OKW 91 RS Build Thread (Photo Heavy) - Camaro5 Chevy Camaro Forum / Camaro ZL1, SS and V6 Forums

Third-Gen · 07-04-2012, 03:16 AM

Ok guys, this car is a few years in the making so far. I bought this car all original about 5 years ago. 305 TBI, 700R4, peg-leg, rear drums. I have the build sheet from the factory somewhere, Ill scan it when I find it. Well, after 150k miles the head gaskets threw in the towel. Time for some upgrades. Ill spare you the long story of how all the parts were aquired, but just know it involved a lot of long nights, selling stuff I didnt need, and eating Top Ramen for dinner waaaay too often. I am also using this car to do promotional work for my garage based shop (for now), Olson Kustom Works.

A few years ago, I updated the brakes to Corvette C5 Z06 disc/disc. Please ignore the rims, they were all we had at the shop that would fit the new brakes (16's wouldnt clear). The stock master was actually very well sized for the system, and under very hard braking, the rears locked up right after the fronts, and did nice controlled slides when needed. Im very happy with this brake setup, but after you see my engine/trans combo, I might be upgrading to 2010 CTS-V brakes.

heres a pic after the brakes, before all the big work started.

OK now to the most current stuff. First thing, pulled the 305 and trans out. what an ugly outdated mess!!

aww such a sad little 305

Next, I made a call to BMR, who helped me out and I got basically every part they make for the Third-Gen F-bodies. Heres a quick list:
Tubular K-Member
Tubular Control Arms
Front Coilover Conversion
Trans Crossmember
Front and Rear Sway bars
Torque Arm
Trailing Arms
Rear Coils
Panhard Rod and Relocater

Also, ProForge hooked me up with an all new steering setup.

Heres just a few of the pics (im going to go easy on your internet service)

I did this rear frame mods way before the suspension, but its still in progress, so in order of completion, its after the suspension. I never liked the way the rear area of the Camaros were, plus I wanted center exhaust, and to run a fuel cell. The new floor will have a heat shield under it, with 2 mufflers transverse, like a Vette. Fuel cell will go on the top side, with a blast cover over it, and blast venting downward out of the floor. Now I know most of you guys might oppose to the fuel cell in the inside of the car, but its not something im just throwing in the trunk of a Civic and going driving. I wanted to get the fuel away from the rear axle and exhaust heat, and run a remote filler to the b-pillar as well. I also did the mod to get directly to the subframe for the rollcage, which will come later. there is a piece of sheet metal on top of the bracing now, just dont have a pic of it yet.

Just a few pics::

Next, I think Ill show you the cage. I had a nice Mittler Bros bender and notcher at my old work, but now I have a JD2 and a Bridgeport at home to do more cage work. I went a little nuts on the cage. 1.75" Mild Steel, .125" wall. 1-piece main hoop and front hoop. All TIG welded. All frame plates are welded directly to subframes and suspension points on the car, not just the floor sheet metal. See pics for details. I wanted to make sure this car is suuuuper rigid.

Next up is engine. I bought a blown up LS3 from a company I worked for. EVAP lines were hooked up wrong, and dumped raw gas into manifold, which made the engine run rich during tuning, then after tuning it was done, it ran lean 1/2 the time. Ka-Boom. So a nice complete, blown up LS3 is waiting for a rebuild. I also bought a Harrop TVS2300 off a GTO. Its for the cathedral port heads, but I plan on using a set of LS6 heads to make it all work.

Just ordered my trans from a guy on the forum. Excited!!!!!! I bought a TR6060, ACT Twin Disc, and all the parts to make it work.

I build custom headers and stainless exhaust in the home shop, so once I get started on that I will post up some pics. Lemme know what you guys think!! Try not to be too harsh :-)

Oh, BTW, Im putting a 5th Gen dash in it :-) Just needs some trimming.

25thanniversary · 07-04-2012, 03:50 AM

Nice build keep us updated I can't wait till my 305 engine to blow up so I can mod my car. But so far I need a lot of miles to go. I have 71,000 miles on the car and she still runs strong.

Third-Gen · 07-04-2012, 04:15 AM

Thanks! ya you have a few more miles to go before you catch up haha. Wish I had a Vert to drive on sunny days, I love how those look. Ill just have to settle for t-tops.

