DIY Shaved Door Kit Installation

Twisted C5

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Hey Guys here you go my step by step instructions on how to install a shaved door kit on a C5 Corvette, which can also be installed on a C6. Guys also wait to respond to this thread until i have loaded all the instructions, pictures and videos because I sure ain't a pc genius here, LOL

The following Items you will need for job:

1. A Corvette

2. 2 60lb Solenoids (Buy from Eletriclife.com )

3. 2 30 AMP Relays (5 Prong, see pics in instructions) Buy relays from local auto store

4. 1 40 AMP relay ( 5 Prong) Buy from local auto store

5. You will need 12 gauge wire, get green, red and black, not like me because I used what I had.

6. Small Twist Ties (50 count)

7. Black Electrical Tape

8. Electrical Connectors(look at pics to see what kind)

9. Wire Cable and clamps (get from Electriclife.com)

10. 2 Door Poppers ( Buy from Electriclife.com)

Tools:

1. Voltage Meter (actually you won't need since I have shown you which wire, but keep it handy anyways, never hurts)

2. Flat Head Screw Driver

3. Philips Screw Driver

4. Star bits for door screws

5. Wire Coat Hanger, LOL I know what your thinking but you will need it.....

6. Wire Stripper/Cutter

7. Razor Blade

8. A soft rag, PLEASE use this to wrap around screw driver when trying to pry off door panels so you dont tear them.mark them up

9. Some good old music to get the feet moving and plenty to drink and if you smoke run to the store now and get your cig's.......

This should take about 3 hours to complete, I kept track of all time spent. If you are like me lay parts out on garage floor in safe area as you take them off so then you reverse the process when you re-install. I will also include two video's at end of thread showing you how they work, mind you the body work is not done. Also I am giving you 2 versions of the kit. I found out by accident that you can take handles off car for shaved look, but also you can still leave handles on car and it works (this method will allow you to enter the car with a key and open the handle if you loose power. The other method u r @#$% if you loose power and don't hook a emergency cable up.)

Twisted C5

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Print this out and keep it close. This wiring Diagram has been throughly gone threw by Autoloc and now tested on my car and not one problem.

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Twisted C5

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this diagram was courtesy of Wicked99 and Junkman2008, can't have enough friends out there in the Corvette World........

[IMG][/IMG]

Twisted C5

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ok its no time like now to jump in with two feet and remove the panels, first remove the door handle bezel. There is two slots one upper inside the other lower inside, you will need a small thin flat head screw driver to pry this off. Rem. if its getting hard to get off stop and rest why break it and pay!

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Next remove plug inside area of door grab handle and take out the two star screws

Twisted C5

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Ok guys for you that haven't taken the switch out, first as always when working with panels, use a rag to cover your screw driver. As for the switches it is very IMPORTANT pry from the top and outwards, if you pry from bottom or sides you will break the tabs!!!!!!!



When taking off panel make sure you pull out and then up, if not the white tabs that hold it in will break and guess who is running to the Chevrolet Dealer spending more money for a simple part.........

Twisted C5

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Here you go, the hard part is over, LOL

This is a general look of the door, notice black matt, remove and put some place safe.........







Also notice the black control module next to the speakers, this is where a Tan wire later shown you will need to cut and use, so at this point get familiar with the door and parts. Also make sure you pull the battery cables off. Don't want any new hair doo's out there

Twisted C5

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ok now find the black control box on door and follow the wire up to the door lock actuator. look at pic below and you will see two blue covers over door handle/locking mechanism now you see a group of wires in balck tape going the same way. Peel the tape back and you will see a Tan, Gray, Black, Black/White Wire. You will need to cut the Tan wire in half.


Now cut Tan wire



Now take a 30 AMP Relay and twist tie it to wire loom, this is just to hold it while you do your work. Now attach a wire and connector to the Tan Wire that is coming from box, the other end of the Tan Wire going to the Locking Actuator you will just tape off. Now take the wire you connected to the Tan wire and place a connector on that and attach to Pin 86 on the relay

Twisted C5

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Now grab your shaved door kit, here is a picture of everything you get. You get 2 60lb Solenoids, 2 30 AMP Relays, 2 Door Poppers, 2 key Fobs and a control module





Let me save you some money on my own account. You don't need everything pictured. You can call and order everything sepreate. You will need the 2 Solenoids and Brackets, 2 Door Poppers and 2 sets of cables to attach solenoid, see I bought the whole kit not knowing how to hook up all this and found out through Autoloc all I needed was the fore-mentioned parts, you can then go to your local auto parts store and buy 2 30 AMP relays like pictured and 1 40 AMP Relay and make sure they are 5 Prong Relays

Twisted C5

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Now take out both Solenoids and you will wire them both up at same time to save time when you do the other door. Connect Solenoid to bracket

There is a connection with a screw on back of solenoid, this will be a +12V Pulse Line going to the Pin #30 on relay(but dont connect to relay yet). also you will want to hook your ground wire up, this is important(on back of solenoid you just hooked up the +12V line now on the other side there is a screw going into the back of the solenoid. Unscrew it and place one end of your ground wire into there and screw the screw back in.) Now you have both solenoids set up for installation. By the way since you went this far hook the wire cable up to the solenoid also, very little room to do all this once solenoid is attached to inside of door.

