Construction And ReassemblyBody: Body and paintwork is time-consuming and expensive on a fiberglass car. When selecting your car, look for a solid body. When converting to modern suspension there will also likely be some modification to the body to get things to fit, and that should be considered.
Chassis: A solid frame is key, whether you plan to convert the stock frame to modern suspension or plan to use a new frame. More companies such as Car Creations and SRIII Motorsports either convert a stock chassis to modern suspension or build a new frame from square or tubular steel.
Suspension/Steering/Braking: The choices here often involve using a suspension system (such as that from Vette Brakes) or converting to a C5 or C4 setup. The former is much less involved and less expensive, but the latter is a great choice for handling and ride.
Wheel & Tire: Your choice depends mostly on the look you want and what will fit within the original body unless you also plan to widen the fenders.
Drivetrain (engine, transmission, and differential): Your choice here is wide open. Many folks select the small- or big-block Chevy while others like the LS1 or LS6 series engine. The LS engines involve more work for installation, electrical components, exhaust system, engine accessory drive brackets, gauges, and computer programming. As more and more folks are going this route, there are more sources for these parts than there were just two years ago. The transmission used is often a five-or six-speed such as the Tremec T56. These also usually involve the use of a conversion to a hydraulic clutch setup. The choice of differential is often the Dana 36 or 44 when using the C4 suspension. Make sure the differential gearing matches the gearing of the transmission used.
Interior: Maintain the original style of the interior while upgrading the gauges, sound system, and materials used. But that is only one approach and we've seen some great custom interiors with newer-style seats and custom upholstery.
Electrical: Since these cars are 40 years old or so, avoid future problems by replacing all the dash and body electrical wiring. Depending on your choice of engines (such as the LS engines) you may also be involved in custom engine wiring and computer programming. There are sources for both of these.
Fuel System: If using the LS engine, it is also necessary to convert to a higher pressure (and often an in-tank) fuel pump. We like the Rock Valley stainless tank, which also has the in-tank pump.
Cooling System: The LS engine has a different arrangement for the radiator hoses and we like to use a new aluminum radiator made with the inlet, outlet, throttle-body line, surge tank and electric fan setup.
Heating and Air Conditioning: Many folks want to convert to an upgraded heating and A/C system. Several manufacturers can provide these components, including Vintage Air.
Exhaust System: These projects usually require a custom bent system. Headers or stock manifolds can often be used along with your choice of mufflers.
Custom Components: As with any custom car project, some components will have to be modified (such as the steering linkage connection) or custom built (such as the motor and transmission mounts, exhaust, wiring, brake and fuel lines gauge setup, engine accessory brackets, and intake assembly), but coming up with your own solutions and approaches can also be a fun part of the project.
Reassembly And Test Fitting: Before final finishing, test fit the body to check for clearance and the major components for fit and function. This avoids the potential in having to redo some areas that have been finished.
Systems Test: Some folks also go to the extent of road testing their cars before the paintwork or interior is finished. At the very least it's a good idea to test for the operations of all systems and for any leaks.