OldAndyAndTheSea

Well, I've been slacking..... The days have been nicer than anticipated and instead of working, like a good boy, I decided to enjoy the outdoors instead. My two week deadline was destined to fail from the start, as today I realized I actually don't have enough carbon on hand to make the dash, even if I did have the mold ready. Whoops. Oh well, I've got 10 yards on order. So I'm going to continue fairing the plug for an hour or two each day until it is ready. I'll be sailing, at the winds discretion, any chance I'm not at work or working on the car(s). It is pretty close to the first spray. A few hours of futzing and I'll have it in one color. The console insert plug is just about finished. I should be pulling a mold off of it within a couple days. V1 part vs. V2 plug Will be a much simpler layup. So not as much as I, arbitrarily, wanted.....But progress nonetheless. Tomorrow I'm definitely going sailing. I'm soo close to a foiling gybe on the moth I can taste it ....I'm an addict.

Well, the weekend weather turned out to be wonderful, so instead of sanding on a beautiful day, I went sailing instead. Lost a little time there.... So I'm not sanding primer as anticipated. But, I did make some progress this evening. Started working on the top portion. Crack kills, people.. Still needs some fairing, but it's getting there. And finally the insert plug. I'll be finishing that up tomorrow. I lost a little time, but gained a little sanity. A fair trade. Thanks Moth. Now back to the task at hand...

Thanks, I am really looking forward to the outcome. Although it is highly unlikely that I will be making these for others, as I am fairly certain the tooling (plug and mold) will have to be destroyed in order to make the part. I'm going to try for that not to happen, but it probably is. I can certainly start thinking along these lines. Perhaps a gopro video of some of the process. A better understanding of the process will help people realize how much time, effort, and money goes into even the simplest of parts. I thank you for the kind words. As a 25 year old guy, teaching himself, working out of his garage, I am humbled by the wonderful support and feedback this site provides. Thank you all for keeping me on track and in check. The insert I made failed quality control. I didn't snap a picture of it, but I've decided to modify the inset plug to make it much easier to lay up. One large storage compartment instead of two. Simplifies things greatly - allowing for higher quality control. Here's the beginning of that. I hope to have this finished in a day or so. Chopped! I did a little bit of sanding tonight. Won't look like much in the pictures, but the bottom is essentially, for all intents and purposes, what I'd call "roughed out" The top won't be needing nearly as much work, as it isn't as crucial cosmetically. I expect to be sanding primer by the weekend.

Got my daily sanding in. The bottom half is beginning to take shape. I'm right on track. I'm feeling more confident the more I work on it. This thing might just happen after all

You shouldn't need to replicate that framework, if you develop a proper layup. My initial plan is to only use bits of the framework, to retain the mounting points. I can chop and tab on whatever I find necessary. Time will tell though. Should that plan fail, I will always opt for using the frame in full, but I'm fairly confident that I won't have to use the vast majority of it. I never use my glove box anyway, and designing a dash that has a glove box would mean at least 4 more tools, and that complicates things exponentially... Plus I like a nice solid plane of carbon. I am however, keeping my heater function. It's cold up here, and defrosters are nice I intend on making a heater control panel out of carbon, as well, I just don't have a donor panel that isn't mounted in the car. I'm averaging around two hours of work on it a day. Made some progress last night, more pics tonight after I fiddle. We'll see what I can accomplish...

Forgot to reply to this. For any composites based inquiries/purchases, head to our website. Shoot us an email if you have any questions or would like us to make something for you. Palmcomposites.com Moment of truth. Cool! Looks acceptable. Certainly an improvement over the original console. Should be a nice replacement. I made the insert for the console today. Contingent on it passing quality control, I will bond it to the console tomorrow. Then we can see it in the car. I'm going to work out in the garage for a couple of beers.. ...We'll see what I can accomplish, if anything, on the dash plug.

A little sanding after work today. Not much, but a little progress to the, once, glove box area. I also infused the first new version console today. Can't wait to pop that tomorrow! More to come...

Hows the fuel pressure? Could be detritus or rust in the lines occasionally causing fuel pressure issues. Sounds like, under load, it isn't getting enough fuel. I'd investigate my fuel pump/screen/filter lines for blockage.

