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Heavy Duty frame rails and connectors

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Finishing the Exhaust System-

    The Two Rear 2 1/4" Exhaust Pipes make  Right Angles heading to the Mufflers.



Midway to the Mufflers, V-Clamps connect the pipe to the Mufflers.



Rear View of Rear Exhaust Pipes with V-Clamps.



Exhaust Pipes are welded directly to Mufflers to provide clearance for the  rear tires.



    I welded the Two Thrush Hush Turbo 2 1/4" Mufflers together.   Note the straight 1/2" Steel Rods  are the Upper Muffler Hangers.



The Forward Muffler Hanger is bolts to the Rear Deck Floor Pan.  Two Rubber Mounts are used because they will be supporting Two Mufflers.



The Rear Muffler Mounts are also bolts to the floor pan,   Two Rubber Mufflers Hangers are also use to support the mufflers.



Pic of the Rubber Hangers seperately.



The Two Mufflers can easily installed by pushing the Steel Stud into the Rear Mufflers.   Then, lifting the Mufflers upward and pushing the Forward Rubber Mounts into the Forward Stud.   Then lifting the Mufflers and insert the 

Flat section of the mounts onto the Floor Stud  Bolts.   With the Mufflers hanging from their mounts, you just have align the Two Muffler Exhaust Pipes to the Straight Exhaust Pipes under the Differential.   Then, install both V-Clamps.

IMG_2929.JPG.2d89029a202feb66e58a8a48438505df.JPG   Both Mufflers Hanging up.


Rear View of Mufflers Installed.



The Muffler Rear Exit Hole was completed with a little bodywork.   A 3/16" Brake Tubing was bent to form the 

Muffler Exit Area shape.   It was tacked welded to the body then Polyurethane Seam Sealer was applied to seal

the both edges of the brake tubing.   Body Filler was applied to smooth out the edge of the Muffler Exit.



After sanding the body filler, the area was painted with White Polyuretane Paint.





Repairing the Brake Light Socket in Dash Board

    The Brake Light Socket has a problem with its Grounding Connection.   It consists of a Tiny Strip of Brass that contacts the socket hole to make Ground.   This Ground Strip usually breaks off or becomes loose.   I used the Terminal Retaining Strip on a 6.3 Brass Terminal(See Pic below}

IMG_4105.JPG.2dc0810343fb74e24e6e1b616444d1e3.JPG  Note-Small Terminal Retaining in the Terminal.


IMG_4106.JPG.dcf1189ad0d9fe5f342f91bcae865019.JPG  Using a Small Electronics  Soldering Iron to solder the brass strip to the bulb socket.


I tested the bulb on a piece of sheet metal with a 15mm hole to stimulate the dash board.IMG_4108.JPG.d6be8a69a7b4e6189ca0ffc8bf5c9210.JPG Testing the Ground Connection.



It Works!!



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  • 3 weeks later...


     The Wheels that I selected were custom made by Love20Bee in Los Angeles.  They specialize in custom wheels especially for JDM cars.   

I wanted Watanabe Insets with deep offset wheel barrels.   The owner  has several 240Z himself.

    The Front Tires are Nitto G2 285/40/17 with 11" Tread Width.



 The Rear Tires are 315/40/14 with Thread Width of 12"




The Wheels are Custom Made with Watanabe Inserts(with Dark Grey Metallic Spokes) with 11" Wide barrel in the Front and 12" Barrels in the Rear.

IMG_E3614.JPG.dd7f001c51f7e57bfaa1f638ff561ddc.JPG Checking for Leaks.


Wheels and Tires Installed.


Rear Wheel



Front Wheel



Cutting Rocket Flares for Tire Clearance-


     The Greddy Rocket Bunny Flares had to be cut because of the Deep Wheel Offeset for Tire


    Front Flares before Cutting.

IMG_4436.JPG.fa0ea369126ffcd602252d01b6fd7dc3.JPG  Note-Without cutting, Tires could not turn.