Twisted C5

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Now you will mount solenoid to inside of door. To ease your mind after you have placed the solenoid in the spot on the door where I have pictured you can run your window up and down to see it does not interfer.

Now place it in door where you see in picture as close to door as possible with fish eye loop facing door latch. Now take a marker (Sharpee and mark where holes are at). I used a Dremel because it fits inside of door. You will drill all four holes. Then you will place solenoid back in and tighten down with supplied bolts and nuts, also don't forget pull your +12V and Ground Wire out.







Now don't worry about the underside of door or sill when door is closed, the bolts do not hit sill at all, believe me like I said my car was the guinne pig.

Twisted C5

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Now you will connect Solenoid up to Relay and fish wires through car to engine bay. It all looks great when done, now get your small twist ties out guys, because if you are like me you want it professional looking and no chance of failures down the road.

Connect +12V from Solenoid to Pin #30 on Relay and connect ground from Solenoid to Pin #85 on Relay

Now you will attach Solenoid to Door where I have placed on Picture

Twisted C5

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Now you will twist tie all wires up to exsisting wire loom, I have attached tape and wrote what wires were for, this was for later identification purposes and for this DIY. This will also help if an outside source works on your car!




Now connect a new +12V line to Pin # 87 and connect a new Ground line to Pin # 85 , you will need about 6 feet of wire coming from passenger door to engine bay. You will need about 8 feet from drivers door to engine bay.



Cut a small hole in the gromet and run wires through here

Now fish lines through the door/body harness sleeve, I used the coat hanger, LOL

Twisted C5

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Now you will have to take the kick panel off and on the passenger side you will also have to take off the panel above the floor and front panel on floor where BCM is at. All this is for ease of access and work. As far as the drivers side I took off parts of the dash and center counsel so I could run wires from drivers side through dash to passenger side for a more clean apprearence and also to have all wires coming into engine bay at one access point, again I stress a clean look, not a hack job, we are driving bad ass corvettes.

now the kick panel on the right side reach up and you will see and feel an access panel (see picture) Pull this panel out a bit and this is where your wires from the doors on both sides will come out.

Now on rightside of firewall on floor look and feel for this gromet with a wire loom going through it. This is where you will make a small home to pull all ground wires, +12V and ignition +12V wires through. Please be careful and do not go through to close to exsisting wire loom, I went throght bottom of it to avoid damaging exsisting wires. Now this is where the coat hanger comes through. You will tape all wires to one end of coat hanger and pull through to firewall. Now if you haven't yet, take out battery so you can pull coat hanger through and do wire work.

Wires pulled through to engine compartment

Wires marked for identification

Twisted C5

Points: 1,529, Level: 23

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Now the ignition work,

Ok listen carefully. You will need to take the lower section of dash off where the ignition switch is. See picture, this is the yellow wire you will shave the coating off down to the bare wire. Then take about 6 feet or 7 of wire( i always do more just in case of an oops) I soldered the new wire right to this yellow and taped it up for protection.



Now run all your wires from the door through the dash, you will need to take out center counsel and lower dash under steering wheel and have wires go through same wire loom passenger side did



Don't make fun of the chicken leg you see,

02RonZ06

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Very nice! Excellent. Great information and pictures and description, this will definetly be of asset to anyone that is looking to do this kind of proceedure.

Thanks for taking the time to make all this happen It looks like you spent a lot of time just putting this thread together.

Glad to see that you figured out how to use the photobucket pictures too.

__________________
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473 RWHP - 481 RWTQ - Methanol turned off. To many mods to list, see them all here and videos on dyno and take off... 2002 Supercharged Z06 Corvette

Twisted C5

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ok now all your door wiring is done and pulled through along with ignition wire to engine bay in back of battery tray. Now you will attach the wires to the 40 Amp relay. I hope you still have the beautiful wiring diagram I made and you can see where all the grounds and +12V go, but I wll go through it here.
Now drill a hole here to attach 40 AMP Relay from bottom. I drill here and used a small amount of silicone to seal it as well as the groment where wires came through


Now attach a single ground wire from Pin #85 to ground on battery and also take 2 ground wires from car to battery. Connect Ignition wire to Pin # 86,Connect a wire from Pin#87 to + on Battery

Twisted C5

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Now you will remove door handles.

Look up into door where handle is, there are two nuts, remove them, and there is a bar going down to latch on door you will see a yellow clasp, open it and remove bar but leave clasp on bar in case you want to reverse this


Now when you remove handle pull bottom out first and pull out.

Twisted C5

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now you will attach the wire to the solenoid and use clamp to secure. Take the wire and loop it through a small hole on latch. Look at picture of yellow clasp and you will notice a small hole in a piece of the latch on left side, this is where the wire will go through. Do not make wire tight, leave a small bit a slack for wear and tear. Now your doors are complete other than the poppers

Twisted C5

Points: 1,529, Level: 23

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Last step is putting in popper. Look where I drilled the hole and attach your popper.

Twisted C5

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Now here is two videos of one with door handle on and the other with it off, hope you like what I have done and hope it makes the install easy for you