toolman
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Posts posted by toolman
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i will discuss my Interior Modifcations created to add to the "Race Car" Imagine of 240Z Restro Mod.
Using Dimple Dies -
Dimple Dies are used regularly in Race Cars to strengthen and at same time lighten vehicle weight. Dimple Die tools are basically a Male and Female Round Hole Dies. In the center, a Bolt is used to squeeze the sheet metal into a Reinforced Round Hole.
Completed Dimple Die Panel
To create Upper Strut Tower Covers, A Paper Template was made First.
Strut Tower Brace Covers with a Polished Aluminum Rear Deck Plate
Rear Hatch Area also Large polished Aluminum Pan was added.
Another view of the Hatch Area
Interior Mouldings
Front Passenger Side Interior Moulding
Front Driver Side Aluminum Moulding
Lower Interior Rocker Panel Covers
Dimple Die Panel installed on Right Rear Quarter Panel
Aluminum Door Panels
To install Aluminum Door Panels on a 240Z took more work as the interior side of the doors are not flat as most cars are. They were constructed this way because of the confined inteirior area.
Trial Fitting of the Non Polished Aluminum Door Panels
This Test Determined that Spacers are needed because of the "uneven interior door surface'. A Straight Ruler. It shows that 3/4" spacers are required to attach the Door Pull Handles'
Note-Three Black Round Plastic 3" Spacers glued to the Door Skin with JB Weld.
The Other Problem is the Window Crank Handles is be extended by about 1/2" longer for clearance to operate.
A Extra Window Crank Handle must be use to cut the Spline End off to extend the shaft. A Hole Saw is used to remove the shaft off the crank..
The 1/2"Cutoff Section is attached to the Original Crank Handle with JB Weld Adhesive. This will allowe the Window Crank Handle to "clear" the Door Panel.
Also, Other Modification that must be made to the Door Release Mechanism.to function properly.
First, the Aluminum Panel must cut out to mount the Door Release Mechanism.
A Dremel Tool was used to perform this task.
Also, the Door Release Mechanism itself must be"Tilted upright" in it mounting position. This is accomplished by fabricating Triangle shaped wood blocks under the bracket.
Oak Blocks was used for its strength ,avaiabllity. and ease to fabricate.
Two Longer 6mm x1.0 bolts are necessary due the Wooden Blocks.
Door Release Mechanism installed
Window Crank Modification
Using a Hole Saw, a section of an extra Window Crank was removed. This section
was filed down so the core portions would match for sectioning.
Window Crank Handle Extension joined using JB Weld
With this 1/2" Extension, the Window Crank Handle has enough clearance to operate.
Aluminum Door Panel now Completed-
Drivers side Door Panel
Fastners Used
All of the Dimple Die Alumunium Covers were fastened using Rivet Nuts and Small Machine Screws
(4MM x o.7 ). The only exception were The Upper Interior Aluminum Covers were fastened with 1/4"log Phillips Screws.
Radiator Support TopCover
I also added a Aluminum Dimple Plate to hold a 1/4"x 4" wide Rubber Strip which seals the Hood and Radiator Support Area. This Seal directs more air through the radiator. Right now, the Water Temperature runs 193 degrees and up to 200 degrees with AC running.
Hatch Interior Cover
A Polished Aluminum Flat Panel was attached to the bottom side of the Hatch. It was attached with Plastic fastners.
Next Topic-Rust Proofing the Vehicle
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Techno Tuning 240z 8.8 conversion kit cost $56850 plus freight is the most complete kit available but also the most expensive.
https://technotoytuning.com/nissan/260z/complete-ford-88-rear-end-conversion-z-car
Anybody have any comments on this conversion ?
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Thanks for all comments about restoring a 240Z. I decided to post these videos because when I started to put my 240Z in car shows, alot of people(young and old)
didn't really understand how much work was involved, I spent working on the car for 5 years(working after work, weekends and holidays and about 2 years straight after I retired. i was lucky because My father own a Autoi Body Shop and I have ASE Certified License in Auto Mechanics and Automotive Collision. This experience allowed me to do 99% of the work by myself including painting. Built the whole car in my home 2 car garage. Also, made a Wooden Rostisserie to do the floor pans and some under carriage work. Since a new crate motor LS3 6.2L motor was going into the car, I constructed a 3/16" X 2 1/2"square tubing frame and midframe made of 1" x3" tubing. The main reason for going through all this work was this 240z was my First Car that I ever bought on my own. Everyone wishes they still had their First Car. right?
Toolman
Before
After
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Replacing Precision Door Weather Stripping
I found out that the Precision Door Weather Stripping was not doing its job. It seemed too hard and not sealing the
interior from air leakage. Even after adjusting the Upper Chrome Window Channel inward to the Maximum Adjustment.
So I decide to look for a Weather Stripping Replacement. I found an Univerisal Automotive Door Weather Stripping gasket on Amazon.
Two of these Univerisal Weather Stripping Gasket are needed for both sides(Left and Right. This Gasket was soft but large to handle large door gaps. This style of weather stripping is used on most late model vehicles. The only problem was the 240z has a Right Angle-90) degree on the Upper Rear Corner of the door opening. The gasket was made for Slow Sweeping Corners. So some fabrication of the weather stripping would be necessary;
Pic of Precision Corner Section which made by Vulcanizing rubber to create the Right Angle section.
Precision Door Weather Stripping gasket
First, A DoorTemplate had to be created to make the Right Angle Corner Piece which will hold both ends of Weather Stripping. This template will be used only for the constrution for the Right Angle Rubber Weather Stripping portion. A Corner Template made of 22 gauge sheet metal will be made to hold the two parts of the Corner Weather Stripping. This thin sheet metal right angle piece will inserted into in the slots of the each end of weather stripping. After Trial Fitting, this piece will glued with E6000 to fasten both ends of weather stripping forming the Right Angle or Corner Piece.
Trimming of Connector piece to Fit..
The Connector Template inserted into both Weather stripping ends to Corner piece.
A Foam Square was cut out of 1/2" Soft Foam to fill the Corner Gap between the Two Weather Stripping Edges. Note, this Right Angle Connecting piece will become a permanent part of
the weather stripping after glued all together(connector piece, Foam Filler and both Edges of
Weather Stripping} with E6000 adhesive.
Test Fit of Weather Stripping on Door Template without Corner Connector. This Template is flipped
over to create the opposite( Left) Door Template.
r
The Best Rubber Adhesive that I found is E6000. It is made by the same manufacturer makes
Shoe Goop. It can be found on Amazon. If you ran a bead of E6000 on piece of wax paper and let dry hard. Then, peel it off the wax paper and you can stretch it 3 times its original size!! There are two versions of E6000 -low viscosity and high viscosity. It depends if you want the glue to fill in gaps or stay on the surface.
Interior View of the Door Template with Weather Stripping installed
Note-a Right Angle Corner Bottom Piece was made from 1/16" rubber sheet which is glued to lower side of the Right Angle Connecting piece to provide a Bottom Sealing Surface.
Exterior View of the Corner Section
Test Sample Section
Note-Foam Gap Piece installed. E6000 is used to attach both weatherstripping edges to the Right Angle Connector and later gaps and edges will be filled with E6000 to prevent water intrusion.
Top View of Weatherstripping Corner
Test Section without Construction Template
Testing Weather Stripping by shining Fashlight along window sealing edges
*Light shining through area with no gasket
Right Side Door Weather Stripping installed on vehicle.
I have not Road Tested the car to check for Air Leakage or Water Leakage yet. Will let you
know the results of both tests when they are completed.
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Rayaapp, I am curious "Has your Gap insert made a differance in additional air flow for your AC system?"