I have to send my ECU away and I don't expect it back for roughly two weeks. (To Kurk Hospital ) So in the meantime.....I'm going to make my carbon fiber dash! *he says confidently* Two weeks. From plug to part. That's my tentative deadline. We'll see how that goes. ....So it begins.... Onto the pictures and process. Starting out with essentially the worst plug in history. Literally falling apart in my hands. Metal framework. I'll be going back to this to chop mounting bits off for attachment points on the new dash. Weight savings is the #1 priority with this micro project. The OEM dash is heavy (at least 20-30lbs). I'm hoping to have my gauges weigh more than my dashboard. That's the goal. With room to spare, I started capping off all of the openings - No more glove box. hoping for a clean look. Grassroutes composites, glue gun, five minute epoxy and scrap wood. And where I've left off. Some filler - beginning to fair the plug. Contrary to how I have been making parts in the past I am changing my approach with the dash. With the dash, due to some complications in the geometry, I'm planning on having the plug be entirely sacrificial. Meaning that it will essentially have to be torn out of the mold, most likely in pieces. So obviously I won't be spending too much time beefing it up. The same will likely have to be done to the mold. It will most likely have to be either cut, or broken in order to release my dash. A couple things to note - Only the bottom half has to be pretty, as the top will be flocked. - These will be hand laid parts, instead of infused - I'm doing this from home, and not the composites shop. - I only get one attempt at this, as the tools will have to be destroyed. And one more bonus picture. Had a moment of light peak through the doors. Had to snap a picture as finally my seats and black trim no longer looked eggplant in color, due to my phone's confusion with the typical lighting. Now imagine a two tone carbon dash there instead. Yes please.

I've put around 500 miles on the car since I've started driving it again. It's going great. Getting me all sorts of places. Next step: NYS inspection and then alignment. Sweet! That's all for now.

Minor updates. I made a set of half door panels for MY car. Infused. Popped. Mounted. I NEED to see the car outside...Taking low light indoor pictures of this stuff is beyond tedious. And a small look of the theme I've created for the interior. Even with the janky #001 console, and gorrilla taped clamshell it looks decent. Once I build my dash, then that will REALLY complete the execution I'm shooting for. Here are some awful pictures. But use your imagination, I think there's some potential here. Console - not lined up - just mocked (I'll be making a new console soon, that's why it isn't bolted in yet.) This is the first time I've been able to appreciate the interior work I've been doing behind the scenes as a build the car. I'm very excited for what I know this will become. For a starting point, I'm quite happy. I can work with this. Oh yes, I can work with this.

Thank you, and yup, I am aware of the length issue. I have adjustable Lower control arms on all four corners. I should be able to space the axles appropriately....At least from my research. The axles were basically free in my transaction. I'm still way ahead (money wise) on my CV/ companion flange purchase. So even if I have to buy shorter CVs down the line (or modify mine), it wouldn't be a big deal. Getting the companion flanges was my main concern at that moment.

Haven't been out to work on the 240 in a few days...That'll change this week. More parts arrived today. Couple odds and ends. Differential mount stuff. Lug nuts - gambled on the Gold. Not 100% sold on the color, I think I like it, though. Too soon to tell for sure, but either way they're staying for a while. For $113, yeah, they're staying. :laugh: And...some protection. Always use protection. And some composites odds and ends. Finished up the Console v2.0 mold. No more ash tray. And made a widget - fuse box cover. plug mold part Good, it'll work. That's good news, considering I sacrificed my cover to make the plug. Always a plus - replacement value As always, I'm working....on something.

Thanks everyone, and yes, we are willing to work with people on the first set(s) of one piece panels, as they are not a 100% bolt in solution. You'll be responsible for mounting your own felt strip, and drilling out the door lock holes. You may have to modify (cut a couple slits, so I bends) the OEM strip slightly, as it is fairly flat, and the new panels have a gentle curvature to the top area. The one piece panels are, in my opinion, more suited for a racecar. If, for some reason, they didn't fit we'd certainly be willing to work with people. The nice thing, is that one piece panels can easily be converted to the two tone sections. Just some random thoughts. Also, a couple pictures of some more progress. New console mold. No more ashtray. And I've been fooling around making widgets, when I can. Fuse box cover. Rough, but an idea. http://www.palmcomposites.com

Today I made the car earn its keep. It drove me to and from work without a hitch. Got a chance to pop the T-Tops and finally utilize these really neat hooks that I had ZERO idea what they did until a couple days ago. At first I thought: Tie holder? Obviously that didn't make sense. OH! THAT'S where they go. Keeps the wind out of your face. Works flawlessly, even at 80+mph. Tip of the hat Nissan, that was clever. Now it's the weekend baby! Time for my first sail of the season! Gonna be chilly, but I need my fix man. *shakes*

I've yet to make any attendance... I'd love to caravan though! an hour to you, for me, then an hour or so to Rochester. Would be fun. Especially in my budget 280zx

Going to be driving it this summer?

