toolman
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Posts posted by toolman
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Part 10-Middle Connection Frame Rails are fabricated and installed.
In this this video, the Frame Rails connecting the Front and Rear Frame is being constructed and installed. It is pretty heave duty but besides acting as a
regular Body Frame, it must also support those Gull Wing Doors. As the Roof will have be cut out for the doors too, extra support must be provided for door operation
and replace the roof structure. I imagine the roll cage have a strong Center Roll Bar Section to accomplish this task. The Doors will be a major problem with sealing and allowing adjustment of the Gull Wing Doors;
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PART 9- ROLL BAR WELDED IN AND FABRICATING SQUARE TUBING INTERMEDIATE FRAME
Thing are really moving along now. The Roll BAR is welded in and a frame connecting the existing front and rear frame rails is being fabricated.
Excellent metal fabrication is demonstrated. i can for see that the original Transmission Tunnel will have to be removed to provide clearance for the Mercedes transmission. e Firewall probably have to be widen also.
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EXHAUST SYSTEM REPAIRS-
My 240Z Exhaust Pipes were damaged from scrapping them on Speed Bumps. I found a cracked at one
welded joint and a few exhaust leaks. Since repair required their removal, I decided to raise the pipes higher as the
same time. I designed this exhaust system so that whole system consists of three major sections. First -Front Section
goes from Hooker Exhaust Manifold to the X-Crossover pipe. Second Section runs from X-Pipe to the Rear Right Angle
Exhaust Pipes. The Last Section finishes at the Two Turbo Mufflers. So this repair and raising the pipes only required
the Intermediate Pipe. Also, since I used Evil Energy V-Band Clamps to connect the pipes, it was a simple job.
The Intermediate Pipe Mount consist of 1/2" Steel Rods bent at 90 degrees and bolted to the Differential Housing.
To Raise the exhaust pipes, only the Mating 1/2" Mounting 90 degree Rods had to be shorten.
Pic of Mounting Rods cut off and rewelded
Pic of Mounts Powder Coated and out of Oven
Pic of Fully Assembled Exhaust Mount
Evil Energy 2 1/4" Lap Joint Clamps( Amazon $20 a pair)
Rubber Exhaust Pipe Hangers(Amazon-$6 a pair) and 1/2" Steel Rod-Bent to (90 Degrees-Home Depot)
Right Side Pipe Mount
Left Side Pipe Mount
The Exhaust Pipes were raised about 1 1/2". The job can be accomplished in one days if materials were at hand.
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Part 8-The Roll Cage is now installed so the Roof Area is being prepared for the Gull Wing Door Build. A Major Obstacle that I foresee the Transmission Tunnel and Firewall
may have to cut open because of the Huge Mercedes Motor and Transmission. But if they are willing to Eliminating the Tunnel and Widening the Firewall Opening, they should not be a Big Problem.
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Part 7-More work on the Rear of the Hatch area to install the 370 Rear Suspension Subframe. The Entire Rear Deck and Frame must be removed to make it fit.
The Workmanship is excellent and the Shop High Tech Equipment makes this big job alot easier.
https://www.youtube.com/watch?v-EY6HaMiWFE48&t37s
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Part 6-Major Problem delays SEMA PROJECT
A major problem occurred in using a late model 370z suspension into this SEMA SHOW car. Its wider size and different mounting points created
a major obstacle in this construction, Time is the Real Problem so this build will be exciting to watch.
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Second Owner of the SEMA SHOW Toyota A86 Body
The First Owner of the SEMA SHOW Chinese Made Copy of the Toyota A86 Body decided to sell the body. The real question is why? The next Owner
bought it with the idea of attempting to assemble the body and create a drivable car. As the body has No VIN Number and No Manufacturer ID Number, they
knew that car registration in most states would not be possible. They intended to use this body as a Race Car as no registration would be necessary.
As the video demonstrate that most mounting holes that not align with OEM parts. Also, they discovered a lack of sufficient welds on the body panels.
Mounting brackets were missing or mislocated. So even if it was going to used as a Race Car, major welding and reinforcement of the vehicle would be necessary.
So far, there has no one that I know who purchased a 240Z body from this same manufacturer. So far, we could not get a firsr hand through inspection of the Zbody
and find if that body is manufactured better or not.
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10 hours ago, toolman said:
Part 5-Major Problems in the build -time may run out before the car is finished.
https://www.youtube.com/watch?v=DcXWWiwmGSI
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Part 4-Fixing the Gull Wing Doors and create special Interior design work
Finding a mistake costs a lot of correction time but when you doing a one of a kind project that is to be expected.
Go to---https://www.youtube.com/watch?v=itN99F8VKbQ
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Part-3 The Whole Plan is explained in this Video,
Liberty Walk Body Kit and other exterior modifications are exposed. But Time is the greatest enemy as the Sema Show is now less than a year away.
go to ======https://www.youtube.com/watch?v=Merq9wrCZns
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PART 2- Working on Gull Wing Doors
Demonstrating the process of converting old door shell into the Gull Wing Door. Fabricating new door frame from scratch is something to be hold.
The craftsmanship is excellent. Their equipment is First Class and expensive. Most body shops don"t have access to scuh expensive equipment
but work can duplicate by regular metal working tools but taking more labor and time.
Go to https://www.youtube.com/watch?v=LGEWDhsnRoE for video
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240Z Wiper Blades Problem
The problem with the 240Z Wiper Blades is their availability. As these cars go older, their parts tend to
almost impossible to find. When found, they cost about $200 on Ebay. Those Universal Wiper Blades use
a Plastic Universal Adaptor. However, these Adaptors don not hold the Wiper Blades to the OEM Wiper Blade
Arms. Mine came off during a rain storm several times. The last time It scratched my windshield glass but
fortunately it was polished off. So I decided to see if I could create a better design. Most Late model cars
use a "J HOOK" design Wiper Arm. So I went to the Junk Yard and got two arms. As I was a regular customer,
the owner said "just take them, I got hundreds of them". After carefully measure the distance between the Wiper
Nut and the End of the Wiper Blade Tip. I just cut the donor arm about 3" off. The Univerisal Wiper Blade was installed
on the J Hook. Then, slide the J Hook piece on the OEM wiper arm until the measurement was acheived. A Visegrip
Plier was used to hold the two pieces together. These two pieces were tackwelded together. The newly form
wiper arm was installed and tested thru its full arc. When that was achieved, I fully welded the two overlapped pieces together.
A Simple Fix for the Wiper Problem. Very Low Cost and ended up with a Wiper Blade that will always be Available.
Those those of you who want the original Blade-just keep the OEM one in a safe place and make one for every day use.
Unless you can afford $100 when your blade wears out.
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This video is the Second Video concerning the Toyota A86 reproduced assembled body. They have several individuals that discuss the quality, licensing, and infor
about this car body.
In my opinion, the more detailed pics of the alignment and welds show that this body was not assemblied properly. If even used for the street, the body would require closing the panel gaps and alot more proper welding. Unitized bodies require proper panel alignment and sufficient amount of welding to provide a safe cafe.
Please give your comments about this car body. Remember this same company manufactures the 240Z assembled body also.
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The Video is the most detailed Rebuild of the Power Brake Booster Unit. As the 240Z family goes older, aftermarket rebuild boosters
are getting harder to find. In some cases, they are impossible to find so rebuilding maybe the only solution.
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The reason for this video is investigate the Quality of Car Bodies that are produced by a Chinese Manufacturer who also produces the
240Z assembled body. The Actual Chinese Reproduction of the 2025 SEMA SHOW Toyota A86 Body was purchased and examined by several individuals who expressed their opinions about the body. The owner will attempt to assemble the vehicle with available Aftermarket Parts( tail lights, interior parts,etc. This body was the same one at the SEMA Show so time will tell its quality and parts fitment is up to the OEM Standards. This body came from the same factory as the 240Z body at the 2024 Sema Show.
I checked this at the Sema Show and after watching this video, my opinion on this car is there is a definite lack of quality control in the welding of this car. There seems to be a lack of spot welds on some of the panels. On Utilized Body Cars, spot welds
will determine the strength of structure. Normally, the original manufacturer would use Robotic Spot Welders on the Assembly Line. On this car, the welds are not located close together thus not providing a strong panel. Another major flaw is the Front Strut Mounting Holes are oval not round as they should be. This shows a definite Quality Control Issue. It seems that assembly of this car was rushed and put together just for the show.
The Collision Industry has a established Standard -ICAR which provides proper methods of assembly of Body Parts. A ICAR Body Specialist should inspect this car before it is put on the road or used as a race car.
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This 260Z Build for the 2026 SEMA SHOW comes all the way from Great Britain. Yorkshire Car Restoration is performing a Wild Build
with a complete Liberty Walk Body Kit, Mercedes V8 Motor and featuring Gull Wing Doors. This company is well known car restoration
companies in Europe. Since the car will represent them at a SEMA SHOW, you bet they will go all out. I seen some of their previous
restoration work and their workmanship is excellent. The 260Z Project Car is from California and is pretty good shape. The body seems to have relative only minor corrosion problems( even the floor pans probably don't need to be replaced.
https://youtu.be/QsBzrxPXM2c Use this Link________________________________________
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Happy New Year!!
I decided to upgrade my alternator on my Z. During my engine swap, I wanted to install an alternator with at least 150 Amp Output. Unfortunately, due to tight spacing, the only alternator that would fit was a General Motors One Wire Connection 110 Amp Output one. That was before added a Silver Mine Electric Power Steering which had Max 50 Amp
Draw. So an upgrade was warranted. A POWERMASTER 165 Amp CS130 Alternator was selected. As it was the same
alternator model as the original one, no mounting modifications would be necessary.
Installation of the POWERMASTER ALTERNATOR in vehicle
A larger Battery cable was also installed to compensate for the high Amperage Output.
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Larry Chen interviews the Aluminum 240Z owner for more info on this car.
https://www.youtube.com/watch?v=rNBOYGraHU8
Use Link to watch video-------------
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Larry Chen checks out the Aluminum 240Z at Sema Show
Larry Chen reviews the owner of the Aluminum 240z at the Sema Show and gets more details about it.
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This You Tube Video shoes the actual conversion of this Aluminum Panel 240z in a home garage.
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This You Tube Video goes over the conversion of a regular 240z to one with mostly all Aluminum Exterior Panels.
The work seems to done at a home garage located in California. The owner never said level or how much his experience with aluminum panels. However, most of the panels are bolted on to the original sheet metal structure. The aluminum roof, both rocker panels and rear quarter panels were probably attached using a special aluminum to sheet metal epoxy. I worked with Japanese after market body panels and found their fitment was very good. Most of the corrosion damage found on the 240zs was actually caused by rust starting on the exterior panels. Then it spread into internal structural parts. So using these Aluminum Panels ,new Seam Sealers and Rust Preventive Methods will make these 240s last a long time.
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These Aluminum Body Panels were introduced to the Public at the 2025 SEMA SHOW in Las Vegas. They were manufactured by
Yahagi Industry Company located in Japan. The 240Z vehicle was in the Toyo Tire Booth at the Show.
Front Head Light Bucket
Front Hood
Bottom Side of the Hood
Right Front Fender
Front Cowl Panel
Front Aluminum Grille
Right Front Fender
Roof
Right Rear Quarter Panel and Fuel Door
Rea Hatch Pic
Rear Panel
left Rear Quarter Panel
Flyer that describes Weigh Savings between Steel Panels and Aluminum Panels
They would not give the price at the show but say it would be give out at the end of the year. I believe they are waiting till the Tokyo Auto
Salon Show happening in Tokyo in January 2026. They were planning a production run of 100 of these Aluminum Panels. The well known
Japanese Performance Company-Star Road is handling the sale of these 240Z panels. The panels have an excellent fit and well constructed. I would definitely recommend them.
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I found this video on the Net about the Factory producing the Complete Assembled 240z Body. The video show the process that their bodies undergo after
being welded together. They do dip the bodies into some kind of primer in a large tank. As to why there was no primer in those storage compartments that 240Z
at the SEMA was not addressed.
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Aluminum Body Panels of 240Z manufactured in Japan
These 240Z Aluminum Body Panels are originally manufactured by Yahagi Industry Company in Japan.
They will be marketed by Star Road Specialist in Tokyo, Japan.
The body were installed on a private owner's car for the Sema Show 2025. I hope they have a video of the
installation process so we can see how to done. That way, potential customer can determine whether their
body shop can duplicate the installation. Working with Aluminum is not an easy task and requires some specialized expertise and tools.
This vehicle was on display at the Toyo Tires Booth at Sema.
Pic of Hood
Bottom of the Hood
the Hood Skin was riveted to the Hood Ribs.
the Engine was a Turbocharged Nissan Motor.
View of the Front End
Rear Hatch Lid
Right Side Door
Rear End Panel
Roof Panel
Left Rear Quarter Panel
Right rear Quarter Panel and Fuel Tank Door
Left Door
Left Rear Quarter Panel
Left Front Fender
Front Cowl Section
Front Grill Section
Headlight Bucket
Information Sheet
Weigh Saving Information Card
These Aluminum Body Panels are very well made and looks great. It will provide a another
option for restoring 240Z and save many Zs from being scrapped.
i talked to the guys who actually manufactured the aluminum panels with the little Japanese that
I know. They told me that right now, they plan to run only a Production Run of 100 body panels.
Star Road is handling the sales side. But they would not give a price yet. I think they are waiting till the Tokyo Auto Salon Show occurring in January 2026 in Tokyo.
Pic of Mounting Rods cut off and rewelded
Evil Energy 2 1/4" Lap Joint Clamps( Amazon $20 a pair)
A 2026 SEMA SHOW 260Z Build all the way from Great Britain
in Body Kits & Paint
Posted
Part 11- trial Fit of the 370 Rear Drive Sewction into the 260Z.
In this episode, the Car is finally on the ground for Rear Suspension construction. Since they are using a Fiberglass
Hatch Delete section, there will be very little space for anything else but a Fuel Tank Cell. the major problem is time
to finish the car as they are not even at the half way point of the build. The craftmanship truly amazing as they solve problems with building a one of kind vehicle.
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