1992 RS Camaro. First car for Der Burger.

We worked on the car on Sunday.
I had her finish cleaning the seats as she totally missed the sides of them.
After that we oiled up the adjuster wheels and pivot points so they moved freely.

Then I confirmed that the neutral safety switch is a pile of crap.
I loosened the mounting bolts and moved it around until the car started cranking again.
So looking around the net seems to turn up few options on the switch.

I will improvise.

I just bought her this little button that will be mounted under the headlight switch.
There is already a hole there where something had been mounted and removed, so it will be perfect.
She will now have a push button NSS while cranking the ignition.
I will simply splice into the wires without disconnecting them, kind of an anti theft thing as the OG switch will still kill the starter.

While on the Billet Automotive Buttons web page, I found this one for my truck.
Max has yet to actually fix my horn, so this will work like a champ in the meantime...

BearKing said:

I own a 1991 Z28 with the factory 5.7. It hasnt been out for almost 4 years. Just bought new Plates for it and I am putting in new injectors next week. It’s a mover for sure. Factory G80 rear and no T Tops. The rear Wing/Spoiler is one of my favorites. I have a few Second, Third and Fourth Gen Z28’s. Anyway, nice Third Gen. I love Camaros, Corvettes and Squares. GM all day long.

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Bear, let's see it dude.

JamesSam said:

Bear, let's see it dude.

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I will get a picture tomorrow. It’s on wheel dollys in my shop. Very dusty but it’s all mine. It’s sitting next to my 98 Z28 and my 94 Vette. I need to drive them more. Only put about 200 miles each year on them for the last 3-4 years. Life is just too busy.

How it came to us on brand new Generals on 14 inch wheels with Autozone hubcaps installed....


Without the hub caps is nearly as hideous on this car...


Here we have the Camaro on its fresh Z28 wheels and tires.
It looks so very much better with them on...


The 205's on the left and the new 235's on the right.
I thought about getting wider tires for the rear, but its not mine and I wanted the tires to able to be rotated.

Since I paid for them, I got to drive them first.
I tested them in front of the house and even though it is only a 305, it still does V-8 things.
Some day we will make it able to spin both tires by swapping in a Gen 4 rear-end with limited slip and disc brakes.


I parked the car in the driveway and Burger hopped into the seat for a test drive.
She backed out and jumped on the gas a bit hard and left her own black mark in the street...

Yesterday we put the car up in the air to start on the fresh exhaust for it.
What came on the car is just a pile of crap.
I knew this after getting it home and looking under the car the first time myself.

Here we are behind the front passenger tire.
The Y pipe looks to be in decent enough condition, so we are going to be removing everything from there back as it is all crap.


You can see the spot where they attempted to weld onto the OG exhaust pipe and the random cut they made and abandoned.
It was welded so well that all it took to remove the cat off the pipe was a bit of wiggling and a solid pull.
Popped right off...


This is just after the cat that had been installed by a PO.
On the right you see it has a reducer from the cat to the exhaust pipe.
Under the soda can and hose clamps is some fine JB Weld plugging a hole where it looks like a hanger broke away.
The center dark pipe is some random piece that was put in to connect to the parts store crinkle bend pipe that goes to the rear.
That connection was very poorly welded and it was covered in exhaust wrap, but the gasses still blew out of all the pinholes...



That fine crinkle cut French fry pipe looks to have been installed quite low by the finely qualified installer.
It seems to have met many speed bumps to help it fit the shape of the bottom of the car just that much better.
Note the lack of rusted parts on the bottom of this 32 year old car...

More of the first connection to the Y pipe.
They used lots of different pieces to get all this contraption all connected up, poorly.


We are going to use this as sort of a template to follow-ish and improve upon for the new 3 inch that we are going to put back in place.
There will be every consideration made to get the piping up tighter to the bottom of the car, speed bump friendly like...




The old muffler was a Magnaflow and it was booger welded on as well.
A sawzall made quick work of it.
Now you can see it has been bashed on something as well and more of that fancy JB Weld booger hole patch.


