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Suspension And Tire Upgrades - Playing Catch-UpFrom the August, 2012 issue of GM High-Tech Performance By Scott Parker Photography by “trans Am” Justin Cesler
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Up until a few years ago, the Z51 package was a hot ticket on the sixth-generation Corvette. While it lacked the visual impact of the Z06 or ZR1 body, among other things it came with a no-frills, performance suspension with higher rate springs, shocks and larger sway bars (some of which were shared with the Z06). But of course, times change and after the LS2 was replaced with the LS3, Chevrolet decided it was time to replace the Z51 package with the Grand Sport–better bridging the gap between the Z06 and the base Corvette. The Grand Sport received not only the wide-body treatment, but the wider and stickier wheel/tire package that came along with it. The addition of the larger Z06 brakes only reasserted the Grand Sport's dominance over its predecessor. So what is the owner of a 2005 Z51 to do? In the case of this particular owner, I decided to call Pfadt Racing about its new Johnny O'Connell Signature shocks and sway bar package. As many of you know, Johnny is a four-time Le Mans winner and ALMS Corvette Racing driver, and he worked closely with Pfadt to develop this package to marry "racecar level road holding ability" and "streetability you would expect from a daily driver." Considering the usage of this car, as a daily driver, I couldn't have picked a better setup. Pfadt says in developing the suspension, O'Connell compared several versions and revisions on the "race track, mountain passes and pot-hole riddled roads." They even have a slick video with Johnny discussing the suspension and of the testing (http://bit.ly/x3O6dh). For those of you wondering, this suspension is also a great upgrade for a base Corvette, Grand Sport, or Z06 as well. Though the revised dampening capabilities and reduced body roll of Pfadt's Level I Suspension would potentially increase cornering grip, there really is no replacement for displacement–or contact patch. So first thing was first, we'd need a wheel that would allow a larger tire, especially in the front–to help prevent the all-too-familiar front-end plow (aka understeer). And since our Johnny O suspension was a recession-friendly $1,000; it didn't make sense to spend three times that on custom wheels, which we didn't have (by the way). Thankfully SLP Performance Parts had the perfect solution, a set of ZR1-style wheels (18x9.5 front, 19x11 rear) with an offset for the base Corvette body that would allow for Grand Sport and Z06 size tires. For $900 we had ourselves a great looking set of wheels that fit the overall theme of our build, and would allow for more substantial meats. A win, win. Speaking of rubber, we liked the stock sized Nitto Invo tires so much, we decided to stick with them except in 275/35/18 and 325/30/19 (courtesy of Discount Tire). If nothing else, this would give us a very accurate A/B comparison of the difference between a larger and smaller contact patch (using the same compound and tread design). The Invo has the added benefit of being fairly grippy while extremely quiet and wearing well, perfect for a daily driver. With all of the pieces set in place, and my office filled with parts, there was only one thing left–a quality installer. Thankfully Greg Lovell at AntiVenom, a Pfadt dealer, was more than happy to accompany us to Gainesville Raceway to swap the suspension track-side to get an accurate A/B comparison. Prior to the install, though, we had AntiVenom drop the C6 as far down as it would go on the stock bolts, and then have the car aligned at a local shop. Using this plan we figured to gain some significant ground on the Grand Sport, even without its fancy big brakes and dry-sump LS3.  1 Before heading to the track,...  1 Before heading to the track, Kyle Miller of AntiVenom ratcheted the bolts on the transverse leaf springs as low as they would go at all four corners. Unlike coil spring cars, lowering is free on a C5 or C6.  2 The drop was noticeable...  2 The drop was noticeable at first, after driving around the block, but a week or so later it settled even further. [Check out the final picture at the end to see how far.] After leaving AntiVenom, we stopped by a local shop to have the alignment brought up to factory spec (-.9/-8 front, -.4/-.2 rear camber; .07/.08 front, .01/.02 rear toe; 8.1/8.3 front caster).  3 On the stock tires and...  3 On the stock tires and suspension the C6 was sometimes a bit unpredictable while finding the limit of traction. Understeer and a lack of front grip were the over-riding factors in running a mere 1:06.84 during baseline testing at Gainesville Raceway.  4 SLP’s ZR1 style 18x9.5...  4 SLP’s ZR1 style 18x9.5 and 19x11-inch wheels (PN 81065) came in Hyper Black (deep silver) with a machined face and the appropriate offset to fit the standard Corvette body (53mm front, 73mm rear). We loved the look, fitment, price, and larger tires that it afforded.  5 Since we had previously...  5 Since we had previously been running the stock sized Nitto Invos, it was only fitting that we replace them with 275/35/18 and 325/30/19 like the Grand Sport and Z06. The idea of using another stock size set of tires was appealing as mixed diameters can play havoc with the ABS system. Though the tires were just as tall, we gained about 1-inch in width up front and 1.5-inches in the rear.  6 Just like the stock sized...  