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Swiss two-become-one 240Z Ground up restauration / JDM mods

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Nothing big, just spent another two hours at the garage compling the sanding down of the wing. Before:

P1150426-Kopie.jpg

 

and done :)

P1150428-Kopie.jpg

 

there are a few damages in the FRP surface like it's normal for a 40 year old FRP-item, but no problem. i know a good FRP-specialist and will bring it to him for repair.

P1150429-Kopie.jpg

 

Also needs new studs in the bottom end as well as a new foam-sealing ;)

P1150432-Kopie.jpg

Edited by jdmjunkies.ch

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While i'm waiting for some parts from japan and for some answers from USA i realized i never showed you some pictures i made a few months ago (Only a teaser shot for my FB-followers was published). I made a mock-up of the  Front axle and steering setup to see how everything fits together and get the idea. So first i adjusted the steering rack according to the manual:
P1140298-Kopie.jpg

And then mounted it the the front subframe:P1140299-Kopie.jpg

Next was the stabilizer bar, steering knuckles, tierod endlinks and new bushings allroundP1140302-Kopie.jpg

And then while at it i decided to add the Doglegs. Seems like everything fits as it should. perfect :D
What you see here is:
- Nagisa NAMS adjustable tierod endlinks
- Kameari engine mounts
- Rocky auto adjustable doglegs
- 555 Ball Joints
- Autorefine ARC stabilizer bar
- Datsun competition short steering knuckles
- Rebuilt steering rack
- All new energy PU bushings

- All other parts have been sandblasted and powdercoated
- All new OEM Nissan Screws, bolts and nuts used whenever available, otherwise replated original bolts!

P1140306-Kopie.jpg

 

oh, and then this:
P1150437-Kopie.jpg

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A while ago i wrote about different intake Manifolds and that i probably want to go for a FET (Better known as "Far East Trading" Japan) Manifold. But as i have other priorities at the moment i wasn't really looking for one. Well untill my Friend Stefan remembered my Post when he scanned the Internet for some Kenmeri parts and stumblet upon one. He immediately sent me the  link and because it was a Steal of a deal i had to get it. Today i had something in the mail :)
P1150443-Kopie.jpg

Thanks to the finned or striped design i think it perfectly fits the Kakimoto intake once it's painted in the same wrinkle-paint colour. And yeah i know the balancer tube might make everything a bit mor difficult to adjust, but i'm sure there's a way to work around it (like plugging the holes going to the tube or so...)P1150449-Kopie.jpg

And because it's too expensive to only send one single part from Japan to here i ordered my self a set of Projectu Drumbrake shoes which will go nicely together with the hayashi racing drums :) The other set is for stefan's Kenmeri Project. Thanks again, mate!
P1150442-Kopie.jpg

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A while ago i started the assembly of the Pedalbox. While i still wait for some small components like the flasher unit and the Brake light switch i couldn't resist assembling all the shiny new zinc-plated and powdercoated parts smile.png
After putting the new rubber to the pedals i installed them to the box with the fresh plated bolts.
P1140105-Kopie.jpg

 

Then the stopper bolts and springs came in.
P1140106-Kopie.jpg

 

Looks brilliant, doesn't it? smile.png
P1140107-Kopie.jpg

 

here's a comparison between the old crappy one (right side) and the completely rebuilt one, left.
P1150452-Kopie.jpg

 

Oh and while at it i did the throttle pedal as well smile.png
P1140446-Kopie.jpg

Oh and then i have some good news from Japan again soon smile.png

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I have a truckload of parts on my way from Japan, but other than that i don't have too much news. Im going to be out of country most of the time of the rest of the year for some business trips and some long-needed vacation. However i wanted to get some stuff done before i leave and mainly it was about cleaning up the mess in the garage. I've collect parts from two chassis and the internet and put them in various boxes but somehow i lost the overview over time so i wanted to have that fixed. this is what it looked like before i started cleaning yesterday:
P1150495-Kopie.jpg

P1150496-Kopie.jpg

So i started sorting all parts from various boxes to other ones and marking everything nicely to find the parts whenever i need them :)
P1150498-Kopie.jpg

And while in the garage anyway i decided to remove the old brake calipers from the front struts
P1150497-Kopie.jpg

