Boben

You sure know your way around. My hat goes off to you.

I've been thinking about integrating a rear diffuser from a newer car. One of the obvious reasons for this is that the area below the bumper in my car is totally f#%ked up. Its got huge dents and bents and as a finishing touch, somebody has totally rape the area of the original exhaust tail pipe location with a hacksaw! An old picture where all this is visible: I wanted something subtle with dual exhaust and after several hours of searching on the internet and constantly looking at rear diffusers on parking lots etc. I finally decided to go with an Audi A4 B6 unit. The curvature of the part is definitely not the perfect match off the shelf since the rear of the 240Z has only a slight curvature, but after some minor modification, the fitment was surprisingly good. The OEM Audi part is a made of plastic and this is a key point to notice. There are good looking carbon fiber tuning parts for Audi, but they simply wont fit the 240Z. The plastic part can be forced to follow the shape of the 240Z rear. This is the diffuser I used: In the Audi, this part is attached to a plastic bumper. The orignal retaining scheme needed to be modified. Also some reinforcement plastic needed to be removed so the part will bend more easy. I made these rectangular shaped cuts to the rear valance where the diffuser is to be attached. The diffuser is fixed in place with metal clips from the back side (I forgot to take a picture of those clips). The fitment is already quite good although I did not fix the part with the retaining clips yet in these next photos. I still need to fabricate some sheet metal to the sides. There is also a screw hole on the side of the diffuser so I need to make a bracket for that inside rear quarter panel. I plan to weld a small-diameter metal bar along the top seam of the diffuser to create a sort of lip above the diffuser which is going to sit flush with the surface of the diffuser. The metal bar is then bondoed to the sheet metal so that everything integrates together nicely. My new fuel inlet location is also visible in these pictures.

I believe that is a heater core for a "no A/C" model. The pressure of an A/C system is considerably higher, so using a heater core as an evaporator might be risky.

While trying to prep all the small details and fixing points to the body to get this thing finally undercoated, I am aiming to tackle some upcoming challenges of the build. I am planning to install an AC-system to the car and I think all other stuff is going to be straight forward, but the evaporator core is giving me a headache. Here you can see the heater box of the 240z: I believe there is room under the dash to bring the air routing scoop (the part in front which is bolted on the rest of the unit) outwards. The plan is to make a spacer and locate the evaporator core in between the scoop and the rest of the unit. While doing this, the scoop attached to this part which routes the air to the midlle air vent on the dash needs to be cut into suitable lenght, but that seems to be doable. The problem is to find a small enough evaporator core. The ideal dimension would be 120mm x 200mm with which, the original fixing points for the scoop could be retained. Does anybody have an idea where I could find a core this small?

Yes, that's the plan. I ordered a license plate fuel door such as this from ebay: But I doubt I am going to use that for it requires some modification. The height of our license plates here in Finland is smaller than the US plates so it would look goofy without modification. Also, the plate does not sit flush on the surface with the door I got. I am probably going to make my own custom bracket/door. One idea is to make the plate slide to the side and uncover the fuel filler cap. If I remember correctly, there is just enough space to slide the plate aside. The fuel filler neck I got is a maritime item ment to be mounted on the deck. It has an O-ring seal on the cap, which I think is a must in this installation.

Thanks ditto64! It is nice to get an interception on the monologue for a change. I was not too so happy with the original wiring harness fixings and a lot of them had cracked loose so I decided to replace them with something new. I am using some Audi fixings. I made these little brackets which are tack welded in place and the cable fixing is going to be slipped on the bracket. Also continued on the BMW shifter retrofitting. The shifter has a nice rubber boot to seal the hole and prevent any dust from entering the cabin. I cut the hole on the tunnel a little bigger and cut a suitable sheet metal piece with a right diameter hole on it for the boot. Ready to be welded: With the new piece tack welded in place, I checked the alignment with the stick. Nice and center: Here is the finished assembly: