Tuesday, September 29, 2015

Found out where white noise was coming from

So my Retrosound Zuma radio has always had a constant white noise.  At first I thought it was the Rockford amp I have running the rear speakers and sub, but then I discovered it was in the front speakers too.  Those are run solely by the head unit.  After playing with ground loop isolators on the inputs as well as completely disconnecting the inputs, I tried an antenna filter.  That didn't do anything either.  So then I was convinced it was a bad ground.  So I cleaned all grounds and even added a couple body to frame connections.  Still white noise...

At that point I was frustrated...  all the wiring in the car is new, all the speaker wire is new, and even all the speakers are new.  I contacted Retrosound, and they agreed something wasn't right.  While in contact with then I added a power filter to the 12v line to the radio.  After adding that I discovered something about the noise.  It only happens when the EQ in the radio is used.  A preset or using the bass/treble adjustment.  Any amount of EQ (positive or negative) and the noise started.  It was a constant level of noise unless volume was set to 0.

After telling this to Retrosound they said I would need to RMA it so they could test it.  However since its over 1 year old (the warranty length) I would have to pay full price for the new model to replace it if it was bad.  Drives me crazy to hear things like that...  It's always been this way, and I didn't have the time until now to prove it was a problem with the radio.  Why would I bother sending it in?  It's clearly the radio...  Seems like the least they could do is offer a discount on the new model.  I mean this radio has maybe 2 hours of total use on it and has been in the car for about 1600-1700 miles.

Still deciding if having an EQ is worth the cost of the new radio.

Sunday, September 13, 2015

Feels good... Should have started sooner

It really does feel good to be getting things done on the car again.  Extremely satisfying when my projects turn out to work!

Got my service cart last week.  Works great and is now full of tools and parts.

As for all my routine service on the car, done!

  • Power steering fluid change and leak fix, check!
  • Removal of the transmission cooler filter, check!
  • Flush coolant, check!
  • Install stainless steel flex lower radiator hose, check!
  • Clean all chassis ground contact and install new grounding straps, check!
  • Change engine oil and filter, check!
  • Fix power steering pulley alignment, check


The power steering fluid leak appears to be on the fitting for the output side of the rack-and-pinion hose.  It seems that it's leaking because I was not able to tighten the fitting around the hose enough.  Since these are high pressure SS braided Teflon hoses, the fittings do not swivel.  In order to get the fittings aligned properly I had to install the final fitting with the hose installed.  I could probably mark the alignment, take the hose off, and tighten it outside the car but I'd lose all the fluid I just put in (Royal Purple is freaking expensive).  As I tighten the fitting around the hose, it twists and ends up causing the hose bend strangely.  So I just tightened it up and fixed the twist by changing how the hose was routed.

The stainless steel flex radiator hose was kind of a pain to get on, but in the end, a little easier than I'd assumed.  First, I used a flapper wheel to enlarge the opening of the hose end covers.  They wouldn't fit over the lip of the water pump or radiator ports.  Then I trimmed the tubing to the right length.  Finally, I soaked the couplers in boiling water for a while to make them softer.  I ended up having to put a little dish soap around the outside of the ports, but with lots of awkward angle pushing and some cut up hands, I got the couplers, covers, and tubing in place.


You're probably wondering if it was worth removing a perfectly good hose and putting in this expensive stainless steel one that was a pain to put in.  To be honest, I'm not sure.  It gained me extra clearance between the spreader bar and hose as well as between the hose and serpentine belt.  There's also less of a chance of rupturing the hose.  Only the couplers are susceptible to rupture and they are covered with aluminum hose ends.  One top of that this new hose does look cooler than a normal hose.

The cleaning of the chassis grounds and getting new body grounding straps had a great result.  The car now starts immediately with a single pump of the gas pedal.  It freaking scared me the first time I turned the engine over.  I was expecting to hold the key for a while and pump the pedal.  This also appears to have fixed my rough idle.  I was having to double foot it previously to keep my RPMs up, but not any more!

