoration.
Many of these cars have gone beyond simple repairs and upgrades and now focus more and more on restoration.

You can still find, and always will find, low mileage survivor cars from 53-82. Their numbers dwindle however, and the economics of bringing well-used one back to day one condition are breakeven to favorable.

As C-4's age, and with ZR-1's as a subset, this evolution will likely continue and also continue to grow. The economics have not supported restoration but that is changing slowly as well.

You, and a handful or two of those before you, mostly on this Registry, are essentially the pioneers of these all out restorative efforts with ZR-1's.

Your efforts and results are outstanding!
As an example, I too likely have 1000 hours invested in my ZR-1.
The difference being my 1000 hours consisted mostly of cleaning and waxing.
Big difference between keeping a near new car new ( which many of us do ) versus a restoration.

Perhaps a final round of pictures of your completed project, as well as the before condition might be a more graphic statement of your results.

Regardless, your results are indeed outstanding. Even more so when done away from the source of most parts!

Maybe we should create a new sub forum for Extensive Restorations.

I found your summaries of each step fascinating!

Well Done!

:cheers::cheers::cheers:
Marty

[Ccmano]

After the test drive it was time for the official technical check at the German T?V. The ZR-1 passed the required tests including the special check for getting registered as a classic vehicle in Germany.

Based on the porting of the injector housings and the plenum the engine seemed to be really powerful. So I checked the engine power on a car dyno in Cologne with 406.5 PS (401 HP) as result. This was over 25 PS (24.7 HP) more than stock. It?s justified on the better air flow into the engine by the ported intake.

All I can say is WOW! 🤩 Your level of detail work is amazing. I'm curious, did you upgrade your "tune" on the EPROM chip or are your running stock? If you did upgrade the chip, who did the tune? If your running a stock chip there are a few more hp (~10-15) available given your top end porting.
H
:cheers:

[Thomas ZR-1]

Yes Hans it`s not a stock EPROM. I installed a chip from Marc Haibeck for the standard engines: AYBKG5 calibration. The more HP are probably a result of the top end porting with the not reduced flow diameter in the first muffler (70mm from end to end).

[Thomas ZR-1]

Hi Marty you are right...there might be many reports such as mine but are these really so detailed and extensive...? Can`t remember such a report in the last years so in fact: I?m not sure.

Does it make sense to restore a ZR-1 in Germany in that way: the answer is: YES! If you purchase a Z in the US and bring it to Germany you have to count: car`s price + shipping costs + 10% toll + 19% taxes + the costs (hardware and checks). That`s the reason why prices for used (and rare) ZR-1s in Germany are double compared to the US.

[Thomas ZR-1]

BTW Charlie you should hurry up with visiting Germany for driving on the Autobahn. The f**king green party in Germany grows up more and more and all the "Greta Tumbergs" wants to have a permanent 130 km/h (80 mls/h) Autobahn speed limit...40 hp would be enough per car...?!?

[Thomas ZR-1]

Ok guys here are some pics before and after the restoration but first: the one and only picture from the Z when it came from the factory / dealer. It was taken from the previous owner Dennis Richard Lape, Itasca, LA.

At the beginnig of the restoration I was in contact with him. I sent pics from what I was doing with his former Z but after 3 month his email answers stopped. I didn`t here anything more from him but he really seemed to be very interested in what I dwas doing with the car.

Dennis was a member of this forum until 2016 or 2017. I hope he is ok in this Covid19 time...maybe some of you could know him.

[Thomas ZR-1]

Body before:

[Thomas ZR-1]

Body after:

[Thomas ZR-1]

Engine before:

[Thomas ZR-1]

Engine after:

[Thomas ZR-1]

Exhaust system before:

[Thomas ZR-1]

Exhaust system after:

[Thomas ZR-1]

Interior before:

[Thomas ZR-1]

Interior after:

[Thomas ZR-1]

Some more...:

[Thomas ZR-1]

Suspension before:

[Thomas ZR-1]

Suspension after:

[Thomas ZR-1]

Wheels before:

[Thomas ZR-1]

Wheels after:

[Thomas ZR-1]

I have many many more pics from the restoration but I can`t post them all...that`s it folks.

[DRM500RUBYZR-1]

OUTSTANDING!

:cheers:
Marty

[Thomas ZR-1]

Thank you Marty!

[dredgeguy]

BTW Charlie you should hurry up with visiting Germany for driving on the Autobahn. The f**king green party in Germany grows up more and more and all the "Greta Tumbergs" wants to have a permanent 130 km/h (80 mls/h) Autobahn speed limit...40 hp would be enough per car...?!?

Thanks Thomas, about 15 years ago I had the pleasure of driving on the Autobahn. I was in Amsterdam and had a meeting in Sweden so drove with my rep rather than fly. He had a diesel turbo Peugeot that ran well once you got it moving. Would love the opportunity to drive my Z at no speed limit!

[Top Toy]

What an outstanding restoration! Incredible job! Thanks for all the photos and detailed explanations. Will be a great restoration guide for others in the future.

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[Thomas ZR-1]

Thank you...you`re welcome

[willseph]

What a great build, this is my gold standard for what I'm trying to do with my newly acquired '90. Thanks for sharing the details!

[Thomas ZR-1]

Yes I think it?s a pretty good guidance for: How to restore a C4 ZR-1.

[Erik]

Amazing work and an amazing thread. Thanks so much for sharing it with us.

[tiegsd]

Very enjoyable thread, and excellent work. Congratulations on a successful rebuild, and thank you for sharing the story here!

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[daviddu79]

very good job, the car is beautiful

[Corvette95]

That's awesome. Don't know how I missed this post prior.

[Thomas ZR-1]

Thank you guys for all the nice comments. The Z is still waiting in the garage for next comming spring....happy new year to all of you✌️🇺🇸

[Jagdpanzer]

Excellent work Thomas.
Enjoy your clean machine.


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[XfireZ51]

Thank you guys for all the nice comments. The Z is still waiting in the garage for next comming spring....happy new year to all of you✌️🇺🇸

👍👍