There was a time when small- and big-block Chevy V-8s could be swapped back and forth without a major hassle. The advent of the C5 and its GEN III (LS1) engine's totally new architecture means that nothing new goes where something old once resided, and that a mountain motor intended for a large pickup ain't gonna fit, at least without a LOT of work, within a C5's engine bay. Larry took a leap of faith and ordered a brand new Vortec 8100 from The General.
Upon its arrival at his shop, Hofer started off by doing a point-by-point check of parts interchangeability between a traditional big-block and the Vortec. Guess what-the valve covers are about the only thing. Among the differences in the Vortec are the cast-aluminum oil pan, different motor mount pads, LT1-style cooling (reverse flow, coolant in and out of the front of the block), cam and crank sensors machined into the block, and the list goes on. To make the beast fit where an LS1 once lived, the front drive had to be shortened a full 4 inches, and to do this meant a new hub for the crankshaft, setup for an LT1 damper and pulley, custom accessory brackets to hang the power steering pump, A/C compressor, and alternator, and an entirely new, ZR-1-influenced water pump and thermostat assembly built around a Meziere electric water pump. At least all of the LS1's sensors fit.
Larry did a comparison, based on crankshaft centerlines, between the LS1 and the Vortec 8100. Opportunities for creative solutions (calling them "problems" sounds so negative) included an oil pan that was too low, an intake manifold that was too high, and a flywheel that was too far aft. Both the intake manifold and the oil pan were treated to extended cut, weld, and re-configure sessions in Larry's shop, with the pan needing a custom windage ray, pump pick up, and drain plug boss. A one-off flywheel was made to spec, set up to work with a Z06 disc and plate. And the C5's steering rack had to be relocated 1 1/2 inches forward.
Ultimately (and obviously), everything came together. The C5's ECM (computer) and the Vortec 8100 V-8 are compatible-once the right injectors were determined. The 8.1 comes with 46 lb/hr gushers while an LS1 has 26 pounders. It ran way too rich on the 8.1L's nozzles, and after much trial and error, Hofer found the LS1 injectors are not only completely adequate for the mega motor but it also runs perfectly on them.
It also runs plenty cool-no overheating problems even in the peak heat of a Southern California summer. The stock six-speed transaxle and differential have proven to be up to the task so far, and the big-block's extra tonnage is controlled by a combination of Bilstein coilovers at all four corners, and Z06 stabilizer bars fore and aft. Custom headers were an absolute necessity, but the balance of the exhaust system is a blend of factory and a B&B stainless steel cat-back system. Hofer's hauler looks amazingly normal, with custom wheels, an RKSport rear spoiler, and Z06 rear brake vents its only external changes.
What is likely the world's only 8.1 liter C5 Corvette looks, sounds, and even drives like a normal fifth-gen-until Larry mashes the loud pedal and that extra 100-plus lb-ft of torque provides an explosive thrust forward. When we asked Larry Hofer if he was happy with his creation, he simply said, "I'm still amazed!"