How was it assembled?

[Sandra H.]

Could someone please tell me in what order a Corvette was assembled? Including wiring, paint, etc?
Thank you in advance.
Best, Sandy

[John H.]

Re: How was it assembled?

Could someone please tell me in what order a Corvette was assembled? Including wiring, paint, etc?
Thank you in advance.
Best, Sandy

Sandy -

The raw fiberglass body was built on a carrying truck, including the doors, hood, and trunk lid; that assembly then went through the Paint Shop, where it was primed and painted.

When it left the Paint Shop, it entered the Trim Line, where it got wiring, instrument panel, windshield, door glass and hardware, heater, fuel tank, and all of the exterior moldings and trim pieces.

While that was going on, the frame went down the Frame Line upside-down, where it got the front and rear suspension and gas & brake lines; then the frame was turned over right-side-up and transferred to the Chassis Line, where it got the engine/transmission assembly (which was built up separately on the Engine Dress Line), driveshaft and exhaust system.

At Body Drop, the trimmed body met the completed Chassis, and the body was "dropped" and bolted to the frame; then the wheels went on and the car proceeded down the Final Line where it got bumpers, radiator, and the soft top. At the end of the Final Line it was driven off into the Roll-Test machine, the toe-in was set, and it went through the Water Test booth. There was no interior in the car yet, so the driver sat on a temporary removable seat; this was done to simplify diagnosing and repairing the source of any water leaks.

After Water Test, it went on the Final Trim Line, where it got the interior soft trim (carpets, seats, door trim panels, etc.); at the end of this line it was complete and ready to ship.

[Sandra H.]

Re: How was it assembled?

Thank you John,
Now the next question is this.......I will be replacing all the wiring and interior including dash and door panels.
The mechanics shop will actually put the motor in and will replace the gas tank and have the transmission rebuilt, brake lines, etc.
The mechanic has graciously agreed to babysit me while I do some of the assembly of the motor connections, etc.
The car has been completely taken down to fiberglass, including the deck behind the seats (inside the car).
At what point would be best to paint it? Or should I just put a sealer on it and then do the motor, etc? Or not?
I would like to wait until the motor is installed, but it still seems like it would be a good idea to paint (at least that interior deck) while the inside is gutted.
Any guidance would be really appreciated.
Sandy

[Larry S.]

Re: How was it assembled?

and it went through the Water Test booth. There was no interior in the car yet, so the driver sat on a temporary removable seat; this was done to simplify diagnosing and repairing the source of any water leaks.

I wonder why they bothered, at least on C1's and C2's!

[Ridge K.]

Re: How was it assembled?

Thank you John,
Now the next question is this.......I will be replacing all the wiring and interior including dash and door panels.
The mechanics shop will actually put the motor in and will replace the gas tank and have the transmission rebuilt, brake lines, etc.
The mechanic has graciously agreed to babysit me while I do some of the assembly of the motor connections, etc.
The car has been completely taken down to fiberglass, including the deck behind the seats (inside the car).
At what point would be best to paint it? Or should I just put a sealer on it and then do the motor, etc? Or not?
I would like to wait until the motor is installed, but it still seems like it would be a good idea to paint (at least that interior deck) while the inside is gutted.
Any guidance would be really appreciated.
Sandy

Sandy, if I'm understanding correctly, you are asking if you should have the body painted, or at least, sealed and prepped, before instaling the engine back in.
This is an issue where I have found multiple different views and opinions on correct steps. I have discussed this issue with many, many experts. The consensus opinion I trust, is to get the body completed as soon as possible, but then everybody working on the project must be on the same page as to protecting the completed body.
If you feel you can trust the mechanics, etc. to PROTECT your paint finish, then why not finish the car in somewhat the way it was assembled (as so elequently described by John)?
It is always possible to receive a ding, or paint chip, but I will take that over "paint overspray" issues, anytime.
That's the path I'm taking, but I'm not an expert at all, just a guy who pretty good and picking the brains of the true experts, and there are plenty of them to go around in the fine organization.
Your question also sheds light on one of the very few downpoints of this fine club. Who really should be answering your question, is one of the several professional Corvette restorers, who are also members of the NCRS. Several of them, advertise for business within the club's publications. One I can think of, asks questions of fellow members on virtually every single new restoration he takes in, yet rarely passes out information. Hopefully, one of the fellow members who makes these decisions every day, will return the favors they've had, by supplying some helpful advice to you. Wouldn't that be great, and fair to boot?
Best of luck to you in your restoration. Ridge.

[Harry S.]

Re: How was it assembled?

This is a pilot line picture but essentially this is the marriage that occurs on the production line.

[Sandra H.]

Re: How was it assembled?