Inside view of Front Flare before Cutting-clearance.

IMG_E4388.JPG.4ebeeb59d849c3128eba0de85d523fcf.JPG About 3" had to removed for Clearance.


Rear of Front Tire Clearance

IMG_4437.JPG.5a9ba5e7cf9205a8934a929d4f9e0860.JPG After Frontr Cutting


View of Front Tire

  IMG_E4468.JPG.166a157d02f869f8ba22c7609df45cbd.JPG  View of Front Tire


View of Rear Tire

IMG_E4469.JPG.49529df91125ec24e5bb9e24481e9256.JPGRear Tire Front View


IMG_E4471.JPG.4c1acb9b84ecac4498755cf4dc2f60c5.JPG Rear View of Rear Tire


IMG_E4473.JPG.8a8ff02e525ccd20682fa9bed8962909.JPG Top  View of Rear Flare


Rear Tire Clearance with Muffler/Exhaust Pipes.

IMG_E4462.JPG.8e57875ee67dce5e5db6bc7723c7d209.JPG    Inside View of Tire Clearance.


Full Right Turn




Side View of Car



Four Watanabe Wheels (Polished lips and Gun Metal Spoked Face---$4000.00

      Love20BEE                                                                           2nd Day UPS Freight    240.00

Four Nitto G2 285 and 315/17 tires (Amazon)                                                             860.00


                                                                                                        Total    $5510.00




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Man what a cool build to follow along! Amazing job so far! How do you like the sound of the mufflers? I recently put the Dynomax super turbo on mine after having a race bullet. LOVE how much more mellow it is. Dont feel like I los tmuch power either

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     Yes, I had to trim the back area of the Tocket Bunny Flare to provide tire clearance when turning.   I tried to

maintain  at least 1/2" clearance between flare and tire during the full tire movement.   I think this tire clearance also

allows for body roll too. 


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Removing Fuel Sender unit-

   To Check your Fuel Tank Sender Unit Electrically, you must remove the Unit from the Fuel Tank.  First, you must remove the Passenger Side Strap as it is right over the sender unit.   If the Tank is relatively empty, the Drive side strap alone will hold the tank up.   Now, you can remove fuel from the tank so when you remove the sender, fuel doesn't leak on you.  To

remove the sender, most people use a screwdriver and small hammer to tap the sender tabs to release the locking ring.

I decided to make a Sender Removal Tool as the tool will make installation easier.

     Using a Hacksaw, I cut about 1 1/2" section from a 2" exhaust pipe.



  Then,I cut Four Slots into one end of the tubing.

IMG_4484.JPG.5a13ae9cb8e1d753cf400eb00b4e34b1.JPGSender Locking Ring and Removal Tool


The slots were cut and bent 90 degrees to fit the Locking Ring.  A crossbar was added so a 3/8" socket could welded on to aid in sender installation.



Fuel Sender Removal Tool was painted Gloss Black.




Testing the Fuel Tank Sender Unit-

    The Sender Unit can be tested tested electrically using an OHM Meter.   Place the two Leads on

Sender- Yellow and Blacl-ground wires.

        Empty Reading should have about a 3.7 OHM reading

        Half Tank Reading should have about a  32.0 OHM reading

        Full Tank Reading should have about a 86.4 OHM reading


Adjusting the Fuel Sender-

        Id the Fuel Sender has to be Bent alot, the Arm can be removed to prevent unit damage.

IMG_4481.JPG.78af2101d480546589af70abc7c2b522.JPGLoosening this screw with a Phillips Screwdriver.


Bending the Upper Arm Stop will effect the Full Reading




Bending the Lower Arm Stop will effect the Empty Reading.




Next-Starting Car Up














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  • 1 month later...

  Sorry for not posting in a while but I was rushing to get my 240Z finished enough to put it in a local car show.  There were some more things to do in a short amount of time.   

