My '90 ZR-1 project update thread
 

Thought I'd start a new thread and post updates and pictures as I progress. Go to this link to for the beginnings of this project:

http://www.zr1.net/forum/showthread....ight=bdw18_123


I'm still in the 'cleaning everything real good' stage, which is turning out to be a very large project just by itself. I just can't stand putting something back together dirty, even if it takes a lot of work to get it clean.

The previous owner replaced the fuel injectors, but I didn't know where he got them from. Then I happened to look in the bag of the old, original injectors and I found these:

http://i13.photobucket.com/albums/a2...3/STA70002.jpg

Which was a pleasant surprise as I have heard nothing but glowing reviews about FIC, so I know the injectors are good quality.


Here are a few before and after clean-up pics:

Fuel injector rails & IH's before
http://i13.photobucket.com/albums/a2...123/IHs_b4.jpg

Fuel injectors & rails after (also installed the new fuel pressure regulator, which came with the car)
http://i13.photobucket.com/albums/a2...3/STA70001.jpg

IH assemblies after
http://i13.photobucket.com/albums/a2...3/STA70003.jpg

http://i13.photobucket.com/albums/a2...3/STA70004.jpg

Re: My '90 ZR-1 project update thread
 

Plenum, throttle body & airhorn before
http://i13.photobucket.com/albums/a2.../plenum_b4.jpg

Plenum after
http://i13.photobucket.com/albums/a2...3/STA70007.jpg

http://i13.photobucket.com/albums/a2.../STA700082.jpg

Re: My '90 ZR-1 project update thread
 

Throttle body & airhorn after
http://i13.photobucket.com/albums/a2...3/STA70005.jpg

http://i13.photobucket.com/albums/a2...3/STA70006.jpg

Alternator before
http://i13.photobucket.com/albums/a2...ernator_b4.jpg

Alternator after (I painted the aluminum case halves with paint that imitates new cast aluminum look, cleaned interior of alternator also)
http://i13.photobucket.com/albums/a2...3/STA70009.jpg

http://i13.photobucket.com/albums/a2...3/STA70010.jpg

The plenum, IH's & airhorn/throttle body cleaned up pretty good. There are some stains I can't get out and the top of the throttle body has an area where the coating is missing, but they look much better than before.

That's it for now. :thumbsup:

Re: My '90 ZR-1 project update thread
 

nice work . did you have to put the heads back on it ? wasnt sure of the shape it was in when you got her ???

Re: My '90 ZR-1 project update thread
 

Jon, go to this link for the whole story from the beginning:

http://www.zr1.net/forum/showthread....ight=bdw18_123

Re: My '90 ZR-1 project update thread
 

Ben:

Looks like she's cleaning up really nice.
:-D

One small thing though...
There is a ring of special sealant called "DAG" around the blades of the throttle body that seals the blades and helps with the idle.
Hopefully, you accidentally didn't clean it off too...
http://www.zr1netregistry.com/forum/...32&postcount=9


TomC
"Crabs"

Re: My '90 ZR-1 project update thread
 

Hmmm... Thanks for the heads up on that, I had no idea about that stuff. There was a line of blackish stuff at the edges where the rod goes through the throttle body, but there wasn't much there. Is it supposed to go on all 3 throttle blades, or just the 2 big ones? Does it go on the blade itself or on the throttle bore walls? Can you still buy this "DAG" stuff somewhere or its equivalent?

Re: My '90 ZR-1 project update thread
 

Ben:

I don't think it's something that you can buy at the local parts store, I've never needed it so I've never looked.
If you've cleaned the bores 'till they shine, then it's gone.
My thoughts would be to put it back together and if your idle is *way* high, then think about finding some or have the throttle body serviced by a pro.
I know that Marc Haibec offers a rebuild service, here's a write-up over on his website.
http://www.zr1specialist.com/HAT%20W...tle%20body.htm

TomC
"Crabs"

Re: My '90 ZR-1 project update thread
 

Couple more before & after cleanup pics. :thumbsup:

Before:
http://i13.photobucket.com/albums/a2...3/STA70011.jpg

After:
http://i13.photobucket.com/albums/a2...3/STA70012.jpg

Re: My '90 ZR-1 project update thread
 

Before (it was actually much more oily/dirty, I wiped the worst off before this pic):
http://i13.photobucket.com/albums/a2...3/STA70015.jpg

http://i13.photobucket.com/albums/a2...3/STA70016.jpg

After:
http://i13.photobucket.com/albums/a2...3/STA70019.jpg

http://i13.photobucket.com/albums/a2...3/STA70020.jpg

Re: My '90 ZR-1 project update thread
 

WOW....Nice Job, parts look like new!!!
Rich

Re: My '90 ZR-1 project update thread
 

Great work! You are welcome to visit my garage anytime. ;)

Jim

Re: My '90 ZR-1 project update thread
 

:mrgreen:

Re: My '90 ZR-1 project update thread
 

Looking good. Might pull the fittings out of the oil filter housing and reseal them along with the oil temp sensor.

Re: My '90 ZR-1 project update thread
 

Yeah, I was thinking about that too. I probably will do that.

Re: My '90 ZR-1 project update thread
 

The parts look great. What did you clean them with, if I may ask?

Re: My '90 ZR-1 project update thread
 

I've been using diluted Simple Green, rags & old tooth brushes to get in the tough spots. It is a lot of work, but the results are great if you're willing to put in the time needed. :thumbsup:

Re: My '90 ZR-1 project update thread
 

Thats what I did when I cleaned up my first 90 ZR-1, the oil cooler lines had made a mess of everything on that side so I tore it all apart and cleaned everything. even the cam covers I painted them back then but later powdercoated them.

good work get that car back together and have some fun with it.

Re: My '90 ZR-1 project update thread
 

Yup, exactly the same on mine. Everything anywhere near those oil cooler lines was/is covered in oil/dirt. :thumbsdo:

Although, I have found there is an upside to having the parts covered in oil. They clean up to near brand new looking, whereas the parts not covered in oil (esp. the aluminum cast parts) have darkened more and don't look as good. The oil must have protected those parts from corrosion.


Can't wait 'till I get to this part!! :mrgreen:

Re: My '90 ZR-1 project update thread
 

UPDATE:

Thought I'd post a few pictures to show where this project is at since I haven't posted any updates in a long time. It's been slow going as I don't have much extra money right now to start buying everything for it. I've just been slowly buying small things here and there that I need. There is lots and lots of cleaning to do though to keep me busy in the meantime. I did some polishing of the paint with some 3M cutting compound, looks a lot better. Here is an exterior shot:
http://i13.photobucket.com/albums/a2.../_IMG_0062.jpg


I decided to start doing some work on the interior and get the stock Bose system back in and working. I bought a full set of stock speakers/amps a couple months ago since mine had aftermarket speakers installed & I want to put the radio system back to stock. I'm going to do the elmer's woodglue trick to the stock speakers to make them have a more clean, crisp sound. Didn't have to buy the head unit or the CDM though, the originals came with the car.

I tested the head unit in the '93 I had before I sold it and it works fine except for the CD player which doesn't matter much since I don't really use CD's much anymore. Just going to hook my iPod up to it with a cassette adapter. The head unit has that "Delco Loc" feature, but it never had a code programmed in, so I don't have that headache to deal with.

As you can see, I've removed pretty much the entire interior except for the door panels. Going to clean everything really good. I had to take apart the dash to replace the wire harness that goes from the radio head unit to the CDM. The previous owner cut it up when he installed the aftermarket radio. I also had to splice the stock rear speaker connectors back in since he cut those off too. :censored: I wrapped the repairs in electrical tape so you can't see them.
http://i13.photobucket.com/albums/a2.../_IMG_0058.jpg

Re: My '90 ZR-1 project update thread
 

I have ZR-1 parts all over the place (including in my bedroom) :mrgreen: :
http://i13.photobucket.com/albums/a2.../_IMG_0059.jpg

http://i13.photobucket.com/albums/a2.../_IMG_0060.jpg


I think something is missing here :icon_scra :mrgreen:...
http://i13.photobucket.com/albums/a2.../_IMG_0061.jpg

Re: My '90 ZR-1 project update thread
 

:jawdrop: That is some major restoration work going on there!

Nice work. That car is going to be right when you're dunn!:worship:

:cheers:
Tom




:o You may want to think about a heater core r&r while the dash is out.:o

Re: My '90 ZR-1 project update thread
 

Ya know, I was pondering the same thing. I noticed there is a layer of some type of sponge/foam type material on the interior side of the core. Where do you get that? Is a new heater core very expensive?

