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Eric Black’s preview artwork of what Lonnie Gilbertson’s RareVair will look like
1. Eric Black’s artwork is a preview of what Lonnie Gilbertson’s RareVair will look like. It’s simple, clean, and packed with V-8 power.
1. Eric Black’s artwork is a preview of what Lonnie Gilbertson’s RareVair will look like. It’s simple, clean, and packed with V-8 power.
RareVair typography
Part 1: The Corvair Chevrolet Should Have Built
By Ron CeridonoPhotography by Lonnie Gilbertson
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hen Chevrolet introduced the Corvair for 1960 it was revolutionary in many regards. The rear-mounted, air-cooled engine arrangement was not unusual for European cars (Volkswagen, Renault, Fiat, and others) but for GM to try it didn’t just push the contemporary American design envelope, it tore it apart.

The new Corvair was well accepted by the automotive press; in fact Motor Trend magazine named it car of the year, however the public was less enthusiastic and sales were slow. The new Ford Falcon, also introduced in 1960, outsold the Corvair by a considerable margin. Then came Ralph Nader, the Corvair’s most notable detractor. In his book, Unsafe At Any Speed, Nader described the car as “The Sporty Corvair–The One-Car Accident.”

Among other issues, Nader claimed the Corvair was swing axle rear suspension and could cause the outside rear wheel to tuck under during extreme turning maneuvers, causing the driver to lose control and the car to roll over (claims a later safety commission report found to be untrue). For 1965 the Corvair’s swing axles were replaced with a Corvette-like IRS system. Along with other suspension modifications the handling characteristics were now thought by many enthusiasts to be first rate. But it was too little too late; the public didn’t trust the Corvair, so production came to a halt in 1969.

Over the years there have been several impressive examples of modified Corvairs: the Yenko Stinger that retained the original horizontally opposed six-cylinder engine modified to produce 190 hp and several V-8 swaps, the most notable being the Crown conversion kit in the late ’60s. But what we have here is what we think is the ultimate Corvair, Lonnie Gilbertson’s RareVair.

Gilbertson has a long history as a hot rodder. He’s campaigned a Buick-powered gas dragster, been involved in circle track racing, and is a two-time winner of the AMBR trophy (America’s Most Beautiful Roadster) in 1971 and 1975. Over the years Gilbertson has built a variety of cars, but this latest effort was inspired by the 1965 Corvair Corsa his brother had in the late ’60s. As Gilbertson explains, “I have always liked the style of the 1965-1969 car; as it happened, I found a 1965 Corsa that was good enough to build. I wanted to build the car with a Yenko Stinger flavor (they were built to compete on the road race circuit), instead of a hopped-up flat-six I thought a mid-mounted V-8 would be cool and satisfy the hot rodder in me.” And so the RareVair was born.

As might be guessed, dropping a V-8 and transaxle in the back seat of a Corvair is not without challenges. There were such things as reinforcing the unitized chassis in all the critical areas to consider, where to mount the radiator, how to deal with shifter and clutch linkage, and that’s just the short list. There were also a host of sheetmetal modifications that would be required, which we’ll get into in Part II of the RareVair build. In the meantime, take a look at what it took to create the Corvair that Chevrolet should have built.

a shabby 1965 Corvair Corsa sits in a garage
2. It required some searching but Gilbertson found a solid 1965 Corvair Corsa, which was the top of the line that year, as the foundation for the RareVair.
rear floor section is removed from the 1965 Corvair Corsa
3. With the rear floor section removed the engine and transaxle were installed from below. At this point there was no turning back.
a Corvette 6.2 LS3 rests in the back of the Corvair
4. Where the back seat once was resides a Corvette 6.2 LS3 that packs considerably more punch than the original 164ci, 140-horse flat-six.
a 930 Turbo Porsche transaxle sits on a table
5. Transmitting power to the ground is a 930 Turbo Porsche transaxle that had been modified for a mid-engine application. Kennedy engineering supplied the adaptor and clutch assembly.
a Fatman Fabrications bolt-in front suspension sits on a table
6. Fatman Fabrications supplied the bolt-in front suspension that uses the stock steering components. It’s equipped with Baer disc brakes and QA1 coilover shocks.
view of interior steering components
7. Steering components consist of a rare Corvair quick-ratio steering box augmented with an electric power steering unit in the column. Steering input will be via a factory sport steering wheel.
view of unitized construction the attachment
8. As the Corvair used unitized construction the attachment points of engine and suspension mounts were reinforced with steel plate. Note the holes for rosette welds that will add strength. This is where the front engine mount/cradle will attach.
the finished reinforcement and bracket for the front engine mount/cradle assembly
9. This is the finished reinforcement and bracket for the front engine mount/cradle assembly. Attachment hardware is all Grade 8.
engine is mocked up with an engine mount
10. Here the engine is mocked up with the engine mount that runs from side to side. It allows all the original engine accessories to remain in the stock location.
a cradle that extends from the front mount supports the rear of the Porsche transaxle
11. A cradle that extends from the front mount supports the rear of the Porsche transaxle. The entire cradle with the engine and transmission assembly can be removed as a unit.
the rear of the cradle attaches with two bolts to brackets on reinforced points at the back of the engine compartment
12. The rear of the cradle attaches with two bolts to brackets on reinforced points at the back of the engine compartment.
custom half shafts connect the transaxle to the hubs
13. Custom half shafts connect the transaxle to the hubs. The lower control arms attach the spindle uprights to the engine cradle—threaded rod ends provide camber adjustment. An antiroll bar will be added.
a hydraulic slave cylinder is mounted to the bottom of the transaxle
14. A hydraulic slave cylinder mounted to the bottom of the transaxle case will activate the clutch.
a boxing plate sits among other parts on a table
15. The stock Corvair rear trailing arms were reinforced with boxing plates. The stock coil spring mounts were removed and mounts for QA1 coilovers were added.
original hub with newly installed disc plate
16. Disc brakes have been added to the original hub assemblies. The stock rear shocks were only in place temporarily.
the LS3 with a Holley Sniper intake and their vintage-style valve cov- ers along with a Comp Cams camshaft and kit
17. Modifications to the LS3 included a Holley Sniper intake and their vintage-style valve covers along with a Comp Cams camshaft and kit. The goal is 550 hp to the rear wheels.
engine block with wild 180-degree headers
18. Tom Phillips was responsible for building the wild 180-degree headers, which means pipes from the two-cylinder banks are tied together at the collectors.
front view of engine block with arrows marking the oxygen sensors
19. As can be seen here, RareVair’s headers are a feat of engineering and a testimony to Phillips’ welding ability. Note the oxygen sensors (arrows) for each bank of cylinders.
the exit area of the unique exhaust system
20. The unique exhaust system will exit through the rear body panel between the taillights in GT40 fashion.
intake air supply tubes
21. Intake air will be supplied through a pair of tubes that connect to scoops behind the doors (more on body modifications to come).
tubing system including the engine coolant passage
22. Engine coolant will pass through 1-1/2-inch stainless steel tubing to the front-mounted radiator. The two smaller tubes will supply the heater.
a Pat- rick Motorsports cable-operated shifter assembly
23. Gears in the transaxle are selected with a Patrick Motorsports cable-operated shifter assembly. The shifter and coolant tubes will be hidden under a center console.
the framework that will hold the radiator and cooling fan
24. The radiator and cooling fan will be mounted in a framework that includes duct work that will bring air in from below the front bumper.
portrait on canvas of a yellow T roadster pickup
25. Bring back any memories? This T roadster pickup is Gilbertson’s two-time AMBR winner (photo by Dale Moreau).
Modern Rodding
VOLUME 2 • ISSUE 12 • 2021