And out they are :)
P1150499-Kopie.jpg

And then also removed the moustage bar from the rear diff and figoured out everything was covered in a thick layer ouf some rubber-stuff. Probably the diff was leaking at one point and they putt this nasty stuff on it to get it fixed cheaply. Anyhow the diff will get a full rebuild or R200 swap (haven't made any desicion yet). so that won't be a problem ;)
P1150500-Kopie.jpg

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Yeah i know - the pace is quite slow lately, but im still working on the project silently in the background. But today is the day i have som GREAT news for you. I got a Package delivered from Japan with some parts i've been looking for over two years now until i recently stumbled across them finally :)
P1150541-Kopie.jpg

I'm talking about the Sumitomo MK63 brakes. But what's so rare about them you might ask? they pop up every now and then on the internet. But this is not your standard MK63 for vented disk, but the very rare first gen. version for OEM Nissan disks, which are FIA homologated and were used in various ex works racing cars. I've even been told that nissan asked them back after the races from their teams.. wow :)
P1150543-Kopie.jpg

Here's a comparison between the standard brake (Also sumitomo manufactured) and the MK63:
P1150544-Kopie.jpg

 

I plan to restore / rebuild the new brakes before they go in.P1150545-Kopie.jpg

 

P1150546-Kopie.jpg

And here's some specs from the NISMO homepage and the old Datsun performance catalogue:
DatsunCompetitionPartsCatalog-13-Kopie.j

Later NISMO offered the same brakes under their brand but they're obsolete since a few years..img_mk63caliper_en-Kopie.gif

Oh and while ordering parts from japan anyway i decided to order all available maintenance and refurbishing parts for the brakes from the NISMO / Nissan catalogue and got them delivered from a local Nissan dealership from Yokohama :)P1150538-Kopie.jpg

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HS30-H    15

I'm talking about the Sumitomo MK63 brakes. But what's so rare about them you might ask? they pop up every now and then on the internet. But this is not your standard MK63 for vented disk, but the very rare first gen. version for OEM Nissan disks, which are FIA homologated and were used in various ex works racing cars. I've even been told that nissan asked them back after the races from their teams.. wow :)

 

 

I said "wow" to myself when I read that too, but probably not for the same reason as you. Where does this story come from? It sounds completely apocryphal to me. Maybe something 'lost in translation'...?

 

Nissan was selling the MK63-20S caliper as a 'Race/Sports Option' part for other cars in their range before the S30-series Z debuted in 1969, so they were already in public circulation. Their original source - as a stock part for the top of the range Nissan President limousine - meant that they could be sourced elsewhere anyway. Why would Nissan want, let alone need to ask teams to give them back after using them? What a bizarre story.

 

I'm also not sure why you are making the narrower, unvented - solid disc - type MK63 caliper sound like it's something cooler than the wider - vented disc - type? It was always easier - and cheaper - to find the unvented type, and it was the more expensive vented type that was more difficult to source. The upshot was that people started machining up spacers for the unvented type calipers to make them fit over a vented disc, leading to all sorts of caliper flexing problems.

 

The reason they wanted to convert to vented discs was the fact that its so easy to overheat the stock - unvented - disc, with sudden fade (just when you didn't want it...) and pad glazing being the result. So the unvented type are fine up to a point, but the weak link is the disc. I would always recommend the vented type over the unvented type. I run MK63-20S calipers on 4 S30-series Zs and a KPGC10, and all of them with vented discs. I would not bother with the solid disc type.   

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I said "wow" to myself when I read that too, but probably not for the same reason as you. Where does this story come from? It sounds completely apocryphal to me. Maybe something 'lost in translation'...?

 

Nissan was selling the MK63-20S caliper as a 'Race/Sports Option' part for other cars in their range before the S30-series Z debuted in 1969, so they were already in public circulation. Their original source - as a stock part for the top of the range Nissan President limousine - meant that they could be sourced elsewhere anyway. Why would Nissan want, let alone need to ask teams to give them back after using them? What a bizarre story.