Toolman
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I found this Four Part Video of a Complete Body Restoration of a 240Z car. This series of videos gives a good idea of how much work
it takes to perform body restoration. The individual demonstrating the bodywork is a very skilled artisan and uses some specialized body
tools. He repairs most of the bodywork with his years of skill. In some cases, a individual not as skilled can replace reproduction Z body
which are now available in the USA. As I found out later, I think these videos were made in Switerland. European and Asian countries have Vocational Apprentice-ship Education Programs that student start into their selected vocations( plumping, electrical, automotive bodywork,etc at age 15. So the student starting learning a vocational trade at least 3 to 4 years ahead of vocational schools in America.
Unfortunately, most people tend to look down on individuals who go to Trade Schools instead of College. Yet, they can make a Six Figure
Income at their Trades.
Video#1
Video# 2
Video#3
Video# 4
rotisserie
To work on the Z Floor Body Pans, the Two Methods most often utilized is Car Rotisserie or Tilt Rotisserie. A Car Rotisserie costs over
$1000 or you could rent on or make your own (using two engine stands). The choice is to construction of a Wooden Tilt Rotisserie.
It built using 2" X 6" lumber and some plywood costing about $80 from Home Depot.
Putting car on the Rotisserie
I hope these You Tube videos were interesting for you. If you have any questions, please ask and try to answer them.
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christianmoller, I forgot to include the compressor # SANDEN SD7B10 (7176). Kwik Performance website also has installation diagrams that give dimensions
the compressor mounting on LS motors. This will enable you to determine if this kit will find in your particular vehicle.
TOOLMAN
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christainmoller, Check out my posting under Heavy Duty Frame Rails underGen iii & IV Chevy V8 Tech Board Postingn 17 and 18. They show y AC installation in my
LS3 6.2L 240Z. I tried several Aftermarket AC Kits that would not fit as I made my own motors mounts and custom made front sub frame( constructed from 2 1/4" square
tubing. The smallest AC Compressor that I found was a Sanden AC compressor which is only 7 inches long total length (comprssor with clutch). I used a Kwik Performance Ac Kit but the mount can easliy fabricated by yourself. I was rushing to enter my car into a car show so did not have time to measure and try and error the mount construction.
But notice that you must use Chevy truck type water pump and longer harmonic pulley to match the belt location. The posting goes into the details of the AC Installation.
I hope this answers your questions, if not post any more questions that you may have.
Toolman
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fturbo930,
Check out -The guy with Larry Chen walkthrough Toyo Tire booth claims the Green 240z has a Lamborghini V12 motor in it. Unforturnately, the hood was not open. I guess we will never know for sure. Green 240Z video at 4:29
Toolman
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rturbo930,
I found one more pic of the Green 240Z at the Toyo Tire Booth. I did recall any sign near the car with more information, though. I hope this pics help you..
Toolman
looks like it has Apex Engineering Time Attack rear suspension
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SEMA Show 2023 Las Vegas,NV Oct32-Nov4
The Sema Show is the Biggest Automotive Show in the World so there are hundreds of cars, trucks and now Electric powered vehicles( gokarts,sport cars,etc) were there. I will try to label the vehicle pics with the proper description as possble.
Sema Show Sign outside of the Central Hall
interior picture of the Show
Nitro Funny Car on Display
240z with LS9 supercharger and 6 speed trans at the show for the Ultimate Street Car Competition Race. This
race consists various street racers who competete a events across the USA(East to West Coast). The events include
racing in a straight line, 60 to zero stopping, a tght sports car track racing.
LS9 into a 240z with 6 speed trans
LS9 supercharged Z
Interior View note-Hand Brake
There were Super High 4WD trucks all over the Show.
K Mini Race Truck
Under carriage
Truck Interior
Crowds of people outside the buildings
How high can you go?
Beautiful Red Ferrari with V10 motor
V10 motor
4WD Truck Lineup
Another Z Race Car
Skyline JDM
I
Interior
Super Clean Green 240Z
Full Blown Black Dodge Charger
Blown Hemi
Inside of Show
Large Trailing Arms
Lambo with Metallic Wrap
You can not get much Lower than this!!
Road Racing 240Z
More Road Racing Zs
California Lower Rider Chevy
Liberty Walk 370Z
Scion Race Car?
Porsche Race Car
Cobra Race Car
Fully Blown Hemi Roadster
Yellow 240z
Interior
Roll Bar in Deck
Engine Compartment
Tri[ple Webers Carbs
This Z Car was build in "Snow Country" -Canada probably costed than 30% more because of that
alone.
K truck
This Blue 240z was in the Battle of The Builders entries. It was powered with Blown LS motor
sticking through the hood.
Rear View-modified Tail Lights, custom Spoiler and Rear Chassis Deflector
interior
It has a small Blower on a LS motor with square tubing front frame and custom strut mounts.
240Z Radio Controlled Car
Fully Carbon Fiber 240Z
Video of Drifting Demo by Three Mustangs
Next- Replacing Precision Weather Stripping
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Silvermine Motorsports has a Ford 8.8 Rear End Conversion kit for 240z. The kit includes the bracketsnecessary for this conversion for
$1340.00 plus shpping. This kit does not include CV axles, strut shocks, wheel hubs, rear brakes,et and the Ford 8.8 differential. The buyer
must purchase the remaining items but uses available parts. The only other conversion kit on the market is Techno Toys who sell their kit for $8000.00 plus shipping. The Silvermine kit seems to be well built and strong enough for most people. I am curious if anyone has installed this kit and would comment about it.
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WIPER MOTOR REPLACEMENT-
i replaced my Original Factory Wiper Motor with one from a 1992 Honda Civic. Amazon had a Cardone New Wiper
Motor #85-1423 for $105. This particular wiper motor has "Parking Return Feature" which returns the wiper blades to return in the Parking postion when Shut off. The original Factory does not have this feature so the Driver has to accomplish this task manually.
This Honda Wiper Motor has the same mounting bolt pattern so the installation is easy. Also the Motor rotation is the same. The Datsun Wiper Mounting Plate has to "notched" for the Honda Wiper Motor Clearance. The Honda Motor
was similar Mounting Slot for the Datsun Wiper Arm and bolts right up.
A Hot Glue Gun was used to glue down the Hoda wiring to prevent possible wiring problems.
The most difficult portion of this installation is the Electrical Wiring of this swap. A Water Proof Relay was utilized as the
Wiper Motor is located in the Cowl Section of the vehicle. I used -irhassody 40.30 Amp 12vt Waterproof 5 pin HD relay $11 from Amazon.
This is my wiring diagram for this Honda Wiper Motor Swap. Double check the wiring colors as I found some wiper motors has different wiring colors.
Honda Wiper Motor installed.
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Sorry it took so long but this Japanese Body Shop does some of Best Restorations in Japan so they really busy. Their workmanship is excellent and very detailed.
This latest video is #49 and shows installation of the Asphalt Insulation Pads on the Interior Floor Pans of the S30 car.
Go to Chevy Gen IV Posting under Heavy Duty Frame Rails-posting #17 to view all 49 Videos of this 240z Restoration.
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Replacement of Heater/AC Blower Fan-
Finding a Replacement Blower Fan especially with the similar mounting arrangement and size was not easy. The
closest one that found was one from a Kai Sportage for $99. This was a brand new one and a rebuilt one. The blower shaft was the same size as the original Datsun. Their Fan was slightly larger (about 1/4"}but made of black plastic..
Its speed was a little faster so hopefully it provide more air flow.
Replacement Electrical Connector Plugs-
Alot of my original Datsun Plastic White Electricl Connector Plugs were pretty brittle.
So I found these Replacements on Ebay.
2.3 connector and terminals
Ebay also had 6.3 connectors and terminals but I could not find its pic.
Repairing Interior Vents-
These vents draw air from the two air tube built into both top sides of the engine compartment. Basically the vents function at high speeds (above 40mph}. Some people forget to close them when running their Air Conditioning and wonder why the Air Conditioning is not cooling the vehicle.
Replacing Foam gaskets on the Vents.
Used Contact Cement to Glue the form the Ducts.
Next- Replacement of Wiper Motor
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Reapairing Right Side Dashboard Ac Vent Hose-
The Right AC Vent 2"Hose was broken off from the Duct Vent. So a method to reconnect that hose would have
to be found. I diecided to use a 3' piece of 2" radiator to"splint' the Vent Hose to the plastic Vent Housing.
Used the Hot Glue Gun to adhere the Spint to the Vent Housing.
Inside View of the Splint
The Finished Repair if the AC Vent Hose and Duct
I had to fabricate a Micro Phillips Screwdriver to remove the Three Phillips Heas Screws to Chrome Duct Vent.
This Micro Phillips Screwdriver also was used in other 'tight spaces" where normal phillips screwdrivers would not fit.
Modifying the Dashboard Center Vent-
The Original Center Console Vent only had a small piece of foam around the vent tube leading to the Blower Box.
I decided to construct a sheet metal Tube that provide a tighter seal to Outlet Vent.
Making Template for the Vent Connector
Bending the sheet metal with a 5/8" deep socket to match the template shape.
Finished AC Vent Connector
Next-Heater Blower Fan Replacement
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1
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Part #47 consists of Painting the Z Interior and Engine Compartment. Part#48 shoes more Exterior Body Work and Paint. Also, Taking the Car to a Local Car Show to advertise for the Shop. Found on my regular postings.
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Finally, Part# 46 video-shows the complete of the Front Radiator Core Support. Use of both Mig and Spot Welding is shown to fasten pieces together. Note,
the use of Weld Through Primer on the connecting sides of the welded parts prevents future corrosion. This step is commonly skipped so corrosion starts immmediately,
Go to Gen II & Gen IV Chevy V8 under Heavy Duty Rails Section on Page 17.
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I just added Part # 45 which consists of Body working the Rear Body Panel. correctly Right Fender gaps and Fender Body Lines. The Bodyman reworked some
of their previous body work to improve the body panels fit. Got to give them credit for their dedication to do a quality job.
Part # 45 can be found on Gen II & Gen IV Chevy V8 under Heavy Duty Frame Rails on Page 17.
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Sorry for Not Posting for a while. After my last post on Jan 30, I went my Orthopedic Surgeon to check on
my Sore Left Knee. He previously did a Partial Knee Replacement on my Right Knee about 6 years ago. At that time, my Left Knee was not too bad but I had pain occasionally. After the 2022 Sema Show, my knee got real bad to the point that I could hardly walk at the end of the day. So I made an appointment to have my Left Knee checked out. No surprises, the X Rays showed Bone to Bone Contact causing the pain. So I wanted the surgery as soon as possible. But I did not expect that there would be an opening for my surgery in only 2 weeks. So on Feb 15 , I had a Total Knee Replacement Surgery which consists of installlation of a Titanium Joint inserted into my leg. I went home the same day but I knew that the Physical Therapy would be Painful and take Months too.
Pic of my Left Knee
Top to Bottom
-Now back to posting - continuation of Air Conditioning Installation
Pic of the Sanden Compressor mounted with 90 degree Outlet Fittings to clear the Hood.
Top View of Compressor Installation.
Vintage AC Condensor mounted in front of the Radiator Core Support.
As the new AC Compressor Location changed the Drive Belt Arrangement for the Alternator so
new mounts had to be constructed.
The New Alternator Mount being Test Fitted.
Front View of New Alternator Mount.
Mount was Powder coated and Test Fitted.
Front View of Mount
Because of the Evaporator Hoses, the Glove Compartment Box had to shortened in Depth by 2"'
So now, the Holley ECU Box was mounted in the Lower Shelve. This postion is better for view the ECU LED Trouble Lights. The Upper Shelve would be the New Glove Box although smaller.
The Glove Compartment Door Hinges were slotted to provide additional adjustment.
Next- More Modifications to AC Vents ,etc.
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More Good News, as of today Feb 24,2023, I posted Two More Videos #43 and #44 on my Chevy V8 Gen III and IV postings. Number#43 goes into more
detail on Door Alignment and Fitment. Number #44 shows how to create Body Lines and repairing Door Gaps. Developing the "Feel Metal"(feeling High or
Low Spots on the sheet metal usually takes a little time to acquire but some people never acquire this skill. Bodywork is mostly learned from experience. These Bodyworkers make their work look easy but it isn't.