Thanks Harry for the photo.....points up once again the advantages to body off restoration.
I'm trying to resist that as this was supposed to just be a rolling resto for a car that would just be an everyday driver.
It's beginning to look more like a snowball rolling downhill....getting bigger everytime I mess with the car.
Ridge, your reply gives me more to think about.
The interior and wiring is something I can work on soon.....if I decide to paint before motor removal and reinstallation, that means it will delay everything until I paint my truck first for practice. (I know, the height of lunacy....I plan on painting the Corvette myself.)
At this point, I just hope I live long enough to get it all done.
Would like to know how other members went about it, too.
Cheers, Sandy

[Grant M.]

Re: How was it assembled?

Sandra,

I bought my 65 as a bare body on a rolling chassis. All trim and glass, the interior, engine and transmission had been removed and set aside. I had a deadline of four months to have the car to "licensed and driveable" condition in order for the moving company to transport it across the country when I moved.

I considered assembling it (as is) in primer and still needing some earlier bodywork corrections in order to meet the timeline more easily and reduce the risk of damage to a new paint job. Conversely, I recognized the hassle involved in dis-assembling it after the move to get it back to the bare body stage for painting, or alternatively, masking and painting it as an assembled car (the "Maaco" approach). It was never to be an NCRS-judged car due to non-matching engine, so a body-off was not considered.

Ultimately, I opted for getting it painted prior to assembly for the move, a decision which greatly added to my workload and angst as I was working to an unchangeable deadline (my employer, the military, was moving me). As we used lacquer (this was in 1987), the very few minor 'dings' during assembly afterwards were easily and invisibly touched-up, and I did virtually all of the assembly, less windshield and windshield trim installation.

Based on my experience, I'm glad I took the route I did and would likely do the same again. The patience required to assemble the car/move it/dis-assemble it/paint it and then re-assemble it, not to mention the additional time involved, would challenge most people's commitment to such a project.

I agree though with another poster who admonished you to ensure that all participants are on-side with the care required in re-assembly after painting, particularly as you won't be doing some/a lot of it. Good luck with whatever you choose to do; the 'reward' starts with seeing that fresh paint on the beautiful shape of a Corvette body and just gets better as the trim, interior etc are added. Then there's the first drive....

grant

[Mike M.]

Re: How was it assembled?

Thank you, John. Great description.
How was the gas tank retained in the body until the body drop?
HaND

[Rich P.]

Re: How was it assembled?

Sandy,

You need to determine what you goal is for the car before you can answer the question of whether to paint before putting the motor in. If you just want a nice cruise night car with a flashy paint job then you should install the motor and detail the engine compartment first. If you are looking for a highly detailed engine compartment that will knock socks off when the hood is popped you should paint it first then detail under the hood and install the engine. There is just no way to avoid dust and some sort of over spray on a highly detailed engine compartment while doing body work and paint on a corvette. This is just what I have found in restoring these cars for over 25 years now.

Rich

[Rob M.]

Re: How was it assembled?

Hi Sandra,

Rethink your decision carefully here. I've restored my car three times in 5 years because I was also starting with the idea of doing a driver resto resulting in a show car resto resulting in a NCRS resto.

Take the body of the frame!!! Really, it is not that hard and only a couple of bolts away. Read Noland Adams guide in doing so (there is a nice checklist in his manual of what needs to be loosened or removed). It is fairly easy to take the body off and it reduces the risk of damaging dramaticly and eliminates any unintended overspray issues!!!

just my 2 euro cents (app. $0.0265 today),
Rob

[Bruce C.]

Re: How was it assembled?

Thank you John,
Now the next question is this.......I will be replacing all the wiring and interior including dash and door panels.
The mechanics shop will actually put the motor in and will replace the gas tank and have the transmission rebuilt, brake lines, etc.
The mechanic has graciously agreed to babysit me while I do some of the assembly of the motor connections, etc.
The car has been completely taken down to fiberglass, including the deck behind the seats (inside the car).
At what point would be best to paint it? Or should I just put a sealer on it and then do the motor, etc? Or not?
I would like to wait until the motor is installed, but it still seems like it would be a good idea to paint (at least that interior deck) while the inside is gutted.
Any guidance would be really appreciated.
Sandy

Sandy, your questions are great and John, thanks for the glimpse into a day in the life of...fascinating.

Sandy, while I've never done a body-off to a Vette, I've restored/rehabbed a couple of dozen airplanes. I'm currently doing a "rolling-resto" to my own Vette and, given the opportunity, coupled with my airplane experience, I'd do a body-off without hesitation.

I just wish the fourth gen Vettes weren't quite so "bonded." Anyway...

With the body off the frame, drivetrain out of the chassis, and harnesses, etc. out of the body, everything is exposed for inspection and correction. Going this route will afford you the opportunity to correct hidden damage and discrepencies that may not otherwise be evident and could be disastrous. Case in point...

My car had the main center-body to aft-body connector (C-401 for those of you who are familiar) so corroded and exfoliated to the point that I'm convinced a fire was imminent. I found it accidentally due to having decided that, since I already had the interior out, I might as well go all the way and remove the carpet and jute pad from behind the seats. I'm SO glad I did.