   Anyway, back to posting-

     Door Panel Repairs-

      Both Door Panels needed to refinish the original  Horizontal Chrome Trim on the upper side of the panel.   See pic below.



To repair this, I purchased 1/4" Chrome Pinstriping Tape from Amazon( for $6).    



First, I used a small paint brush to apply a layer of Contact Cement on the Trim Piece.



Allow the Contact Cement to dry to the touch before applying the Chrome Tape.

Apply the Tape lightly first then checking it for straightness before pressing it down with your index finger.


Trim ends with a Single Edge Razor or Razor Knife.



Closeup view of the Repaired Chrome Trim Moulding.


This repair method can also be used on Door Arm Rests.








Using Velco Heat Sleeves-

  Velco Heat Sleeves were used to protect electrical wires near the exhaust from burning,

Cutting the Sleeves will allow the Velco pieces to unravel as they are only sewn on.  so I use a Hot

Glue to fasten the Velco Tape on.



Heat Velco Sleeve put on Starter Wiring near the Exhaust.



Velco Heat Sleeve on Oil Pressure Sensor Wiring.





Holley 3.5" LED DISPLAY SCREEN-one of three possible screen layouts available.



Note - Easy turning of Steering Wheel with 11" wheels and 285/17 tires.


LS3 First START UP-Sounded Great!




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  • 3 weeks later...

Preparing for Local Car Show-

    There was a Local car Show in my area on Labor Day.   Everybody was encouraging me to enter my 240Z in it.

But, there was still a lot of work to make it even decent.


Installing the Interior Carpet-

     Interior Innovations  provided a Full Eight Piece Precut Carpet for about  $700.   The fitting was good and was made of Good Materials.   I had to decide which method to fasten the carpeting to

the metal floor.   Went to Home Depot and found Double Sided Industrial Grade Velco tape (cost $30).   So No Drilling and Screws were used.



Epoxy Adhesive was used the hold the Velco Tape down.

Passenger Door Panel-



Driver Side Door Panel-



Passenger Side Carpeting-



Fabricating Front Tow Hitch-

     As this car is lowered, In case when the car would need to towed, the normal method of

sliding a tire lift under the car would not be possible.  The Fiberglass Air Dam is in the way.

So Towing on a Flat Bed Towing would be mostly likely method available.   But, you still a way

to hook up the car to winch it aboard.   So I decided to fabricate a Front Tow Hitch.

   the Hitch was constructed of !/4" Steel Plate and bolted to the front frame rail.



Hitch was bolted to the Frame RailIMG_E4666.JPG.6c17f6e08b4718a8b11dfd408bf574be.JPG


The Tow Hitch sticks through the Front Air Dam under the Bumper.



The Labor Day Car Show-

    There were about 400 assorted cars at the Show.   Everything from 32 Roadsters, 57 Chevys,

Cobra Cars, Blown Gassers, VWs, Camaros, Corvettes, Vipers, Hell Cats, Low Riders, etc were there.  






I spent most of the time there, telling people "What kind of Car it was?  - !971 Datsun 240z

What is a Datsun?   Nissan introduce their Brand New Car Line as "Datsun".  There were even some

Japanese Tourists asking questions about my "FairLady"( name of the.. 240Z in Japan).  I did not

have time to even walk around and check out the other cars at the show.   But my car and I were luck to be filmed for an upcoming  Local TV Car Show.













Here are some Black and White Versions of the Pics.   Black and White Photos really gives a 

Restro Mod Feeling.








Next-Air Conditioning installation

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  • 3 weeks later...

Before I go to Air Conditioning  Installation.  The construction of the Rear Tow Bracket will be covered.  A Rear Tow Bracket is a necessity to hold the vehicle securely when towing the car with a Flat Bed Tow Truck.   The Bracket also comes in handy if you ever end up in a ditch.

   Started off by Constructing a Card Board Template .



