RTR Exotics Inc.

Classic Reflections Coachworks

The 1962 Corvette is a classic style still enjoyed by young and old. The first “retro ‘62” took six years and over 5000 hours to make the modifications and complete the car. A stock ’62 body was used to fit over the ’93 chassis, which had to be lengthened to properly align the 1962 body. Engineering and construction on the full front tilt took a year to complete. The car became a show favorite throughout the Northwest and won many awards as well as second looks.

Designing the CRC:

In 1994 the first prototype was started on a C4 Corvette. The concept was very unique and many inquiries came in on how to purchase this car. This interest sparked a parallel project, which started with a C5 Corvette and several months of hand shaping the new design. Inspired by the classic ’62 Corvette, Doug’s new design took advantage of the larger C5 platform. He chose to use computers in the design process to ensure precision of the body panels and the ability to repeat the same exact structure each time. Resolutions (now REALADI), an organization within Boeing Phantom Works, was hired to scan the design and convert it to a 3D CAD program (3-dimensional computer aided design) using reverse engineering technology. This same technology is used in the airplane designs and the NASA Space Shuttle program.

Utilizing the Boeing computers, Doug worked with technicians to ensure his design flowed and the body shape was refined into a “Class-A” surface. This created a surface and preciseness beyond the naked eye that tested all curves, edges and radii. With the body surface complete, the body was removed from the chassis and the same precision process was used to map and identify all the mounting points and clearance issues with the sub-structure.

A test fit was done on the Boeing computers to check the motion of doors and other moving parts, allowing the engineers to identify and correct any errors before the molds were constructed. This also allowed us to discover how the body would behave when attached to the chassis.

CRC Build
The CRC conversion is more than replacing and bolting on a few panels on a stock C5. Every panel on the C5 is replaced with a computer engineered, vacuum formed Carbon Balance part. Each individual part is made without seams to prevent printing on the outer surface. The rear section of the car is permanently attached to the C5 frame and all other parts are attached using removable fasteners. The car was designed to use factory stock parts (hinges, wiring, interior appointments). The bumpers and most of the chrome trim are manufactured specifically for Classic Reflection Coachworks.
Car at SEMA Show Las Vegas Nevada
Each car is hand crafted, panels and trim are custom fit and the car is painted any color the customer chooses. A new soft top is installed and the car is cut and buffed ensuring a quality you find only in high end show cars.
Step 1
All panels are removed. A computerized measuring system checks the understructure pieces and frame alignment to make sure it is within factory specs.
Step 2
There are many panels in our conversion. Our composite shop handles the lay up process for each part. Each panel is vacuum bagged and cured at controlled temperature cycles.
Step3
Each car is placed on its own cart and moved to the fitting room where all exterior panels are aligned and attached.
Step 4
Each car is placed on its own cart and moved to the fitting room where all exterior panels are aligned and attached.
Step 5
It is then moved to the paint room for a coating of special primer.
Step 6
Several blockings produce a quality surface, then it’s back to the paint room for the final color matched primer.
Step 7
The final sanding before painting.
Finished Product

Donor Cars:

One of the more important aspects of building a CRC is starting with a good foundation. The donor car must be a 1998 through 2004 Corvette Roadster. Body panels and interior parts should be in good condition. When choosing a donor car for the CRC, it’s best to find a car with the interior and carpet color you want. It is possible to change out interior colors, but it can be very costly. The car chassis and frame must be within factory tolerances and specifications. It must have stock dimension wheels and tires.

A car can have some cosmetic damage and still be used for the project. If you have any questions about the condition of your donor car, please contact the shop.

Ordering Your CRC:

To guarantee a position in the assembly process, download the order form from the link at the bottom of this page. Complete the form and mail it along with your $1000.00 refundable check to Classic Reflection Coachworks. When mailing, please use the PO Box address. Mail is not delivered directly to the businesses in the park where our shop is located.

Upon receipt of your deposit, we will send you a confirmation letter acknowledging your deposit. We stay in contact with you, as decisions are made that provide you with a customized car.

Approximately 60 days before we begin work on your CRC, we request you make arrangements for your donor car to be delivered to our facility in Lakewood Washington. Final decisions will be made about color and any special options or additions you want included. At this point of contact, we request a deposit equal to 25% of your cars estimated price be sent within 10 business days. This allows us to order necessary parts to build your car.

When we have received your car and before construction begins, we require an additional payment bringing your total deposit to 50%. It will take approximately 12 weeks to build your car. During that time we will post weekly pictures of your car being built on our website. Pick up or delivery arrangements will also have to be made. The balance of your CRC price plus any applicable taxes will be due at the time of delivery.

We encourage you to visit our shop during the construction or at the completion of your car to see the process we follow in building your car. Call Keith Shay at 253-677-1808 for your personal visit appointment.

We would welcome the opportunity to earn your trust and deliver you the best service in the industry.