As mentioned, I got my inner bearing seals Monday. So I finished up the bearing install. Woot! I then proceeded to maintain some other odds and ends while the car was in the air. Things like... - Swapping one of the tension rod poly bushings with rubber, as double poly bushings are commonly known to fail tension rods...So rubber it is, on the nut side. Before - looks better, but needlessly stiff. After - rubber/poly - Oil change - the turbo thanks me. LOOONG overdue. (+$30) - And a 20 dollar interior 'refresh' - that still continues currently. But here's some progress. (+$20 - 3x cans of spray bed liner) I sprayed the shock tower covers and the hatch area trim pieces with bed liner. I like the gray on black theme I've started. Nice contrast. Looks good* *650 dollar car good Initial pictures - I will replace the hatch carpet with black marine grade carpet, once the opportunity arises. Here everything just tossed in place...Still lots to do yet. But at least it looks complete again. No more hanging/exposed wiring - nice. After all of that work.... The car is now the best it has ever been, mechanically, in my possession. So how does the car repay my effort? ...By not starting and fouling the plugs instantly....Hmmmm.....That's never happened before.. Before video link - running with NO FUEL PUMP - haha! She had a bit too much to drink. No more fuel for you! http://vid524.photobucket.com/albums/cc327/twofortyz/Mobile%20Uploads/VID_20150602_202800970_zpszes82laq.mp4 So after work today I decided to do a little diagnosing. Factory service manual to the rescue! Seriously guys, download it if you haven't.. It literally tells you how to fix your car step by step. a few tests later...CHT sensor checked out. ECU was the next potential problem. Confirmed my ECU was at fault. Luckily I had a spare from the 82 parts car. Swapped in the new ECU. Half turn of the key... After video link http://vid524.photobucket.com/albums/cc327/twofortyz/Mobile%20Uploads/VID_20150603_212618219_zpskjege3dh.mp4 Good to go....and dare I say...running smoother than ever. Sawheeeeeeet! Days worked on project to date: 57 Total money invested in project to date: $1613 (+$50 - bed liner/oil change)

Sounds like Bad Dog frame rails are what you'd need. It's a bit of work though. And yes, pictures would be helpful.

Thanks for the support everyone. Website is "done".... Albeit a work a progress. Finally a place interested prospective buyers can go to contact the business directly. www.palmcomposites.com Currently building inventory. All appears to be going well. I'm infusing the newest console mold tomorrow as well. And the clamshell project has now become my personal project. I brought the tools home and will continue to come up with an acceptable solution. It will happen. Oh yes..

^^ yep I literally ordered my RT mount yesterday. Getting closer to wheels on the ground!

Looking good! I'm available anytime to discuss anything you have questions on. For what I can assume is your foray into composites work, you're doing a bang up job so far. Call or text anytime.

^^ Haha, you don't want this one! Some 280 progress. What a great little car this has been. Swapped back to the mesh wheels, as my 240 will be needing the big wheels soon I destroyed the first pair of Fuzion HRIs while honing my alignment "skills"..... So I bought two more 205-55r-15. (+$110) Didn't pick them out. I asked for the cheapest they had. They're Milestar Touring SEs...Bwhahaha. Rears don't match the front; See if this guy cares. The car has always had a bad passenger's rear wheel bearing. I've been putting it off, because I had little hope of the stub axle actually coming free. Regardless, I bought a set of rear bearings, and got to work. (+$80) Here's some before. Obviously the grease seal wasn't working too well. YES! Separation. Sweet sweet separation. ....I don't believe it. Grease cleaned off - Budget car clean. Just lots of never seize, where appropriate. Pressed the outer bearing in place. Loaded up the spacer. And back in place. The seals arrive Monday, so I have to stop here. Have you ever seen anything so beautiful? I love this warm weather. It feels great opening up the garage doors again. I'll be confidently driving this car around again as my primary vehicle starting Tuesday. I'm stoked. Days worked on project: 56 Total money spent to date: $1563 (+$190 - tires/bearings)

Some carbon, in the right orientation and areas would stiffen that piece up significantly, if you cared to or were worried.

Thanks Keith! we're still finishing up the details on the one pieces. Basically exactly what you mentioned. The top window weatherstrip. Attaching the fuzzy strip is proving slightly more difficult than anticipated. The OEM strip is fairly straight, and unable to bend in the Y axis (up and down) to match the gentle curve of my adaptation. That's basically the last detail. I'm looking at all options, and am very open to suggestions - should anyone have any thoughts. I'm also slightly worried about door panel "smush" on the door seals. My doors have always shut hard, due to aftermarket, very "plush" seals (and 40+ year old hinges). The one piece design, like the OEM does, in MY car smushes on the door seal. If I remove that section of the door seal, with any of the door panels (OEM included) the doors shut much easier. I just don't want people who potentially purchase the one piece design, all of a sudden, not able to shut their doors without slamming the bajesus out the them. That's my thought process. Interested in yours, or anyone else's as well. Finished up the rear wheel bearing install last night/this morning. Installed the inner seal - The bearing spacer (never pictured) then the companion flange. They spin like a dream. Cross that off the list - One step closer to wheels on the ground. I suppose it's time for yet another crack at the EFI system. Kurk - You're on deck, my friend. Stay tuned.