Re: My '90 ZR-1 project update thread
 

New heater core is relatively cheap. The install is what sucks. You still have a lot to remove to get to it.

Keep making progress. Just don't let it go dormant for along period of time.

Re: My '90 ZR-1 project update thread
 

That makes my head hurt just looking at all of those parts. I can only offer encouragement. :cheers:

Keep up the good work, there's an end to that project someday. :thumbsup:

Re: My '90 ZR-1 project update thread
 

Listen to the words of Jedi-Master Obi-Wan-Jeffvette-Kanobi....:worship:

Oh, yea, the heater core is proly about cost of an oil & filter change plus a bit more. Inexpensive part and the "while we're here" rule is in play now. Just test the damn thing before you install it to check for leaks. The foam could probably be bought at the hardware store in the HVAC section. You know those bootleg foam filter blanks, 2' x1' x 1'' thick stuff they sell it as a sheet and you cut it to fit your needs. Or if it's strips, you can hi-jack the install kit from a sleeve A/C unit. I have to confess that I don't know what the foam looks like. If I could see it I can probably make a determination of where to get some as I'm sure GM don't sell it at the parts department. I'll go look in my 90's FSM and see if I can figure an answer for you.

:cheers:
Tom

Re: My '90 ZR-1 project update thread
 

Here is a close-up picture of the foam on the heater-core, looks like it's approximately 1/4" thick. How would I get the new core pressure tested? Are even new cores bad right out of the box very often?

http://i13.photobucket.com/albums/a2...3/IMG_0064.jpg

Re: My '90 ZR-1 project update thread
 

That looks like std A/C bootleg filter material....or I'll bet a UPS store has that 1/4" thick stuff in rolls. I still say that an A/C filter....not the new kind that are framed in plastic, but the really old fashioned stuff that used to just stick to the front of the evaporator grid.

I have seen guys complain about leaking H/cores right out of the box! Remember this stuff is made by people that don't even know what a car is....like the hicks in China who assembled those slave cylinders with the seal on backwards, remember them?

I would think that a hose running slowly, fill the core till it starts to come out and them use your hand to cover the outlet to build some pressure, no....you know what i'm talking about, right? Or I wonder if you can adapt a radiator/cooling system pressure tester to do the job....maybe with some heater hose and some clamps. I doubt that you would need more than a few PSI to detect a leak.

:cheers:
Tom

Re: My '90 ZR-1 project update thread
 

15 psi radiator and 60 psi - 100 psi garden hose :mrgreen:

Re: My '90 ZR-1 project update thread
 

Thanks for the tips Tom! I'll give that garden hose trick a try after I buy the heater core.

GM Parts Direct has the OEM heater core for about $72, but aftermarket would probably be cheaper. Would it be better to get the OEM, or are the aftermarket cores just as good or better?

Re: My '90 ZR-1 project update thread
 

Okay with checking to see if the new core will leak I would either use my pressure test kit or I would use one of my hand vacuum pumps. The vacuum pump would proly be the simplest & fastest way....it either pulls a vacuum or it don't. I hate to say this but I would use plumber's putty to seal up the core in & out so I could pull the vacuum! But I'll bet a couple of wine bottle corks would do the trick also! :sign10:

Cliff is correct:worship: about the PSI in a potable water system. I just figured you could adjust the faucet flow to a reasonable level, fill the core & get thru flowing water and block one of the pipes with the palm of your hand to restrict the flow to put some pressure on the core, but then it is going to leak around your hands.:o

A lot of guys use that guy from e-bay, partsladie. I've used them for some stuff also. Their prices are pretty good and they will not bend you over with shipping charges.....like GM parts direct.

Good luck on your restoration, and may the Force be with You!
:cheers:
Tom

Re: My '90 ZR-1 project update thread
 

UPDATE:

I've decided that I'm not going to replace the heater core. :jawdrop: I pressure tested the heater core that is in the car and it did not leak, so I think it will work fine. Didn't feel like taking more stuff apart to get to it. I know I'm taking a gamble, but it's a gamble I'm willing to take.

