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Blu808 C6 Corvette Race Car build

Last year we brought you the Hankook, GM performance, Blu808 2010 Camaro. This year we are introducing the Blu808 X LG Motorsports C6 Corvette Formula DRIFT and Red Line Time Attack Corvette. This is a primary Blu808 effort with partnership, advice, and support from LG Motorsports. Other key members of our Corvette build will be Turn Key Engine Supply, Forgeline, Sparco, Aeromotive, Exedy racing clutch, Lab17 and others.

This thread will be a documented full feature build up of the Corvette.

We will show the following processes in detail.

Complete dismantling process
Weight removal
Chassis modifications
Roll cage design and construction
Pedal box fabrication
Seating mount fabrication
Drivetrain modifications
Engine modifications
Cooling system fabrication
Clutch hydraulics fabrication
Fuel system fabrication
Carbon body fabrication
Aerodynamics
Wiring
Electronics
Suspension design and setup
Steering system modifications
Corner balancing
Paint
Final assembly
Testing.

Any questions or feedback would be great.

Luke

Build start.

Here is our project car. A 2005 C6 base. We would have used a ZO6 but Formula DRIFT won't allow aluminum chassis. Anyway.

http://omgdrift.com/wp-content/uploa...1/omgvette.jpg

We then drove it around for about a week to get a feel for it. Our dog Turbo approves of the Corvette doggy bed in the back.

http://sphotos.ak.fbcdn.net/hphotos-...8_199286_n.jpg

Once we had the car back in the shop we started removing the interior and other unnecessary items.

http://sphotos.ak.fbcdn.net/hphotos-..._7791189_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-...5_325208_n.jpg

Here is our base weight with the carpet, Seats, and Consol removed. The car has 3/4 of a tank of gas as well.

http://sphotos.ak.fbcdn.net/hphotos-..._7984855_n.jpg

Next we started on the bumpers and body panels. It is a treat to work on a car with a removable body.

http://sphotos.ak.fbcdn.net/hphotos-..._5330023_n.jpg

Now that we have a good portion of the chassis exposed we take a closer look to see any evidence of crash damage.

http://sphotos.ak.fbcdn.net/hphotos-..._6788844_n.jpg

Luckily everything looked great.

Since we are now sure the chassis is in good condition we started marking all the areas on the car that will be removed for weigh savings

Every panel is clearly marked with a red X and is documented and cleared with Formula DRIFT for approval.

http://sphotos.ak.fbcdn.net/hphotos-..._1567519_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._5959392_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-...2_219086_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._7778823_n.jpg

After that was all figured out we went back and removed the Dash and the components under it.

http://sphotos.ak.fbcdn.net/hphotos-..._2657228_n.jpg

They sure manage to fit alot of stuff in these cars! The radiator and Ac condenser were removed along with the fan assembly. Then the steering column and wiring started to drop.

As it sits with the heater core/AC, blower assembly, Cats, Headers, Exhaust, Mufflers, Gas tanks, ABS, Pedals, Windshield, rear hatch, and window we are getting pretty light.

http://sphotos.ak.fbcdn.net/hphotos-..._6599813_n.jpg

Not bad for a car that still starts and drives. (well not far without a steering wheel or radiator)

Getting there.

Check back tomorrow for more updates!

this thing is gonna be intense

i think we all expect nothing but great builds from you and your partners as always...best of luck and have fun with it!

I'm looking forward to this build.

Good luck Luke

hey i was wondering , in this build are you going to have the same hydro brake setup as in these camaros. They seem so conveniently place in stock location and still retaining stock functionality. just wanted to know how it was done.

reference :

I'm watching this build for sure!

This thread gets my loins tingling. Can't wait for more.

Andrew Bohan over at OMG Drift put together this great build video of the Corvette.

Please let us know what you guys think.

Blu808 Corvette Build Episode 1 on Vimeo

Your work is always top notch. Can't wait to see how the car turns out and in person at Atlanta next year.

lol it's like a small part of me wishes i would of took the job opportunity you gave back in the day haha good work man.

Thanks for the link to the video. I'll check it out in a bit!