 

I'm also not sure why you are making the narrower, unvented - solid disc - type MK63 caliper sound like it's something cooler than the wider - vented disc - type? It was always easier - and cheaper - to find the unvented type, and it was the more expensive vented type that was more difficult to source. The upshot was that people started machining up spacers for the unvented type calipers to make them fit over a vented disc, leading to all sorts of caliper flexing problems.

 

The reason they wanted to convert to vented discs was the fact that its so easy to overheat the stock - unvented - disc, with sudden fade (just when you didn't want it...) and pad glazing being the result. So the unvented type are fine up to a point, but the weak link is the disc. I would always recommend the vented type over the unvented type. I run MK63-20S calipers on 4 S30-series Zs and a KPGC10, and all of them with vented discs. I would not bother with the solid disc type.   

Hi there, i understand your doubt and let me explain it:

1) I got told this by a guy in the USA who's into historic datsun racing and intended to sell me a set of MK63 solid calipers first, which never happened. Me too thought that story was quite bizarre, that's why i wrote "i was told" into the sentence because i was not really sure if that is true. didn't really make sense to me as well.

 

2)  According to your text i guess in the past the solid type was much common compared to the Vented type. But if you check Yahoo auctions now there are allways a few sets of MK63 vented types for sale while this was the first set of solid type within two years i gould get hands on. Maybe i don't know where to look but it was much harder for me to find a set of original solid type calipers than a set of vented ones which is even available as reproduction in japan. I know there are other options which would also work but i wanted to have the real deal. I guess the reason for aviability is because everyone is looking for the vented type and nobody wants the solid type. thats why vented ones have bevome more common and are usually sold. maybe i'm wrong, you're the expert :)

 

3) Now why i went for the solid type istead of the vented ones? That's not because i wanted to. i would have preferred vented ones for sure. but due to the fact that nissan in germany (which is responsible for switzerland as well) destroyed all records on old option parts (according to the guy at their office i had on the phone), and due to the swiss law regarding registration of after-market parts and cars i cannot switch to vented disks without an official german or swiss certificate. which is not available anymore. I decided to use the stock solid disks with the MK63 calipers and hope that nobody will notice the brakes are "wrong".

So for me that's actually the only option to upgrade the brakes without (hopefully) running into trouble. that's why. not my first choice but the only one i have ;)

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After i was on a long vacation and visited tokyo auto salon as well (see tons of pictures on www.JDMjunkies.ch) im finally back at the project..
P1160525.jpg
Good news guys. I thought it's about time to get the project rolling a bit faster again. that's why i'm currently preparing a few things. However thanks to my buddy stev (big thank you again, buddy!) i was able to get hands on another NOS piece: A New-Old-Stock Datsun Front lower center valance Panel thingy. Probably the last Bodypanel which was missing. Well i had one but it was rustend and totally crushed so this came in handy :)
P1160803-Kopie.jpg

P1160804-Kopie.jpg

With partnumber and everything :)
P1160805-Kopie.jpg

Oh and last week i got this picture from my bodyshop, letting me know that the car is back at the main workspace and ready to crank work up again. Hope to get some updates from him soon :)IMG-IMG-20160129-WA0000-Kopie.jpg

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The 240Z Project has been really cooking on a low flame last year. I was too busy with my Job and travelling. Luckily this year started out smoother and i'm really working to get back on the Z-Project. I Ordered one expensive part which will show up in a few months but so far i started reading a lot about the Z, because i forgot most of the things i knew maybe two years ago since i never used them :) However im starting to make plans for the next small projects of the Project and i'm super excited about it. However before i started to work on car bits, i had to get rid of the mess in my home-workshop (aside from my garage i have a little hobby-room for small work and parts-storage at home). So i bought some new shelves, moved everything and this is how it ended up. I'm super happy with it :)
P1160806-Kopie.jpg

I can finally work without searching for the right parts and tools for half of the time :)P1160807-Kopie.jpg

Then it was time to complete a simple but not-so-simple job i've started a while ago. Before i had the Door locks replated a while ago i removed the old damper rubbers and after i never figured out how to get them back in, i never did it.P1160809-Kopie.jpg