Anyway, I've got the dash vent ducting back in and bolted the dash skeleton back on.

http://i13.photobucket.com/albums/a2...3/IMG_0009.jpg


When I was taking the ducting out and had removed this piece (I put new foam on it, the stock stuff had crumbled away)...

http://i13.photobucket.com/albums/a2...3/IMG_0010.jpg


I found that GM messed up and forgot to completely remove the plug from the hole, so I removed it all the way. That vent sure wouldn't work very good with that plastic in the way! :rolleyes: :mrgreen:

http://i13.photobucket.com/albums/a2...3/IMG_0008.jpg

Re: My '90 ZR-1 project update thread
 

Gauges have been reinstalled after removing the clear plastic and cleaning both sides with plastic polish. Also cleaned up the dust that had collected below the gauges behind the clear plastic. I also removed all the bulbs in the back one by one and cleaned them since I had found that they were really dusty.

http://i13.photobucket.com/albums/a2...3/IMG_0011.jpg


Dash pad had some issues around the top of the glovebox door...

http://i13.photobucket.com/albums/a2...3/IMG_0013.jpg

http://i13.photobucket.com/albums/a2...3/IMG_0012.jpg


You can tell someone tried to glue it, but obviously that didn't last. I decided to use screws to hold the edges down since those areas are pretty much hidden from view. I drilled pilot holes and put the screws in. It's not perfect, but it looks a lot better. The door will also open and close better now.

http://i13.photobucket.com/albums/a2...3/IMG_0017.jpg

http://i13.photobucket.com/albums/a2...3/IMG_0016.jpg


I've been using Mother's "Back to Black" plastic restorer on all the non-painted plastic and vinyl interior parts. I love this stuff! What a difference it makes! The parts don't have to be black either. It makes the plastic look almost new again, as long as it isn't too oxidized or brittle. It takes away that dull, flat look that old plastic & vinyl has.

Here is an example. In this picture, I have applied "Back to Black" to the glove box door, but not the surrounding dash. You can see that the door is a lot blacker (the flash lightens the black somewhat, it's darker in person).

http://i13.photobucket.com/albums/a2...3/IMG_0015.jpg

Re: My '90 ZR-1 project update thread
 

Comin together.I was in Madera not too long ago,I should have got in touch.

Re: My '90 ZR-1 project update thread
 

You were? Ya, you could have stopped by & and seen my Z in pieces all over the place! :mrgreen: Would be cool to meet another ZR-1-oner in person!

Especially if you take your ZR-1, I'd love to see it! I still have never ridden in a drivable ZR-1 yet, or even heard an LT5 running in person! Let me know next time your in the area, we could meet up.

Re: My '90 ZR-1 project update thread
 

It aint gonna be for a loooooooooooooooong time.My uncle John Wells was the mayor down there for years.If your anywhere near Fremont give me a call.It would be great if somebody put together a Z gathering not too far from me.

Re: My '90 ZR-1 project update thread
 

:thumbsup:Heck of a job Ben!!

Re: My '90 ZR-1 project update thread
 

Continued work on the dash pad. Part of the hold down tab above the headlight switch assembly was broken...

http://i13.photobucket.com/albums/a2...3/IMG_0018.jpg


...so I cut out a small piece of thin aluminum sheet metal, drilled pilot holes in the remaining part of the plastic and attached the aluminum with screws (I have scraps of aluminum sheet metal from when I used to work on aircraft).

http://i13.photobucket.com/albums/a2...IMG_0023-1.jpg


After I cleaned and detailed the dash pad (including the carpet section) & gauges surround piece, I reinstalled them.

http://i13.photobucket.com/albums/a2...3/IMG_0029.jpg


Windshield interior pieces have also been cleaned & detailed.

http://i13.photobucket.com/albums/a2...3/IMG_0028.jpg


Cleaned and reinstalled DIC & A/C control head.

http://i13.photobucket.com/albums/a2...IMG_0033-1.jpg


Cleaned and reinstalled headlight switch assembly.

http://i13.photobucket.com/albums/a2...IMG_0035-1.jpg

Re: My '90 ZR-1 project update thread
 

what are you using to clean all the interior parts?

Re: My '90 ZR-1 project update thread
 

For all the plastic and vinyl parts, first I clean them real good with some diluted Simple Green. Then I apply "Back to Black" to take away that old, flat look that old plastic and vinyl gets. Makes a huge difference.

For the carpeting, I'm using Turtle Wax's "Power Out Carpet Cleaner" with the scrub brush cap. It brings back the true color of the carpet and gets smells out, which is good because I could tell the PO smoked in this car. :nono: :thumbsdo: