I have not kept a note on the man hours spent on this project. I can tell you that the PT Cruiser has been on jack stands from April of 2004. Most of that time was spent on the Chevy 3.8 V-6 application which had numerous electrical problems. I troubleshooted the electrical system for 2 years. Due to that, the engine then started knocking. It sounded like a main bearing knock. I believe that because the electrical system was so screwed up, the computer feed more gas than necessary through the system and eventually the gas got into the crankcase and did the damage. I was changing the engine oil and oil filter every two weeks trying to avoid something like that from happening, however it happened anyway. For this Buick application, I would say I have been working on it off and on for about a year. I work on it only when I feel good. I'm 61 now and it gets harder as time moves on. Those of you who are at the same age know what I'm talking about. If I were in my 20's, the project would have been completed long ago. I'm doing most of the work by myself. The new gas tank is being built by a shop. I did not want to deal with that! Projects like this take time. When you do something that has never been done before, it takes up allot of time. There are no kits out there that you can use for the structual work. Everything has to be designed and fabricated by yourself, using your own thoughts and skills. Today, 5 years after I started the project, there are much more kits available for the electrical and mechanical side, but still no kits for the structual side. There are no bolt on crossmembers for the engine and trans, or for the main cross member that I'm aware of for this V-6 conversion. For the engine compartment, the hardest part is done. It is just a matter of getting all the new wiring in, fuel line, exhaust system, cooling system, brake lines routed and hooked up. Then the next challenge will be the installation of the rear end housing. As mentioned previously, I will be using a 2002 Jeep Wrangler rear suspension which will also be modified to use leaf springs. It currently has a coil over suspension system. Here's a picture of what my PT looks like now. I have a few plans for some changes on the exterior as well. Let's see what happens! Thank you, Tommy.