The Bracket will be cut out of !/4" Mild Steel Plate with a Plasma Cutter.   Then Finished Shaped with a 4 1/2" Angle Grinder.



The Bracket was then Powder Coated RED.



It was installed on top of the Factory Rear Bumper Bracket.



Rear View of the Rear Tow Bracket.


Air Conditioning Installation


     There are many  ways to install Air Conditioning in a 240Z.   Since I had constructed my own engine mounts, most After Market AC Compressor Mounts interfered with my Custom Made Motor Mounts..

Dirty Dingo Mount Kit was one example of these kits.



ITC Billet was another kit that would not work with my mounts.


Kwik Performance #L10291 Air Compressor Mounting Kit that located the compressor in front of the Right Side Cylinder Head.   Also, the Location was not too high like many After Market Kits.   Because of the 240Z Low Hood Configuration,  clearance  would be a problem.   But, using the Kwik Performance Kit would require replacement of the Water Pump and

Harmonic Balancer(about $236 additional cost on top of $230 Kit cost).    These parts were required to move the Serpentine Belt ! 1/2" Forward.

AC Delco Water Pump # 252-976 from   $156-Amazon was used.

IMG_4772.JPG.cc7ffaa51b3089ddab736c2ea49226b4.JPG   Note- 1 1/2" height differance


AC Delco Harmonic Balancer #19300488   from Amazom  $85



Also, Note - 1 1/2" height differance


LS Harmonic Balancers require a 3 Jaw Type Puller to remove the Balancer from the Crankshaft.

This is because LS Balancers do not have any Pulling Threaded Holes and also require a Spacer 

Rod under the Puller Screw.   If you do not have one, some Part Stores have them to Rent Out.


Also, A Harmonic Balancer Installation Tool

IMG_E4755.JPG.9385168bdd84f1ae9675ec6f1b6d061f.JPG Note-Spacer Rods under Puller


A Harmonic Installation Tool will be necessary to install the New Harmonic Balancer on the crankshaft.  Using a heavy hammer to install the balancer can damage the Rubber Inert

Ring in the Balancer.




i will continue this AC Installation Process later as I am leaving for the SEMA SHOW in Las Vegas

this weekend.  I will post pics from the show when I return.


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  • 1 month later...

SEMA SHOW LAS VEGAS ,NV  Nov. 1 to Nov. 4, 2023


     I went to the Sema Show from Monday to Thursday.    Because of Covid, I missed going to Two previous Shows.

This years Sema Show was Huge in size.   The Show now occupies the whole Las  Vegas Convention Hall area plus

all the outside area of the major Halls.   Also, They built a Giant Building called the West Hall that was the Convention 

Hall Parking Lots.   So the Hotel Shuttle Buses dropped Attendees about 400 yards from the Convention Property.

   I was so tired from walking around the Show and must have walked 4 miles each day.   I tried to take pics of Nissan

and some other JDM Cars for you guys.   Please forgive me if I could not remember all the car descriptions to go with

the pics.

     Pics  from the outside of the  Main Show Halls:











Crowd of people watching Live Burn Outs and Optima Street Car Races,


Inside the Halls

   Computer Guided Upholstery Sewing Machine




Lowered Nissan 370Z



Dodge Charger with a 392 Late Model Hemi with Twin Turbochargers



Electronic Controlled Mufflers which Driver could control the Exhaust Sound.





  Drifting VIDEO-    



1500 HP   5.9 Cummins 24 valve turbocharged motor




Drifting Demos in Exhibition Area





 Custom Made 4 Rotor Mazda Race Car



Driver Seat area



This Mazda puts out 2000 HP and costs $500,000 to build!!!!!!!!!





Skyline with Full Liberty Walk Body Kit




Skyline with RB30 with Huge Turbo




Traxxas had a huge Rock Climbing display where people could try driving RC Four Wheel vehicles 

on it.