6 Just like the stock sized tires, a 32/30psi split in tire pressure was used with the new wheel and tire combo prior to testing.  7 The difference in grip...  7 The difference in grip was noticeable on track, and allowed me to push the car a bit harder at turn-in and start applying a bit sooner. It was also a little more predictable. This translated to a modest improvement (1:06.67) of nearly two-tenths.  8 Behold the Pfadt Johnny...  8 Behold the Pfadt Johnny O’Connell Signature Stage 1 Suspension (PN 1150029). Working closely with the ALMS winning driver himself, Pfadt designed a package that includes shocks, sway bars, bushings, and end links at a very affordable price. The concept was to design a simple suspension setup that would vastly improve the handling, effectively making the car easier to drive, and at the same time maintaining ride quality fit for a daily driver. The dampening curve on the shocks has been engineered to keep from floating or unsettling at speed, while also providing enough stiffness to keep the car planted in a turn and allow for quick transient movement (side-to-side). The sway bars are designed to reduce body roll and increase cornering grip with excellent balance using a unique rate. The front is less stiff than a GM T1 as well as Pfadt’s C6Z SS and Racing LR bars on the stiffest setting (yet more stiff than the middle setting).  9a Greg got started on the...  9a Greg got started on the rear sway bar by supporting the rear and front subframe on jack stands...  9b ...Using a Torx T-40 on...  9b ...Using a Torx T-40 on the end links and an 18mm on the bushing bracket, the stock sway bar can be liberated from the lower control arms and subframe.  10  11 Though the C6 Z51 rear...  11 Though the C6 Z51 rear sway bar is quite a bit stiffer than its C5 predecessor, it pails in comparison to the C6 Z06 or the Johnny O’Connell bar. The middle and lightest setting rank somewhere between the two OEM bars, meanwhile the stiffest setting is just below the C6 ZR1 (according to Pfadt’s handy chart).  12 Removing the shocks requires...  12 Removing the shocks requires a 13mm socket for the top and a 24mm for the bottom. However, Greg finds the process easiest with the upper control arm (UCA) out of the way, which is solved with an 18mm socket. Thankfully the alignment is not dictated by the UCA or the shocks in the C5/C6.  13 The new shocks came fully...  13 The new shocks came fully assembled and did not require transferring any bushings, washers, etc. Pfadt recommends 22 ft-lbs on the upper shock mount, 81 ft-lbs on the lower shock mounting nut and upper control arms (48 ft-lbs with aluminum frame cars).  14 The provided polyurethane...  14 The provided polyurethane bushings are greased and slid over the sway bar prior to installation.  15 The sway bar is loosely...  15 The sway bar is loosely bolted in place, the bushing brackets first, and then the end links. Note the bar is put to the middle setting, which is recommended as a starting point, and the end links go to the inside. Pfadt suggests 50 ft-lbs on the end links and 48 ft-lbs on the bushing bracket (34 ft-lbs on aluminum frame cars).  16 Greg gets started on the...  16 Greg gets started on the front by removing the bolts on the upper control arm with a 15mm wrench and the bayonet (or upper shock nut), paying close attention to the position of the washers between the UCA and frame. A 13mm socket is used on the bottom of the shock. Removal and replacement is nearly identical to the rear, aside from the different location and type of shock bolts. The shock nut requires 19 ft-lbs, the lower shock mount receives 21 ft-lbs, and the UCA bolts get 48 ft-lbs.  17 Just like the rear, T40...  17 Just like the rear, T40 and 13mm sockets are used to disconnect the end links from the control arms and unbolt the front sway bar from the subframe.  18 The front sway bar is...  18 The front sway bar is noticeably more beefy, perhaps why it is considerably stiffer than any OEM bar and right up there with Pfadt’s other bars. Though it lacks the adjustment of the rear, it’s simplicity is definitely a positive and is a large reason why this package is so affordable.  19a Just like the rear, the...  19a Just like the rear, the polyurethane bushings are greased and installed prior to bolting...  19b ...the Pfadt sway bar...  19b ...the Pfadt sway bar in with 50 ft-lbs on the end links and 48 ft-lbs on the bracket.  20 We decided to make a few...  20 We decided to make a few quick laps back on the stock sized tires before the final test. The Pfadt suspension made the C6 so much more predictable, balanced and fun to drive. I had a blast sliding it around our test track, calling even more attention to the lack of grip with the stock sized tires. Issues with our timing equipment prevented us from quantifying these runs, but we’d estimate a half second improvement over running just the larger tires.  21 With the larger wheel/tire...  21 With the larger wheel/tire package, though we finally had a near optimum amount of turn in response, grip, predictability, and balanced handling. The car was remarkably easier to drive when we started the day, and ran a best ever 1:06.016. Since our test track is fairly low speed, it is difficult for the brake cooling ducts to do their job. As the result, the only way to avoid brake fade is with a much more substantial brake setup such as the '12 Grand Sport. With the ability and confidence to late brake there is no telling how much more ground this C6 could gain.
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