Legal Requirements (Inspection, Insurance & Registration)Consider these three areas long before finishing the car. Each state has different laws and requirements on inspection and registration. Others who have built these cars and live in your state might be of help. There are many good insurers that provide classic car insurance; check into this as well. Look for "agreed value" physical damage coverage to pre-establish the value of your car in the case of a total loss.
A Final NoteThe intent of this article has been to answer the questions of "how do I get started" and "what's involved" in a project of this type. While not intended to be exhaustive, we hope it has addressed some of the key considerations and given a better idea of what is involved. These are involved projects but can provide you with a great end product and experience if gone about the right way. One truth on car projects is that they will always take longer and cost more than you thought, regardless of how well you have planned.
We hope what we have learned from our experiences, and the thoughts and suggestions given, have not dissuaded anyone from undertaking a project like this but rather helped make the experience more enjoyable. We've thoroughly enjoyed building our first two cars of this type and we have now started another project, so we're either crazy or really enjoying ourselves. Maybe it's a little of both.
Sample Punch ListCorvette Project, Punch List as of: 6/17/04Engine* Install P/S pump, lines, and remote tank* Install A/C compressor, cover, and drier* Install radiator; rubber seals; modify X-brace* Install all coolant lines (upper/ lower rad; overflow; return; heater)* Install coolant recovery tank; modify as necessary* Install engine covers; trim to clear A/C compressor and alternator* Design and install intake-manifold cover and make brackets* Install gas tank, sending unit, fuel pump, fuel regulator and braided fuel lines* Make MAF to throttle body connection* Design and make air-cleaner system* Design and make stainless exhaust system and mounts; polish and install* Install battery, battery cables, and ground strap* Install computer and engine harness; make bracket aluminum support* Hook up throttle cable; make mounting bracket
Interior* Install door panels, dashpad, kick panels, visors, and seats* Install floor and under-seat heat barrier* Make carpeting for interior, trunk, and decklid* Install leather on center console* Install gauge cluster* Wire all gauges, heating, A/C* Wire all switches* Complete wiper system* Install washer system* Install rearview mirror* Install all air-conditioning and heater lines* Make A/C side-outlet panels, cover in leather, and install A/C vent outlets* Install shift boot* Install center armrest* Make trunk liner boards and have carpeted* Install parking brake and hood release (connect cable to chassis setup)* Install door-sill plates and supports* Install steering wheel, turn signals, and horn* Install interior door hardware: handles, lock release, door pulls* Test all electrical systems
Exterior* Mount and balance tires/wheelsand install* Install bumpers (use bumper protectors and 12-point bolts)* Get front bumper brackets, cut brackets to fit, paint and install* Install grille and surround trim* Install side fender emblems* Install side cove moldings* Install decklid moldings* Install lights: headlights, parking, taillights* Install horns* Install front and rear emblems
Fluids* Fill all fluids (coolant, differential, transmission, engine, power steering)* Fill master brake and clutch hydraulic systems and bleed* Charge A/C system* Test for leaks and operation