Just watched the video and man late night anything sucks...

^^^ We still got it done! Lol I love the video, very good representation of what actually goes on, and still fun to watch. This build is a blast, and going to be a serious contender next year I think.

Subscribed, always love seeing your work.

Awesome build and video! Looking forward to more updates - video style!

Ok so today now that the steering tube position was finalized we measured everything up for the main hoop.

We use Bend Tech Pro here at the shop. It is a great program and makes making complex bends easy. It eliminates any errors in the design process and eliminates wasted material. That is the main reason we use it at Blu808.

Here is what we had come up with after taking some measurements.

http://sphotos.ak.fbcdn.net/hphotos-..._5080382_n.jpg

We then bent up the hoop in the bender.

http://sphotos.ak.fbcdn.net/hphotos-..._4835978_n.jpg

After a quick floor trace, flip, and cross measure to ensure everything was symmetrical we test fit it in the car.

http://sphotos.ak.fbcdn.net/hphotos-..._4198166_n.jpg

Fits perfect!

Now for the rear section. We were planning on removing the entire rear tub of the car, but were declined by Formula Drift due to the weight savings advantage it would provide. So to mount the rear tubes we were granted removal of 2 8"x10" sections.

http://sphotos.ak.fbcdn.net/hphotos-..._1576959_n.jpg

After some action with the cut off wheel out they came.

http://sphotos.ak.fbcdn.net/hphotos-..._4466121_n.jpg

Next order of business was to prep the area for plating. We grind down any high spots, and sand the entire area.

http://sphotos.ak.fbcdn.net/hphotos-...2_479193_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._5382112_n.jpg

More updates tomorrow as we plate the rear section, fab up the down tubes, bend up the halo, and the A pillar bars.

Hope you have enjoyed our update for today.
I will leave you with a cool shot of the sunset we had here today at the shop.

http://sphotos.ak.fbcdn.net/hphotos-..._6215031_n.jpg

We stayed late and started gutting out the doors so the roll cage can protrude into the shells.

http://sphotos.ak.fbcdn.net/hphotos-..._3113106_n.jpg

We also removed the inner wheel house leaving behind the headlight and fender mounts.

http://sphotos.ak.fbcdn.net/hphotos-..._2548638_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._1569235_n.jpg

http://l23.sphotos.l3.fbcdn.net/hpho..._8307945_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._7295098_n.jpg

More updates coming tomorrow!

http://sphotos.ak.fbcdn.net/hphotos-..._1796204_n.jpg

Today we finished notching the tubes for the rear "X" brace and tacked everything up.

http://sphotos.ak.fbcdn.net/hphotos-..._4723444_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._1464138_n.jpg

Started welding up some sections of the cage tonight.
http://sphotos.ak.fbcdn.net/hphotos-..._7033345_n.jpg

Also started chopping out some more of the plastic inner fenders to provide the steering clearance we need for drifting.

http://sphotos.ak.fbcdn.net/hphotos-..._6742249_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._2368776_n.jpg

And yes. Our tool boxes here at Blu808 have Blue under glow.

http://sphotos.ak.fbcdn.net/hphotos-..._2363917_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-...4_110642_n.jpg

All of the body panels fit great. So it should only take some minor bracing for the fender supports.

More coming your way tomorrow!
Also you can keep track of the build on Welcome to Blu808 - Engineering Performance

What final weight are you guys shooting for? and how many horses

Our new fire system came in today. It is a safecraft 10 Lb model.

http://sphotos.ak.fbcdn.net/hphotos-..._1465974_n.jpg

In preparation for our new LG setup we removed the entire drivetrain from the car today.

http://sphotos.ak.fbcdn.net/hphotos-..._5793235_n.jpg

And the engine.

http://sphotos.ak.fbcdn.net/hphotos-..._4237987_n.jpg

All ready for Chassis prep!

http://sphotos.ak.fbcdn.net/hphotos-..._5208346_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._2252818_n.jpg

We will be having a big announcement soon with our new drivetrain package.

Just got a shipment in from the guys over at LG Motorsports.

They sent over their Super Cool Radiator. The pictures do not do it justice. The end tanks are not sheet aluminum. It is actually fabricated out of what looks like 1/8" thick. Should be super durable and add that extra cooling that any race car would need. The execution of the setup is really well thought out. There are all sorts of tabs and brackets already welded onto the radiator so all the stock shrouding and fan will snap right into place. There are even provisions for the AC condenser. How cool is that?

http://sphotos.ak.fbcdn.net/hphotos-..._4900444_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._6421851_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._3198264_n.jpg

The next item that we were really excited about were the LG Motorsports Super Pro Long Tube Headers. Again. The build quality on these headers is amazing. We have used these headers many times in the past and remain the first choice for many top racers in the industry.

Lou and the guys over at LG actually had to formulate a new production process just for the collectors. These are the only headers on the market for your Corvette that come with a true full race collector. Amazing!

http://sphotos.ak.fbcdn.net/hphotos-..._2287576_n.jpg

T304 Stainless steel, beautiful tig welds and construction.

http://sphotos.ak.fbcdn.net/hphotos-..._4544641_n.jpg

This is really shaping up to be a fun build. We would like to invite everyone to come by the shop to check it out in person. We are located in the northern California area.

We also managed to get the halo bar bent up, notched, and fitted today!

http://sphotos.ak.fbcdn.net/hphotos-..._5109438_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._6531196_n.jpg

The fitment on this cage is awesome!

http://sphotos.ak.fbcdn.net/hphotos-..._1490994_n.jpg

Thanks for the comments guys. Please keep them coming!

Another update. We started mocking up all the suspension components tonight at the shop. We have the LG coilovers in place, and will have everything ready for when the LG Billet uprights and Sway Bars show up.

http://sphotos.ak.fbcdn.net/hphotos-..._7654224_n.jpg

Little update.

We have removed the hatch and the bodywork. We will be doing some modifications to the oem roll cage structure to provide proper head clearance with the new roll cage.

http://sphotos.ak.fbcdn.net/hphotos-..._1505672_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._8109925_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._4847328_n.jpg

Tonight we got all the control arms bead blasted to inspect for any cracks. Everything looked good. We also removed the front cross member in preparation for tomorrows cleaning.

http://sphotos.ak.fbcdn.net/hphotos-..._8374782_n.jpg

Our LG Motorsports World Challenge hood arrived today! Looks great!

http://sphotos.ak.fbcdn.net/hphotos-..._7181057_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._2515549_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._2557727_n.jpg

We did some mock up for the custom steering system tonight and we are able to get upto 55 degrees of steering angle with our setup. This should be very competitive.

http://sphotos.ak.fbcdn.net/hphotos-..._1760097_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._7797258_n.jpg

Just received the LG Carbon ZR1 Splitter/Side Skirt Package. I must say that the fit and finish on these pieces is factory tight. I have dealt with many aftermarket body parts over the years, and can honestly say that these will bolt right on without any modifications. The sideskirts are autoclave produced and the weight next to nothing. The front lip features a complete under tray to improve on the GM design, and they reinforced the edges for added strength.

http://www.lgmotorsports.com/catalog...irts%20web.jpg

http://lgmotorsports.com/gallery/alb...tail%20web.JPG

More pictures coming your way tomorrow!

We spent the evening bending up the "A" pillar bars for the cage and tacking everything into place.

http://sphotos.ak.fbcdn.net/hphotos-..._7976950_n.jpg

The fit and finish turned out really great.

http://sphotos.ak.fbcdn.net/hphotos-...1_756056_n.jpg

We always try to position the tubes with the drivers "line of sight" in mind. This configuration shouldn't add any blind spots.

http://sphotos.ak.fbcdn.net/hphotos-..._1684250_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-..._5648382_n.jpg

We also took some of our in house laid Carbon sheeting and covered up a hole that was left after we removed the cabin pressure equalization vent.

http://sphotos.ak.fbcdn.net/hphotos-..._1581028_n.jpg

Thanks for looking. We are working overtime this weekend to finish the cage. Stay tuned!

those door bars are ballin. hell, what part of this build so far isn't?

Looking great so far! Any build videos in the works ;)