Here we have the new "muffler".
I wanted a new Flowmaster 80 series for it as that is what my brothers car had and it was only a 2.8 V-6 car.
They are still fairly proud of that one at $165.
Then I thought that a Spintech would be sweet as well and they were similarly priced at $165, but with a $39 shipping fee attached.
Nope.
I looked at many different brands and listened to them through YouTube videos and whelp, they all sound the same ish.
I didn't want a straight up Amazon brand, so I picked the Thrush variant at its $65 and $11 shipping from Summit.
Dumb part though is that it only comes with 2-1/2 inch inlets and outlets.
We will address this when we get to the rear of the car exhaust work....

Here is one of the tailpipes that came on the car, a nice piece from Magnaflow.
There is a matching one on the other side as well and they are both 2-1/2" inlets that expand up to 3 inch all the way out to the slash cut.
They like the rest of the car, are partially coated in that stupid plasti dip crap.


New muffler inlet at 2-1/2 inch and the 3 inch that we will be connecting to the muffler.
We will be cutting the inlet pipe off at the pipe size and the exhaust pipe will be welded on there.


She was changing all of the headlights out for new ones.
I caught her taking a pic for the 'gram...


Those cleaned up quite well.
At least good enough for a driver quality car for a teenager...


When we get to this point, that is the idea of what the tail pipes will look like even though I have it pointed the wrong way.
The necked down portion of the tip will be cut off and they will be welded to the 3 inch.
The pipe will be painted in BBQ black to keep it from rusting and the chrome tips will be allowed to shine.

So, we are building the cat up to connect to the existing Y pipe.
The one I purchased is this Magnaflow one and it is 2-1/2 inch in and out.

Not the 3 inch the rest of the exhaust will be.
So the other day I purchased 4 V-bands of the 2-1/2 inch variety to make this happen with purpose.
I drew out what I wanted on cardboard and sent the boys on a mission to find stuff.

The Y pipe is something like 2-1/8 inch so we need a increase to get up to 2-1/2 inch for the cat.
After that first increase in size there will be a 2-1/2 inch V-band, then the cat itself, and a short piece of pipe to match what came off the car.
Then there will be another 2-1/2 inch V-band that connects the cat to the rest of the exhaust.
Similarly there will be a test pipe with V-band fittings made up that matches that can be swapped in and out for "test" purposes.

Just after the last V-band of the cat there will be another increaser to get us up to the 3 inch tubing we are going to make the rest of the exhaust out of.

Now young Max has had no real training other than YouTube University videos and getting out there and pulling the trigger on the welder.
With that said, I would say that his welding is pretty decent and exhaust is a great place to learn as it is thick enough to be semi forgiving.
Our welder is from Harbor Freight and does not use gas at this time, so he does quite well in mine own eyes.

Here is the cat and on the right is where it will connect to the Y pipe then the first band.


Three pretty decent welds going on here.
All welds were made with the V-band cage fully tightened down to mitigate any warping of the mating surfaces during the heating cycles.


V-band cage removed after cooling.


Pretty good penetration.

While doing the wheels and tires we noticed that one of the brake hoses was well worn through the outer rubber.


Once I was told, I hopped on the interwebs and found a set of braided stainless hoses from Edelbrock that were on Amazon.
They were available next day, so they were ordered right up.



The car came with a set of wheel bearings, so we will be looking into changing those out as well, because why not?


I pulled these out of the junkyard car, we shall see if they work.
If not, no big deal as they were super cheap from they yard as they may have been buried and not real visible...

So that is where we are today, in the middle of creating a new complete exhaust for it.
We have some brake and bearing work as well.

The kids out on the tire test drive...


Burger had Max take a glamour shot...

Yep, the new rolling stock looks WAY better!

Catbox said:

So that is where we are today, in the middle of creating a new complete exhaust for it.
We have some brake and bearing work as well.

The kids out on the tire test drive...

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Burger had Max take a glamour shot...

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Is it just me or does the steering wheel look to be on the RH side in picture #1 lol
the car is coming along real nice! Go team!!

squaredeal91 said:

Is it just me or does the steering wheel look to be on the RH side in picture #1 lol
the car is coming along real nice! Go team!!

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Everything is backwards on the gram!