Toolman
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Good News-There is now a #42 Video Episode of The Complete S30 Body Restoration. It seemed that Japanese Body stopped working on the S30 when they painted the
Under Carriage of this car. But I think a Emergency Job for the Tokyo Auto Salon Show (This show is Japan's Version of the US SEMA Show) in early 2023 was squeezed in.
But anyway, there should be at least a couple more videos coming down the road. Enjoy!
Toolman
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Kwik Performance Compressor Mounting Kit# L10291
Kwik Performance Kit sits high above the Passenger Side Valve Cover.
Sanden Air Compressor($250)
Designing the Card Board Template
Trial Mounting of New Mount
Front View of Mountront View of the Mountt
Bolt Arrangement of Alternator Mounting Bolts
Comparsion between Old Corvette Water Pump and New Camaro Water Pump
Vintage Condensor#03701-OVA 12' Tall x 20" High x .83Thick was utilized($100 Amazon).
It was bolted to Front Core Support in Front of Radiator.
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New Foam was installed around Outlet Opening of Evaporator Core Unit for sealing purposes.
New NAPA Expansion Valve on Evaporator Core was used.
Factory Interior Wiring Harness had to be relocated to the Right Interior Panel to create space for
High and Low AC Pressure Hoses entering the Core from the Firewall.
Pic of the ARA Air Con Unit installed to Factory Heater Unit with Pressure Hoses to the Firewall.
A !/2" Rubber Hose was also installed to allow Core to drain water out of vehicle.
A High and Low Pressure Valve installed in-line to turn off Air Compressor to prevent its damage.
top view of Kwik Performance AC Brackets
Next-More Air Conditioning Work
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While in Tokyo, I came across these Videos which shows in great detail show a Complete Restoration of a S30 Datsun Z. The videos even show what tools,equipment, paint, primers are used. The only problem is that the initial videos are in Japanese without subtitles. However,
due to popular demand, later videos came with English SubTitles. I posted telling the general subject of repair so you can skip videos that
you are not interested in. Go to V8 Z forums ---To Gen II& IV Chev V8 ----to Heavy Duty Frame Rails---Go to Page 17---Go to Posting dated December 22,2022. I hope you enjoy them.
Tap on Arrow below to go to my site to view all 49 videos.
Toolman
Precision Door Weather Stripping gasket
Trimming of Connector piece to Fit..
r
Test Sample Section
Test Section without Construction Template
*Light shining through area with no gasket
2.3 connector and terminals
Top to Bottom
Heavy Duty frame rails and connectors
in Gen III & IV Chevy V8Z Tech Board
Posted · Edited by toolman
add text and pics
Upgrading Interior Rear View Mirror-
The Original Factory Interior Rear View Mirror has Blindspots due the Quarter Panel Pillars.
So I decided to upgrade it with a Multiple Rear View Mirror. Race Cars use them to see better
when passing other cars.
Amazon had this one that was for Golf Carts that was 36" long. Usually they had 24" rear view mirrors for cars but I felt the longer the better. Plus , it was only $25 anyway.
This is a pic of the Rear View Mirror upon opening package.
I decided to.make my own mounting brackets using the original rear view mirror mounting holes.
First, Paper Templates were made using existing mounting holes as a guide.
Brackets are first created out of aluminum sheet metal making the shape easier.
Then, after the basic shape was established, Brackets were made from 16 gauge sheet metal. The 16 gauge sheet provides the stiffness to support the weigh of the Mirror.
With the Brackets mounted and tight, their shape was acheived by slowly bending and twisted them to fit the mirror properly. The Tilt Adjusting Knob was installed with a Small Rubber Gasket between the mirror and knob to provide additional tightness.
The New Rear View Mirror was installed using the original mounting holes.
Close Up View-of Right Side view with the New Mirror
The Viewing Test was successful ( the Girl was visible in both Rear View Mirrors).