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Heavy Duty frame rails and connectors

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Posted (edited)

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...
Posted (edited)


     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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     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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