Russ' AP GT40 Rebuild

Russ Rittimann

Russ Rittimann
Supporter
I acquired a Active Power GT40 that was started several years ago. Sat for a good while and deteriorated a bit so am in the process of rebuilding it back to it's intended condition . Relatively new Ford 302 with rebuilt Porsche transaxle, Corvette C5 suspension, Mickey Thompson tires. Needs a lot of work but that's what I enjoy. Tearing it down to the chassis. Replacing all brake lines, master cylinders, etc. Replacing all suspension bolts with Grade 8. I'll go from there. Everything has to be be precise for this engineer. I've got some frame mods in mind to make to help me fit better. I'm a big guy (6'3"). Dan Gurney fit so I should too!!! Russimage1 (2).jpgIMG_3078.jpgIMG_3081.jpgIMG_3096.JPGIMG_3100.JPG
 

Russ Rittimann

Russ Rittimann
Supporter
Another update on my GT40. Cleaned up the rear suspension components, painted the calipers, axle shafts, etc., replaced the bolts with Grade 8 components and put retaining bands on the CV bellows. Looking better. Some before and after pix. Still got plenty more to work on.

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what are you running for front a rear shocks and springs. Building an Active Power car as well and just curious what you are running

stack
 

Russ Rittimann

Russ Rittimann
Supporter
Springs - QA1
Front - 3.5" x 10", 450lb
Rear - 3.5" x 10", 650lb

Shocks QA1
Not sure of model. They are non-adjustable. These came with the car. Might be able to identify them on the QA1 website based on how they mount.

Note that I have an early model AP GT40. Rear calipers are on trailing edge. AP shifted the control arms/shocks and put the rear calipers on the leading edge. Chris said there were some concerns about the rear shocks interfering with the lower control arm and/or the CV joints/boots. My rear shocks have some brackets that offset them on the lower control arms towards the rear. Welding of the brackets was not that great and had to be redone..

Russ
 
Congrats on the new project, always glad to see another Active Power GT40!! I got mine almost 2 years ago now, and driving on the street this past summer. Look forward to seeing your progress!

-Peter
 

Russ Rittimann

Russ Rittimann
Supporter
Thanks much for the words of encouragement. My car had been started by a previous owner. Right now I have the front suspension components removed to bead blast them, replace all of the bolts with Grade 8, although the C6 suspension uses metric 8.8 so some will be metric, weld up some extraneous holes, powder coat some brackets and touch up the frame powder coat. I've found POR15 works real well to touch up black powder coat. Plus I'm replacing all the master cylinders and brake lines. The weather here in south Texas has been absolutely gorgeous so I've had to take care of outside home projects and the GT40 has had to wait. Our winters here are pretty minimal. Summers are brutal. I'll post some new pix soon.
 
Sounds like you and I are on a parallel path! I have stripped a car back in much the same way. Built originally in 1989 and updated in 1995, mine had a MK3 body (which I am replacing with a MK1) and BMW 740i hubs, brakes etc. In fact it has BMW stuff everywhere, including the radiator and did have the BMW V8 in it too. I am replacing the engine with a '68 302 which I am currently building. The car was in a very sad state. The previous owner got dementia and unfortunately did some very odd things to the car, like cutting the rear arches off with an angle grinder. It's an evil disease.
I am also refurbing the suspension components at the moment. Luckily, the chassis and suspension is all stainless so cleans up really nicely. The chassis appears to be bespoke and a one off, so I am having to work quite hard to get it to work with the new body and dash.
I shall follow your progress with interest. I confess yours is looking a lot better than mine at the moment!!
 
I've found POR15 works real well to touch up black powder coat. ...
The weather here in south Texas has been absolutely gorgeous so I've had to take care of outside home projects and the GT40 has had to wait. Our winters here are pretty minimal. Summers are brutal.
I love POR15...used it on several areas too!

Your winter sounds nice...I'm up in Seattle, it's mostly wet with intermixed freezing days. The 1 good thing about our winter & COVID 19 is that I'm getting plenty of garage time.
 

Russ Rittimann

Russ Rittimann
Supporter
Here's an update on my GT40. Rework/refurbed the front suspension and brakes. Painted the Corvette calipers and bead blasted the rotors. The calipers no longer have Corvette on them. Ground that off and sanded smooth. Sure don't need to advertise Corvette on a GT40. Reworked the bulkhead that holds the steering rack. PO had done some welding that burned thru the sheetmetal. Welded that all up and touched up the powder coat with POR15. Also, welded up the master cylinder holes and redrilled so the master cylinders fit correctly and the pedals bolted to the bulkhead/floor. Reworked the steering shafts so my big fat feet/shoes would fit between the side bulkhead and steering shaft. Added some components to the engine to give it more "bling". Removed/replaced the intake manifold to determine what type cam so I had the correct distributor gear (flat tappet). Drilled and tapped a 1/8NPT plug to vent the air out of the radiator. Still have plenty to do. Also, had both my Cobra and GT40 in the garage at the same time. Cobra in garage to adjust the front end alignment before the TCC meet later this month. Alignment was off (my fault) from changing the broken control arms from a few months ago. Here's some pix.
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Very nice pics of your project. I am awaiting a roller to be delivered on May 8th. It has been a journey as I ordered it in December 2020. I have not seen as nice and as detailed of pictures as you have supplied. Here is one taken a week ago. ThanksView attachment 114713
I’m also waiting on a roller from Chris but I’m a little farther down the line than you. Hopefully I’ll get mine around July. If you haven’t seen it already check out Umi Mech on Facebook. It’s Peters active power that he’s built. He posts on here some but his Facebook he updates more often and it keeps me entertained while I’m waiting on mine.

 
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Hello Russ, I wanted to congratulate you on rebuilding your GT40. Superb project that you have there.
I will also follow your journal closely as well as take a good detailed look at your photos.
Because I will also be leaving on a project similar to yours. 302Ci engine with a Porsche G50 gearbox.
I also want to equip the chassis for the complete front end of the Corvette C5 (upright and wishbone...) and probably for the rear end as well, although for the latter I am still thinking about it. I am only in the study phase, and I am missing certain dimensions to be able to modify my plans.
Maybe you will share them if you want to, that would be very nice of you.
Sincerely, Olivier.
 
Great progress!! In the pedal box, consider adding a dead pedal for your clutch foot...I added a small L bracket in front of the clutch pedal, so that I had a place to rest my foot; it's such a tight seating position, and there wasn't really a place I could relax my left foot.
 
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