B is for the Build had a Lambo wit Twin Turboed LS motor with Carbon Fiber Body Panels.




This Purple 240Z with LS9 Sugercharged Motor was one of about a dozen cars in the Optima Ulimate Street Csr Races.







an Older Nissan Skyline





Beautiful Leather Interiot in the Toyo Tires Booth




240Z Motor Compartment



exerior of the 240Z



Another Build for the Build Project Formula Race Car




BMW with a one of its kind V-12 motor Mercedes V12 motor.



 A Wild Custom A Single UTV Built on Top of Two Big Jet Skis



Closup up the Frame between the UTV and the Two Jet Skis



!970  Datsun Restro BRE Race Car




Another LS Swaped JDM Race car





Hand crafted all Alumunim BMB with Suicide Frant Doors











Artist used  Marker Pen to decorate this car.




 Next-Back to Finishing Air Condimtioning Installation



I will be heading to Tokyo so the next posting maybe  after Xmas so Happy Holidays to You and Yours111111








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  I just returned from Tokyo, Japan today.   While there, I found this video on YouTube.com-JP    It was one of the Best Video Restoration of S30 Datsun Fair Lady car .   Although it is mostly in Japanese, the video shows in great detail of the restoration process.  The videos comes in 39 parts so I will try to divide the videos up into sections.   Then you can just go to the restoration part that you may be interested in.

     Part 1-Painting Stripping, Abrasive Blasting (normally 80 Grit),Epoxy Priming the Bare Sheet Metal.   This process gives the Bodyman the True Condition of the Car Body.   Then he can start ordering either Repro Parts or Junk yard parts.  As this car is over 50 years old, finding even Junk yard parts would lucky. So, a lot of sheet metal must be fabricated by hand.

  *NOTE-Press "Escape Key" to exit end of video.


PART 2-Test Fitting of Replacement Panels and Hand Fabricating the Parts that could not be found.



Part 3-  Abrasive Blasting Individual Parts and Replacing Floor Panels 


Part 5   Welding Front Frame Rails

A Professional Induction Spot Weld was used to weld up the Front Frame Rails.   A 180Amp Mig Welder could be used as a substitute.  This would be a good time to think about using a good welding primer that will be welded(spot or mig) to prevent corrosion caused by welding.   This treatment should be followed up with a corrosion resistant spray after finish painting the vehicle.

Additionally, Drilling Rust Proofing holes and plugs will allow the spray to go where the factory box panels didn't.


Part 6-Fabricating Wheel Housing Panels


Part7- Replacing Front Door Skins and Lead Soldering Small Rust Damage



Part 8-Repaiing Front Fenders and Rear Quarter Panels


Part 9-Repairing Rear Quarter Panels-interior and exterior



Part 10-Repairing Rear Back Panel


Part 11-Repairing Inner Hatch Deck and Taillight Housing Area and Repairing Wheel Housing



Part 12-Repairing Side rocker Panels and Tail Light Housing Area



Part 13-Replacing Side Rocker



*NOTE- After watching these videos, you may think Japan Body Shops are primitive compared to

American Body Shops.   The real reason is that Japan has a very strict Vehicle Safety Code.  It is

so strict that most cars have only a 5 year life especially in urban areas( Tokyo, Osaka,etc).  Scrap

Yards in Japan are full of seemly good condition vehicles that can not driven on Japanese roads.

Japan Body Shops have a huge supply of ":used parts".   So much, they can order replacement 

parts such as car door in the exact factory color needed.  As most cars are only 5 years old and 

under strict safety standards, there is no market to do corrosion repair except for those people

will to pay the big dollars to restore popular cars.   I could not believe this fact till I saw stacks of

"perfectly good cars" with no collision damage on them in the junkyards of Japan.


Part 14-REplacing Rear Quarter Panel


Part 15-Repairing Rear Panel.



Part-16-Reparing Front Crossmember


Part 17-240Z on Frame Machine to check Frame Alignment and pulling the Frame to put it

in specifications.