As for the pulley squeal...  gone!  My diagnostic using the water lubricant trick was correct in showing it was the power steering pulley.  A shop used some tools and said it was an idler...  I thought they were wrong, but replaced the idler anyway and the problem did not go away.  I pushed the pulley on the power steering pump just a little more and all the belt squeal was gone.  The car is no longer embarrassing to drive...

The final thing I looked at was the blinkers.  They would not work with the headlights on.  I had posted to some forums about this and the responses thought I had bad grounds, so I tested all of them.  Every ground I tested was good.  So then I examined the wiring schematic some more.  I noticed one of my parking lights wasn't coming on.  Took a look at that and discovered a bent pin in the connector.  Then I decided to give regular bulbs a try to see what would happen.  I couldn't explain the problem from the wiring, but I had swapped in LEDs and an electronic flasher.  Sure enough, the blinkers started working.  After trying different combinations of LEDs and standard lights I'm now running with a standard flasher and normal front and rear bulbs.  All my side markers are LED.  I ordered a couple different flasher modules to see if I could get the LEDs to work right without adding load resistors (last resort).  I also tried a different style LED tail light, and the interesting thing was that it flashed at a different rate than the old LEDs even though it was connected to the same circuits.


My son really want to help daddy "fix blue car".  So I let him get tools off the cart, get paper towels, and handle the empty oils bottles.  He liked it.  This afternoon I took him out to the grocery store in it as a quick test.  It was the first time after all these changes that the car had moved.  We had no problems at all!  No signs of leaking, no overheating, no smoke, nothing...  I should have done this stuff at beginning of summer!

Wednesday, September 9, 2015

Working on the Car Again

So it's been months (possibly over a year) since I've gotten to do anything on the car.  Other things just seem to take precedence when you've got a 2 year old, 5 month old, and a brand new house...

If you saw my last post you know my dog died earlier this year, but I didn't post that our second dog died as well.  He never hung out in the garage with us (big chicken), but he was a great dog.  He was a Great Pyrenees about a year younger than our Bernese and he died about 2 months after our first one did.

Anyway, enough with life stuff...  I finally finished the garage enough so that I could start using it!  I still lack a workbench and one overhead light, but it's very usable in its current state.  There was one thing I forgot while I was designing the garage...  If I'm working on the car in 2nd stalls, having all the tools in the shop about 20 feet away gets old!  I'm constantly walking back and forth.  Easy problem though.  I ordered a service cart that should be here next week.

The car has barely been driven this year.  I took it out a couple times in the spring and then it just sat waiting for me to do the first oil change and do a complete fluid flush.  I also stopped driving it because I'm having an awful belt squeal that I need to fix.


Sorry, this is a boring post. No pictures...  Didn't have time.


So I geared up at the beginning of the summer to do the repairs...
Got new beefy grounding straps (cause for some reason when I did the wiring harnesses I left out the grounding straps, what's that about?).
Electrical contact cleaner to address the radio noise and the blinkers not working when the headlights are on.
A couple door/alarm sensors because I broke one trying to mess with it.
Puller pusher and jaw puller (should have bought this from the get-go).
Digital ignition mounting plate.
And of course a new oil filter and coolant.

I haven't ever installed the new ignition system because I wasn't sure how to mount the digital ignition box in the engine compartment.  Hoping I can work something good up using the Summit mounting bracket.


Since the weather got nice on Sunday and we had the kids at their grandparents for a while this weekend I decided it was time to hit the garage.

Started with a simple inspection...

Found that my power system hoses were leaking!  (again)  I'm not sure which fitting is leaking because it appeared that multiple places were wet with fluid.  So I removed the wettest fittings, tightened the connection to the hose, reconnected everything, and then flushed the system with Royal Purple fluid.  I found a little fluid on a hose tonight but it looked like the original fluid so I cleaned everything up and we're going to trying again...

Once I had that done, I removed the inline transmission fluid filter.  According to BTO, it only had to be on there for so many miles and I was well over that mileage, so I took it off.  It was kind of an eye sore and made one of my lines go out of place.  To my surprise I didn't lose much fluid in the removal.  Still have to recheck once the car is level and running for a little bit.

Next I addressed the power steering pulley.  It appeared to be less than a 1/16" off, so I put my new pusher on and tried to align it again.  We'll see once I can start the engine again if I got it right this time.  I'll probably need to get a new serpentine belt because this one has worn from rubbing the pulley edge.

Moving on, I drained the coolant.  I know this isn't REALLY necessary, but since it was a brand new engine I think it doesn't hurt to make sure there was no metal flecks in there.  Plus I wanted to swap in a flex stainless steel hose for the lower radiator hose. The flex hose is smaller and there's less area for failure.  Unfortunately the end covers wouldn't fit over the ports on the water pump and radiator so I'm going to have to mod them a little.  That's sitting to the side for the time being...

So, my last task of the night.  Clean up the chassis grounding...  I went through every ground in the engine compartment and nose of the car with steal wool, a steel brush, and contact cleaner.  I then checked the resistance from each contact to the chassis to make sure it was pretty much non-existent.  Once that was done, I replaced the grounding straps in the back under the antenna and in the engine compartment near the proportioning valve.  The new straps are considerably larger than the old ones.  Makes me feel a little better.  So I checked the turn signals...  They STILL don't work with the headlights on!  It has to be the ground in the passenger compartment.  Those are a pain to get to so we'll save that until all my engine servicing is complete.


So what's left to do before driving it again this year?

Install SS lower radiator hose and refill coolant.
Verify power steering leak is gone and fix if necessary.
Change the oil.
Change serpentine belt if it's still noisy.
Replace in-line fuel filter.
I'd also like to get the blinker working with the headlights in case it gets dark while I'm out...


Ok, a couple pictures of the garage before I cleaned up all the boxes and other crap...


Wednesday, April 8, 2015

A daughter, the passing of my garage buddy, and still working on the garage...

Some good news first.  My daughter was born March 28th and both baby and mother are doing well.  We're home and her brother seems to like her.  My son is 21 months old and refers to the Corvette as "daddy's blue car".  I started it about once a month this winter to keep oil circulating, and he insisted on coming with me to start it.  He sat in the passenger seat while I got it started.  It'd been sitting for a while so it took a little bit for it to start (plus I'm pretty sure I could use a new starter), and he got a little scared.  Ever since he says "blue car...  loud".  It's pretty funny, but he's since gotten over it somewhat and ridden in it twice.  Just this last weekend he got to ride in it with the top down.  He liked it.  (Sorry no pics...)

A few years ago I posted a picture of my Bernese Mountain dog, Charlie, hanging out in the garage as I worked on the car.  He liked the cool cement floor and he usually just liked to be where ever I was.  Last night Charlie died from bloat, a not uncommon condition that occurs in large breeds where the stomach twists.  He was staying with my in-laws while we got used to having a second kid in the house.  I feel bad that he wasn't with us when he passed, and that he didn't get to hang out with me in the garage in the new house.  He was a good dog, he will be missed...


I have continued to work on getting the garage and shop area of the new house ready to do work.  Unfortunately, I'm still not quite there yet.  The remainder of my cabinets are coming this week and I'm working on installing shop lighting.  If you're looking to do LED strip lighting for cheap, check out 1000bulbs.com for some pretty good deals.  I decided that I didn't like having LED fixtures where I couldn't replace the bulb, so I grabbed some 2900K 4 ft. long LED bulbs for $10 a piece.  Converting fluorescent fixtures to use the LED bulbs is really simple because the fixtures are designed to have the ballasts replaced.  I've converted 9 cheap $12 fixtures from Menards and 4 $30 3-light fixture from Home Depot to use the bulbs.  If someone is interested, I can post the process for converting the two fixtures.

The start of my lighting project.  5 fixtures and cable management to go.
3-light fluorescent fixture I'm going to use in the garage portion of the shop.
The Corvette has reached the critical mileage (1500-2000 miles) where fluids need to be changed for the first time after the rebuild.  As soon as I've got the lighting in the garage set, I'll be changing to a synthetic power steering fluid (Royal Purple), changing the oil and filter, flushing the radiator fluid and swapping the lower hose for a stainless one, removing the transmission fluid filter (refilling for lost fluid), and also replacing the inline gas filter.  This should ensure there's no burrs present from machining or making of the hoses in any of the fluids.

Unfortunately, being that I'm getting to this point when it's spring, I don't really want to start projects on the car.  I want to drive it!  I've got the MSD digital ignition, ignition coil, and pro billet distributor sitting here just waiting to be installed.  I haven't decided if that project will be started when I'm changing fluids or not.  The new starter I think will be a project for this coming fall/winter along with "never night" and electric headlight conversion (the stock headlights suck, but I guess I'm used to the HID projectors on my 2013 Charger....).

Thursday, December 4, 2014

Garage is coming along, but not enough to work on the car yet...

Garage storage and equipment is really expensive, but in my opinion very necessary.  I've slowly been accumulating pieces as I see them on sale.  By the way, if you're not aware of the site slickdeals.net, it's awesome.  I set up notifications for when stuff goes on sale (very rarely is a good deal not posted).

Anyway, I've bought into the Gladiator GarageWorks stuff.  It's pretty decently made stuff but expensive normally.  However, when it's on sale it's usually cheaper than generic brand stuff.  Lately it's been on sale a lot at Sears.  I've gotten several wall cabinets, hooks, and baskets.  I've gotten cabinets up, shelving, and a large storage rack.  I've still got some more another rack to assemble, hook rails to put up, adjustable shelving to install, and wheel/tire racks to put up.  Here's my setup so far.  Have I mentioned that there's 4 speaker ceiling speakers in there?


You can see I still have a bit of a mess...  The garage is taking over the duty of my old shed.  I plan to build a work bench under all the wall cabinets and put several floor cabinets under that.  I'm actually sitting on the Vette's fender to take the full width picture.  I have yet to find good lighting to install.


My new digital ignition, blaster coil, and billet distributor are sitting in their boxes still!  It's killing me not to work on it, but the car is running so have to prioritize.

Monday, November 3, 2014

Appologies...

I realized after a comment was posted that I've completely neglected this blog...

A status update on the car...
After my son was born last year in June, I really pushed to get the car done.  Well, at least what I had started.  My last couple posts were around that time.  As soon as I got it useable I basically stopped posted.  With the kid and work it just got hard to find time to work on this.

Everything did work out though.  The SharkBite Suspension is freaking awesome (the alignment shop was really impressed with it) and the TH-200 overdrive transmission makes cruising super comfortable (the 2nd gear shift kicks you in the back though).  As for the brakes.  Holy crap.  The car stops on a freaking dime now.  It can easily beat my 2013 Charger R/T Road & Track with the Super Track Pack in stopping power.  The interior turned out great.  The Vintage A/C is ok, but I would consider not buying a kit next time.  One of the biggest surprises was the seats.  I ended up with Mr. Mike's Fiero seats.  I got black leatherette with black embroidery and they look and feel fantastic.  No one can believe they're from a crappy 1985 Fiero that I found in a junk yard.  The audio system turned out good, but I definitely have some lessons learned that I should share, but that's for another time.

Ok, so what have I been up to instead of the car?
Well, for one, entertaining a little boy that's almost a year and half old one (crazy).  And two, building a new house!  We decided to build a new house at the beginning of the year because we were planning to expand our family further and frankly we were tired of having the garage dedicated to my project.

I designed the new house and had a professional designer tweak it.  In the end, he didn't change a whole lot.  I ended up with a 4 stall wide garage with two of the stalls extra deep and two sized to fit two full size F150s side-by-side.  It's over 1600 square feet of garage!  It's awesome...  I can't wait to get started working on the car again.  I'll have to post more pictures of the garage setup once I'm done.  Looks like a good place for a lift don't you think? =)





Monday, August 12, 2013

No posts because I was working hard on the car

Well I know I said there'd be more posts now that I'm done with school but between the kid and getting the final pieces of the car done there hasn't been much time.  However, the car is finally driving!  It's pretty nice...  Torque spews from the engine and reminds me I need new tires.  I'll post pictures and what I've learned during these past few weeks of fixing things.