Today i decided it was time to complete the job :) So took an old toothbrush and scalpel to remove old glue from the rubber. then washed it in the sink with some warm water and dishwashing soap. worked fine :) Then took me quite a while to figure out how to get the Rubber back in without damaging it, but finally got it after 30mins of fiddling around. Added some of the Super glue like it was from factory, but the rubber sits so tight, i doubt the glue is really needed. Just a small job, but one more box ticked on the 2-do list :)
P1160811-Kopie.jpg

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Got a bit bored from all the reading an investigation in front of the computer, so decided for my own pleasure to test-assembly my rebuild steering colum together with the HKB Steering boss kit and the RS-watanabe falcon steering wheel (Horn button not installed). Nothing big, but enjoyed how it ended up. Now trying to figure out how i can clean the multifunctional steering wheel switches to get them back on the column :)
P1160819-Kopie.jpg

 

P1160820-Kopie.jpg

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I Decided to visit my Bodyshop and talk to my Panelbeater Yves about the progress of my car. Remember it was more than 15 months since he last worked on it, because it's still a side-project. Lucky me he just began working on the car today. Not a lot to show you but i hope for some updates soon. And i'm more than happy with any progress :)
P1160823-Kopie.jpg

As you can see he just started work on the floorpans. And the good thing is i already have another apointment with him for the next week. so pretty sure there are some nice news :)P1160822-Kopie.jpg

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Today i spent a wile rebuilding / refurbishing the headlight switches. The problem with the Original wiring design is that the full headlight current runs through the steering wheel multifunctional switches. This causes contacts tu burn, specially when upgraded to H4 headlights. I decided to refurbish them before putting it back on the steering column.
In future i will run a relay, because the original design is not very long-lasting, nor is it very safe to have 20 amps in your hands when switching on the lights :P
Started with choosing the best of all four switches i had (one beeing a later model or something different): P1160830-Kopie.jpg

Disassembled everything following This great manual:
http://www.doyouevenhoon.com/datsun-240z-gtr/how-to-rebuild-datsun-240z-headlight-switch.html and ended up like this:P1160836-Kopie.jpg

Removed the old contacts and as you can see they're pretty urnt and carbonized:P1160840-Kopie.jpg

Used some "relay contacts cleaner" Fluid and after a bit of rubbing looked like this. Also but the switches back in reverse orders to make sure the "weak" part will be on the opposite side and last longer ;)P1160841-Kopie.jpg

Will continue with the rest of the switch next week. need to buy smaller pliers first :D In the meanwhile i got an update from the bodyshop. Before:
IMG-20160225-WA0004-Kopie.jpg

after: IMG-20160225-WA0003-Kopie.jpg

Now work on the passenger side floorpan and rear quarter as well as the small storage compartment started. More rust than expected. but yeah. t hat's how life is :)
IMG-20160225-WA0001-Kopie.jpg
 IMG-20160225-WA0008-Kopie.jpg

Also ordered ordered the rear lower valance and rear corner valance so basically i will have an almost new chassis at the end *lol*. more updates soon i hope ;)
IMG-20160225-WA0010-Kopie.jpg

Edited by jdmjunkies.ch

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Made some progress again :) First i cleaned all the switches and buttons by hand so the white texture finally came back to life and is visibla again. worked surprisingly good with an old tooth brush and some dishwashing water ;)P1160850-Kopie.jpg

Well and then assembled everything back together. not factory fresh but as nice as an 44 year old switch can get :)P1160858-Kopie.jpg

Then started with the turn signal switch on the other side. seems a bit more tricky...P1160859-Kopie.jpg

The contacts had massive burn marksP1160860-Kopie.jpg

So this is after cleaning :)P1160861-Kopie.jpg

Who needs puzzles when you have cars? I never realized how complicated these switches are until i took it apart :)P1160863-Kopie.jpg

Then got some updates from the bodyshop. Rear lower side cowls (before):IMG-20160301-WA0001-Kopie.jpg

And after:IMG-20160301-WA0002-Kopie.jpg

IMG-20160301-WA0003-Kopie.jpg

And that "triangle piece" inside the rear fender well...IMG-20160301-WA0004-Kopie.jpg IMG-20160301-WA0005-Kopie.jpg

Tomorrow i will visit a shop to repair my wing and on friday i'll drop by the bodyshop again. hoping for some updates again ;)

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That's delicate work on those switches. I usually break that kind of stuff when attempted !