An FYI on the 3rd gens, after about 110k if it starts to run rough, have no power, or start and stall, the fuel pump pickup tube has turned to mush. Had 3 different 3rd gens, all did it between 110k and 120k. Once i replaced the pump and the tube, they all ran strong up into the 150's. Great cars, just time to modernize this one (and show off some skills too)

mikepage0007 · 07-04-2012, 09:00 AM

looks like a lot of work, good start

TCAT · 07-04-2012, 09:53 AM

Bitchin Jesse!! I'm definitely subscribing to this. The build is coming along great, and that ca will be a monster when you're done.

Third-Gen · 07-05-2012, 01:30 AM

ya i cant wait to drive it again. its been down over 2 years, almost 3. transmission should be here next week sometime, then i just have to find an axle.

kyjohn · 07-05-2012, 04:43 AM

That car is going to be awesome.

demonspeed · 07-05-2012, 08:11 AM

Best of luck with the build. Happy to see 3rd gens get the love they finally deserve.

Chito · 07-05-2012, 11:17 AM

When your done I'm sure the car will be amazing, this brought memories of when I used to own a 91 iroc Z. Keep up the good work.

leonardo · 07-06-2012, 01:56 PM

very nice build bro ! you do some great work

Third-Gen · 07-07-2012, 02:36 AM

had a few hours to kill before a bonfire tonight, so i decided to get some exhaust done. Now, before I begin, I have to mention that I have 2 different mufflers. one is a 2.5" in/out, and one is a 3" in/out. The funny thing is, both of them use the same size baffle tube inside (2.5), its just the end caps are a different size. So even if I was using all 3" tubing for the system, the bottleneck would be the mufflers at 2.5". Now, I could do a dual 3" and different mufflers, but trying to run dual 3" under a car that originally ran a single 2.25" and a torque arm suspension would be insanely tough, unless it hung down a bit. I figure for a street driven car making around 700hp, with 2" headers, dual 2.5", no cats, all stainless, heat wrapped should suffice.

Heres some pics:
Converting the 3" Muffler down to 2.5" (sorry for the crappy welds, all my #6 TIG cups are broken i had to use a #4.

As you can see, the 2.5" and 3" inner tube is the same size.

I made a set of tips out of some 304 sheet i had laying around, and some random bends and stuff. I have a small amount laying around (like 400lbs of 1-6"). hehe.

Gotta finish cleaning up and welding the tips, and polishing the inside soon.

heres the whole package tacked up and ready for test fitting, and making the mounts.

And heres the cutout where the tips are gonna come through. not quite sure how im gonna finish it off, maybe some sort of stainless trim with button head hex bolts? who knows. I gotta get a pic of the system mounted and see how it looks.

Third-Gen · 07-07-2012, 02:41 AM

just for reference, this is usually how i weld stainless :-) and thats a 1" diameter tube.

25thanniversary · 07-07-2012, 02:43 AM

that's a nice exhaust set up can't wait to hear it

Third-Gen · 07-07-2012, 02:50 AM

Chito, too bad HT5 is only 5th gens!! I dont know of any 3rd gen, or generic Camaro clubs in so cal. And im sure as hell not joining a "generic" club, unless its all muscle cars lol.

Leo thanks man, I do my best. Even though on my own cars I cut a corner here and there. I guess the saying "the shoemakers kids go barefoot" still has a place in my life.

25th, thanks! I cant wait to hear it either! Ive missed driving this car for almost 3 years. Its sad to walk out of the house every day and see it sitting in the driveway waiting for me to work on it. I just need to win the lotto and I would be all set! haha.