As has been suggested, get everybody on the same sheet of music regarding re-assembly after paint.

I also agree, most heartily, with the suggestion that you can beautifully detail an empty motor compartment and then, when you've reassembled everything, you'll truly have something wonderful to admire. (and drive)

Good luck, whichever way you choose to proceed.

PS, if you're a "journaler" I'd love to write a book about your experiences. I know there are a couple of good ones out there already but perhaps someone could be positively influenced by a more recent account. Just a thought.

[John H.]

Re: How was it assembled?

Thank you, John. Great description.
How was the gas tank retained in the body until the body drop?
HaND

Mike, that sequence was for the C1, to match up with Sandra's question, as the C1 tank was mounted in the body. C2 and later, of course, had the tank mounted on the frame. Other than that, the basic assembly sequence was about the same for all the C1-C2-C3 years at St. Louis.

[Sandra H.]

Re: How was it assembled?

Hi Bruce,
I appreciate what everyone is saying about body-off......something I would truly like to do.

Balance that with wanting to start some work on this car.....anything.
Problems involved now are living in a place that is in no way set up to work on cars.....no garage or shop and no room to build one.
I will be putting in a concrete-floored carport this summer and using my storage shed to store tools, compressor and stuff.

So as I see it, I must sell a piece of real estate first (for car working capital), find or have built another place and then proceed with car.
And finish the work on this house....late husband was a mechanic and general contractor, and this place was supposed to be a resale house. He died before the major remodel was completed.

I know how to finish the sheet rocking and some wiring, rebuild porch, lay flooring, etc.....I just finished the deck last year.
And still keep my business afloat.

So you can see this isn't very straight forward.
I just want to get the car on the road and have some fun with it.
Or maybe take up serious drinking. (Just kidding, I think.)

But I do have some things to think about with proceeding on the car and that's good.

I am journeling all of this, and would be interested in gathering enough material for some sort of publication.
I'm currently gathering ideas for two books, that I will also illustrate......one a book for physically challenged children, based on the adventures of my handicapped kitten, and another on the strength and courage of the women of the west, mainly aimed at widows, young women or anyone needing some encouragement to try new things, be all you can be, etc. (Sounds like I'm recruiting for the military, sort of.)

We will talk about your book idea some time......feel free to e-mail me.
Best, Sandy

[Bruce C.]

Re: How was it assembled?

Hi Bruce,
I appreciate what everyone is saying about body-off......something I would truly like to do.

Balance that with wanting to start some work on this car.....anything.
Problems involved now are living in a place that is in no way set up to work on cars.....no garage or shop and no room to build one.
I will be putting in a concrete-floored carport this summer and using my storage shed to store tools, compressor and stuff.

So as I see it, I must sell a piece of real estate first (for car working capital), find or have built another place and then proceed with car.
And finish the work on this house....late husband was a mechanic and general contractor, and this place was supposed to be a resale house. He died before the major remodel was completed.

I know how to finish the sheet rocking and some wiring, rebuild porch, lay flooring, etc.....I just finished the deck last year.
And still keep my business afloat.

So you can see this isn't very straight forward.
I just want to get the car on the road and have some fun with it.
Or maybe take up serious drinking. (Just kidding, I think.)

But I do have some things to think about with proceeding on the car and that's good.

I am journeling all of this, and would be interested in gathering enough material for some sort of publication.
I'm currently gathering ideas for two books, that I will also illustrate......one a book for physically challenged children, based on the adventures of my handicapped kitten, and another on the strength and courage of the women of the west, mainly aimed at widows, young women or anyone needing some encouragement to try new things, be all you can be, etc. (Sounds like I'm recruiting for the military, sort of.)

We will talk about your book idea some time......feel free to e-mail me.
Best, Sandy

Now you sound like a lot of us guys..."I'm one guy with 50 projects."

You don't need to be that, in my opinion. And...I'm very sorry to hear that you've lost your husband.

Based on what you've described, perhaps an appropriate approach is to correct/restore what you can, organized into small projects requiring no more than 8-10 days of labor for the big ones and one to two days for each of the smaller ones. Any more time consuming than that, and you become a target for discouragement.

I have always kept a "squawk sheet" (in the airplane world, FAA requires that all maintenance be documented) with a "discrepency" column on the left side of the page and the corresponding "corrective action" on the right side. I've done this with my Vette, also.

That's a very useful tool for budgeting both time and money and everytime a squawk is "signed off" you put another little success under your belt. Those successes spur you on until, in time, the car is completed. Additionally, the record of what you did to correct each gripe can be invaluable for future use.

Use this forum to seek advice, to vent, and share victories. These folks are the MOST cordial of any forum I've ever participated in.

Best to you. (Will email re article/book.)