I guess that's my advantage from beeing an electronic engineer mainly repairing old electronics from the last decades. i Know my wires :D but that's the problem. i know more about wires and contacts than about cars :P

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One popular upgrade for the 240Z seems to be swapping out the lame Original Heater blower motor to the one coming from some 80ies or 90ies Honda. Unfortunately all the manuals i found for this swap mentioned a different Honda model as source for the Blower motor so i was confused. They all looked the same in the pictures and some guys on Ebay even sell the Blower swap for around 90$ + shipping. I thought that's too expensive and did some research and figured out the one blower everyone is using is the TYC Genera Model 700077 which is an aftermarket replacement for the aforementioned old honda motors. Funnly this blower is sold for only 23 Bucks so i went the direct route and ordered it :) This is the old Nihon Radiator / Hitachi Blower:
P1160814-Kopie.jpg

 

And here we have the new one. Brand new and factory fresh :)
P1160869-Kopie.jpg

 

As you can see the shape is slightly different (left new, right old), but it wil fit perfectly.
P1160870-Kopie.jpg

 

I compared with the drawing on the TYC website and many people in the internet told this is a 1:1 swap except for the rubber gromments which need to be changed due to different mounting hole diameters (other people probably will enlarge the holes). Also i recommand to paint the now Silver motor cover black as this is installed right in the foot compartment of the passenger and will stick to the passengers eye ;)
blower-TYC-700077-Kopie.jpg

 

According to the poeple in various forums the advantage of the new Blower is: Much more powerful, much more silent, lighter (Due to the plastic squirre-cage compared to the metal one in the old design) and draws less current. Overall it's much more effective. can't wait to install it. Of course i will write about it once i get to that point ;)

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Wo hast du den Lüfter denn genau gekauft für den Preis? Bei dem Bericht habe ich auch Lust bekommen den zu tauschen.

Achja und deine "Location" im Profil hat nen Dreher drin.

Thanks for the input :) I bought it on ebay. I haven't tested it so far (and it probably will take a while until i have it installed, but i'm pretty sure it's the one everyone is using. I bought mine on ebay ;)

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Last friday i spent a visit at the Bodyshop. Mainly to bring him the Passenger side door so he could check fitment after he's done with welding in that area (some parts may have moved a bit and need adjustment). I also asked  him to close the original door mirror holes in the door as i will switch to the JDM Fender mirrors ;) And i had to bring  him some cash as well :)
P1160877-Kopie.jpg

And then i have some good and bad news. The good news is that work in the front right (passenger) sode is almost completed and the work looks fabulous. To the untrained eye it may look a bit patchy but after everything is primered and has the same colour it's almost factory-work - maybe even better since factory welding from datsun was really crappy in some areas :P
P1160879-Kopie.jpg

P1160880-Kopie.jpg

Now the bad news. Specially in the passenger area behind the seat there has been copious amount of cheap patchwork repairs and way more rust underneath every panel which was removed, than initially expected. So well - yeah. the whole thing will be a bit more expensive and take maybe another two years at the bodyshop until completed.. but i'm still happy with the fact i will save one of these fairladies... P1160875-Kopie.jpg P1160876-Kopie.jpg

Inner wheel well has been removed and he's currently fitting the new one from tabco..   P1160882-Kopie.jpg

Also the old sparewheel well has been cut out and the new one placed inside just to save some space. hasn't been welded yet...P1160884-Kopie.jpg

The car looks a bit like a swiss cheese currently :)P1160885-Kopie.jpg

Here's a good example. I wouldn't have noticed but as the bodyshop explained and showed me the patchwork under the gas filler thingy i understoud where there has been cheap repairs in the past. so this one has to go out as well and fixed nicely... many small bits which will take up a lot of work at the end...P1160887-Kopie.jpg

Anyhow, looking forward for updates. And while i was there i also ahd a look at this almost finnished (has been in the works there for a while now as well!), Toyota KE70 Corolla "Kesser Sport spezial". This was a swiss homologation special as far as i understoud (wasn't able to find anything about it on the web..) in all it's early 80ies boxyness. Love it and i'm pretty sure this will be a rare gem once completed!P1160873-Kopie.jpg

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