07-04-2012, 03:16 AM	#1
Third-Gen Olson Kustom Works Drives: 91 Camaro, LS3, TVS2300, TR6060 Join Date: Dec 2011 Location: Anaheim, CA Posts: 134	OKW 91 RS Build Thread (Photo Heavy) Ok guys, this car is a few years in the making so far. I bought this car all original about 5 years ago. 305 TBI, 700R4, peg-leg, rear drums. I have the build sheet from the factory somewhere, Ill scan it when I find it. Well, after 150k miles the head gaskets threw in the towel. Time for some upgrades. Ill spare you the long story of how all the parts were aquired, but just know it involved a lot of long nights, selling stuff I didnt need, and eating Top Ramen for dinner waaaay too often. I am also using this car to do promotional work for my garage based shop (for now), Olson Kustom Works. A few years ago, I updated the brakes to Corvette C5 Z06 disc/disc. Please ignore the rims, they were all we had at the shop that would fit the new brakes (16's wouldnt clear). The stock master was actually very well sized for the system, and under very hard braking, the rears locked up right after the fronts, and did nice controlled slides when needed. Im very happy with this brake setup, but after you see my engine/trans combo, I might be upgrading to 2010 CTS-V brakes. heres a pic after the brakes, before all the big work started. OK now to the most current stuff. First thing, pulled the 305 and trans out. what an ugly outdated mess!! aww such a sad little 305 Next, I made a call to BMR, who helped me out and I got basically every part they make for the Third-Gen F-bodies. Heres a quick list: Tubular K-Member Tubular Control Arms Front Coilover Conversion Trans Crossmember Front and Rear Sway bars Torque Arm Trailing Arms Rear Coils Panhard Rod and Relocater Also, ProForge hooked me up with an all new steering setup. Heres just a few of the pics (im going to go easy on your internet service) I did this rear frame mods way before the suspension, but its still in progress, so in order of completion, its after the suspension. I never liked the way the rear area of the Camaros were, plus I wanted center exhaust, and to run a fuel cell. The new floor will have a heat shield under it, with 2 mufflers transverse, like a Vette. Fuel cell will go on the top side, with a blast cover over it, and blast venting downward out of the floor. Now I know most of you guys might oppose to the fuel cell in the inside of the car, but its not something im just throwing in the trunk of a Civic and going driving. I wanted to get the fuel away from the rear axle and exhaust heat, and run a remote filler to the b-pillar as well. I also did the mod to get directly to the subframe for the rollcage, which will come later. there is a piece of sheet metal on top of the bracing now, just dont have a pic of it yet. Just a few pics:: Next, I think Ill show you the cage. I had a nice Mittler Bros bender and notcher at my old work, but now I have a JD2 and a Bridgeport at home to do more cage work. I went a little nuts on the cage. 1.75" Mild Steel, .125" wall. 1-piece main hoop and front hoop. All TIG welded. All frame plates are welded directly to subframes and suspension points on the car, not just the floor sheet metal. See pics for details. I wanted to make sure this car is suuuuper rigid. Next up is engine. I bought a blown up LS3 from a company I worked for. EVAP lines were hooked up wrong, and dumped raw gas into manifold, which made the engine run rich during tuning, then after tuning it was done, it ran lean 1/2 the time. Ka-Boom. So a nice complete, blown up LS3 is waiting for a rebuild. I also bought a Harrop TVS2300 off a GTO. Its for the cathedral port heads, but I plan on using a set of LS6 heads to make it all work. Just ordered my trans from a guy on the forum. Excited!!!!!! I bought a TR6060, ACT Twin Disc, and all the parts to make it work. I build custom headers and stainless exhaust in the home shop, so once I get started on that I will post up some pics. Lemme know what you guys think!! Try not to be too harsh :-) Oh, BTW, Im putting a 5th Gen dash in it :-) Just needs some trimming.

07-04-2012, 03:50 AM	#2
25thanniversary Drives: 92 Camaro Convt RS,2011 Camaro RS Join Date: Mar 2009 Location: Laredo,TX Posts: 2,167	Nice build keep us updated I can't wait till my 305 engine to blow up so I can mod my car. But so far I need a lot of miles to go. I have 71,000 miles on the car and she still runs strong. __________________ TEAM LLT 1992 Camaro Rs Convertible 2011 Camaro 1lt Rs

07-05-2012, 04:43 AM	#7
kyjohn Victory Red Drives: 2010 Camaro SS Join Date: Jan 2012 Location: Paintsville,ky Posts: 191	That car is going to be awesome. __________________

07-05-2012, 08:11 AM	#8
demonspeed not afraid of the wall Drives: Camaros Join Date: Apr 2010 Location: Pittsburgh Posts: 2,148	Best of luck with the build. Happy to see 3rd gens get the love they finally deserve. __________________ 2023 1LE 1SS BCD GCF JF5 MN6 SIA SLN UQT 10/13/22: 1100 Past Camaros: 13 1LE\|02 SS\|01 Z28\|00 SS\|91 1LE\|91 Z28\|89 IROC-Z

07-05-2012, 11:17 AM	#9
Chito SoCal HT5 Drives: 2010 Camaro black 2ss/rs Join Date: Jul 2010 Location: So CAL. Posts: 1,391 View My Garage	When your done I'm sure the car will be amazing, this brought memories of when I used to own a 91 iroc Z. Keep up the good work. __________________

07-04-2012, 04:15 AM	#3
Third-Gen Olson Kustom Works Drives: 91 Camaro, LS3, TVS2300, TR6060 Join Date: Dec 2011 Location: Anaheim, CA Posts: 134	Thanks! ya you have a few more miles to go before you catch up haha. Wish I had a Vert to drive on sunny days, I love how those look. Ill just have to settle for t-tops. An FYI on the 3rd gens, after about 110k if it starts to run rough, have no power, or start and stall, the fuel pump pickup tube has turned to mush. Had 3 different 3rd gens, all did it between 110k and 120k. Once i replaced the pump and the tube, they all ran strong up into the 150's. Great cars, just time to modernize this one (and show off some skills too)

