Inside the 1957 Corvette Factory: How America Built Its First True Sports Car with Fiberglass

General Motors Corvette facility, Flint Michigan, 1957. Building America's first sports car—6,339 Corvettes with fiberglass bodies, fuel-injected V8s, and four-speed manuals.

Complete process: HAND-LAID FIBERGLASS BODY CONSTRUCTION (workers applying resin-saturated mat in molds creating panels versus steel stamping, 350-pound body versus 600+ steel, enabling complex curves), panel trimming and bonding, two-seater sports car body, fiberglass painting in Venetian Red Cascade Green Aztec Copper Inca Silver Onyx Black (solid colors), thirteen-tooth chrome grille (iconic Corvette face), quad headlights (new for 1957), crossed flags emblem, side cove panels, 283 CUBIC INCH V8 WITH ROCHESTER FUEL INJECTION producing 283 HP (1 HP per cubic inch milestone, mechanical fuel injection rare cutting-edge technology), dual four-barrel carburetor alternative (270 HP), close-ratio four-speed manual, Positraction limited slip differential, performance suspension firmer than passenger cars, bucket seat interior with tachometer, removable hardtop and convertible top, dual chrome exhaust tips, 0-60 MPH in 5.7 seconds, exclusive limited production 25 units daily.

Fiberglass revolution: First mass-produced American fiberglass car. Glass fiber mat saturated with polyester resin, hand-laid in molds, cured creating lightweight panels. 350 pounds versus 600+ steel. Enabled complex curves impossible in stamped steel. Labor-intensive but ideal for low-volume sports car production.

Rochester fuel injection: Mechanical fuel injection achieving 283 HP from 283 cubic inches (1 HP per cubic inch symbolic milestone). Precise fuel metering eliminating carburetor limitations. Cost $484 premium, only 16% of production (1,040 cars). Established technological credibility competing with European sports cars.

Corvette vs Thunderbird: Ford Thunderbird outsold Corvette (21,380 vs 6,339 in 1957) but became four-seater 1958 leaving Corvette unopposed as America's two-seat sports car. Corvette focused on performance establishing 70+ year legacy.

Cultural impact: Challenged European sports car dominance with American V8 power, innovative construction, affordable pricing ($3,465-$4,000 vs $5,000-$15,000 European). Racing success validated performance. Collector values $100,000-$300,000+ for fuel-injected examples.

Documentary using AI-generated visuals based on GM factory documentation and 1957 Corvette records.

Industrial Vault | Episode 15 | 1957 Sports Car Innovation

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