The Left Side (Strut Tower) is bent in about 1/2" so they pulled it with a Hydraulic 10 Ton Ram.

This was only small damage to the frame but would affect Toe -in, Camber and Caster Specifications.


Part 18-Repairing Front Frame Rail Inner Structure


Part 19-More Frame Repair Work


Part 20-Fabricating Front Crossmember Panel


 This Video demonstrates creating Contours on Sheetmetal with only Hand Tools.









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  • 2 weeks later...

I watched episodes 1-8 in one sitting!  Binge Datsun.  :)

So good to see the pros making mistakes too. Cut too small or couldn't make a tape template work and had to start over.  Gives me encouragement in my project.  

Thanks so much for the time it took to put these together and post them!!!

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ShawnM,   I glad you enjoyed the videos.   Did you notice that a lot of the metal fabrication tools (such as sheet metal bender, bead roller, English Wheel, etc) are brand new.  The videos even show the boxes that they came in.  The equipment was Made in USA, too.    As my Father owned a Body Shop, I can tell that their workmanship is High Quality and would recommend that Body Shop to restore a 240Z.    Please bear with lack of English Subtitles, later

Episodes will have more English Subtitles!!!


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I did notice the new tools, they really know what they're doing.  I wasn't implying that they weren't any good, but rather that even the pros aren't perfect.


I especially liked that the camera person showed the wall clock at the start of patching the drivers side quarter panel and again when they were almost complete.  No 'Hollywood time' on this build!  No worries about English subtitles, I am able to infer a lot of what is happening from their hand gestures and tone.

Can't wait until I can get back into them later today.

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Japan S30 FairLady  Restoration Video-


Part 21-Repairing Engine Compartment Panels


Part 22-Applying body Filler and Sanding Engine Compartment.



Part 23-Repairing Core Support and Head Light Doors


Part 24-Repairing Upper Engine Compartment




 ----------------------------------- ENGLISH SUBTITLES NEXT PART-------------------------------




Part 26--Connecting Rocker Panel and  Floor Pans



Part 27-Repairing Right Side Rocket Panel



Part 28-Rear  Quarter Panel Patch



Part29-Tail Light Housing Repair



Part 30-Rear Panel Repair-



Part 31-Changing Right Door Panel



Part32-Repairing Rear Inner Wheel Housing



Part33-Repairing  Right Floor Pan



Part 34-left Rear Floor Pan Repair



Part 35-Rear Deck Repair



Part 36-Body working the Rear Deck Lid


Part 37-Repairing the Car Roof



Part 38-More Repairing to Roof and Rear Deck



Part 39-Body Filling Interior Floor Panels



Part 40-Installing Seat Mounting Brackets



Part 41-Rust Patching through out the car



Part 42-,Seam Sealing, Priming the Chassis and Undercoating the Bottom of Car



   I thought there might be additional videos on replacing the doors,hood,and hatch but

it seems that the shop is finished with their portion of the job.   So this is the Final Video

of this 240Z restortation.     



   2-17-2023    Good News, I was wrong about the previous video being the last one in this series.

This video #43 covers more Rust Repair around the Front Windshield. 



So it seems that there should be maybe one or more videos on this 240z Fairlady Restoration.


Video #44    Assemble and Alignment of Right Side Quarter Panel and Door.  Also. the video describes in detail how to create Body Lines and repairing Door Gaps.



Part #45   Body Working Rear Body Panel, Correctly Right Fender Gap and Right Body Lines



#46 Repairing Front Radiator Support


#47  Finish interior bodywork 


#48 Exterior Bo



#49  Detailed installation of Asphalt Floor Insulation.   I never seen replacement of the Asphalt Insulation in any Restored  240Z before.  This video gives a Step By Step Explaination of this process.


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  • 4 weeks later...

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 MounttIMG_4769.JPG


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.



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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