07-04-2012, 09:00 AM	#4
mikepage0007 Drives: 2010 camaro Join Date: Aug 2009 Location: port st lucie ,florida Posts: 4,273	looks like a lot of work, good start __________________

07-04-2012, 09:53 AM	#5
TCAT Drives: Has Wheels Join Date: May 2011 Location: On Earth Posts: 5,553	Bitchin Jesse!! I'm definitely subscribing to this. The build is coming along great, and that ca will be a monster when you're done.

07-05-2012, 01:30 AM	#6
Third-Gen Olson Kustom Works Drives: 91 Camaro, LS3, TVS2300, TR6060 Join Date: Dec 2011 Location: Anaheim, CA Posts: 134	ya i cant wait to drive it again. its been down over 2 years, almost 3. transmission should be here next week sometime, then i just have to find an axle.

07-06-2012, 01:56 PM	#10
leonardo SoCal HT5 [COTW 11/24/13] Drives: 2011 Camaro SS / Ducati 1198s Join Date: Jun 2010 Location: Orange County Posts: 3,857 View My Garage	very nice build bro ! you do some great work __________________

07-07-2012, 02:36 AM	#11
Third-Gen Olson Kustom Works Drives: 91 Camaro, LS3, TVS2300, TR6060 Join Date: Dec 2011 Location: Anaheim, CA Posts: 134	had a few hours to kill before a bonfire tonight, so i decided to get some exhaust done. Now, before I begin, I have to mention that I have 2 different mufflers. one is a 2.5" in/out, and one is a 3" in/out. The funny thing is, both of them use the same size baffle tube inside (2.5), its just the end caps are a different size. So even if I was using all 3" tubing for the system, the bottleneck would be the mufflers at 2.5". Now, I could do a dual 3" and different mufflers, but trying to run dual 3" under a car that originally ran a single 2.25" and a torque arm suspension would be insanely tough, unless it hung down a bit. I figure for a street driven car making around 700hp, with 2" headers, dual 2.5", no cats, all stainless, heat wrapped should suffice. Heres some pics: Converting the 3" Muffler down to 2.5" (sorry for the crappy welds, all my #6 TIG cups are broken i had to use a #4. As you can see, the 2.5" and 3" inner tube is the same size. I made a set of tips out of some 304 sheet i had laying around, and some random bends and stuff. I have a small amount laying around (like 400lbs of 1-6"). hehe. Gotta finish cleaning up and welding the tips, and polishing the inside soon. heres the whole package tacked up and ready for test fitting, and making the mounts. And heres the cutout where the tips are gonna come through. not quite sure how im gonna finish it off, maybe some sort of stainless trim with button head hex bolts? who knows. I gotta get a pic of the system mounted and see how it looks.

07-07-2012, 02:41 AM	#12
Third-Gen Olson Kustom Works Drives: 91 Camaro, LS3, TVS2300, TR6060 Join Date: Dec 2011 Location: Anaheim, CA Posts: 134	just for reference, this is usually how i weld stainless :-) and thats a 1" diameter tube.

07-07-2012, 02:43 AM	#13
25thanniversary Drives: 92 Camaro Convt RS,2011 Camaro RS Join Date: Mar 2009 Location: Laredo,TX Posts: 2,167	that's a nice exhaust set up can't wait to hear it __________________ TEAM LLT 1992 Camaro Rs Convertible 2011 Camaro 1lt Rs

07-07-2012, 02:50 AM	#14
Third-Gen Olson Kustom Works Drives: 91 Camaro, LS3, TVS2300, TR6060 Join Date: Dec 2011 Location: Anaheim, CA Posts: 134	Chito, too bad HT5 is only 5th gens!! I dont know of any 3rd gen, or generic Camaro clubs in so cal. And im sure as hell not joining a "generic" club, unless its all muscle cars lol. Leo thanks man, I do my best. Even though on my own cars I cut a corner here and there. I guess the saying "the shoemakers kids go barefoot" still has a place in my life. 25th, thanks! I cant wait to hear it either! Ive missed driving this car for almost 3 years. Its sad to walk out of the house every day and see it sitting in the driveway waiting for me to work on it. I just need to win the lotto and I would be all set! haha.