# 7 Cylinder and Door Panels

The issue with #7 cylinder has been resolved.  Matt P and John S helped diagnose the issue and we thought it must be either a missing or damaged intake valve stem seal or a bad fuel/injector.  Both were probable, both were wrong.  When the valve cover was removed I found a dislodged rocker at the #7 intake.

The possibility that normal break-in caused this is highly unlikely.  I found out I could turn the rocker nut with just my fingers and that's wrong.  Rocker nuts have crushed ends and require wrenches for installation and removal.  This one had little to no resistance.  I bought all new rocker nuts and replaced all the existing ones.  I paid special attention to the resistance when removing the old ones and I was surprised that several had little resistance.  The new ones are very tight and almost require two hands to tighten.

Lesson Learned:  Always pay attention to rocker nut resistance during installation.

Our cam card specifies .030/.030 lash on the intake/exhaust valves when hot.  Forum discussions on the National Corvette Restorers web page recommends .027/.027 for optimal performance.  Since a cast iron block with cast iron heads is expected to tighten .003 from cold to hot, I set lash at .030 cold.  I started the engine (it ran great), warmed it up, checked lash and sure enough, .027/.027.  I then checked compression and all cylinders were between 190 and 200 PSI.  We're good!

New Topic

I purchased a used passenger door panel on EBay recently.  I needed this panel because I didn't have several trim pieces, specifically, the hockey stick and the stamped steel upper piece (not shown).

These are the pieces I salvaged.  The stamped steel piece on the far left was sand blasted and painted.  The hock stick was fine as is.  The fuzzy window eyebrow piece, far right, was stapled to the stamped steel at the factory.  I have new eyebrows but I don't have a heavy duty stapler.  Humm...

The new eyebrows came with staples so I decided to use them.  I aligned, clamped and drilled the eyebrow then inserted, bent and secured each staple with pliers.

It turned out great.  One down, many to go.  (Note my fancy 4th of July cast)

Here is the completed passenger door.  The new brow is at the top.

I finished both door panels and they turned out very nice.

New Topic

Al Knoch Interiors finally sent all the seat components.  This Thursday I will drop everything off at a local upholstery shop recommended by several car enthusiasts.  I am told I can pick them up the following Tuesday.  It will be nice to finally get the seats done.

Don't forget, Hot August Nights in Reno, NV is our next car show and we hope to have the Corvette done for that event.  Dennis and Annette K will also be going and they intend to bring their 57 Chevy Nomad.  Should be a fun event.

Thanks for watching.
      

Door Panels

Unfortunately, I am still waiting on parts from Al Knoch Interiors.  They have wonderful products but their shipping policy is horrible.  I found out that when multiple items are ordered they hold shipment until everything is ready.  Any specialty item that requires fabrication will prevent in-stock items from shipping.  They still owe me parts for the doors and the seats.  This is not good.

Cool Desert Nights starts Thursday night.  I can't hold off on the doors and the seats anymore so I decided to assemble the doors knowing I'll have to go back later and add missing parts.  

These are drivers side door panels.  I have to take the parts from the old panel and put them on the new.  The "hockey stick" is simple.  What's difficult is on the back side.  

On the upper part of the door panel, the right side of this picture, is a stamped steel plate that's stapled to the cardboard panel.  These are beefy staples that go through both the steel and the cardboard.  These are not easily removed and I haven't a clue how the staples would be reinstalled.

Here is the sheet metal piece.

After sand blasting and painting I did a dry fit to the door.  No issues here.

I decided to use industrial grade contact cement to bond the sheet metal to the door panel.  It's very strong.   The hockey stick and other pieces were  attached to the new panel.

After the door panel was hung I installed the window cranks, door knob, arm rest, and door lock.  I am pointing at the door lock.  This reflector twists to lock and unlock the door.  It's pretty cool.

I worked on the passenger door but I can't find the old door panel.   I don't know if it's misplaced or I never had it.  I emailed Dennis S. in Hawaii to find out if he remembers.  No luck.  Neither of us can say for sure one way or the other.  So, I am going to assemble the door knowing it has to be redone after CDN.

It looks nice but it's lacking the upper sheet metal and the hockey stick.

So, the doors are ready but the seats are not done.  Thursday night I'll take the Corvette to Dairy Queen for what many believe is the best CDN event.  Richland shuts the street down making way for hundreds of classic cars.  I'll post pictures Friday.

That's it guys.  We are almost done.

Hope to see you there Max!  You too Ty!


My Distraction

Ta-da.