Jump to content
HybridZ

Recommended Posts

*Finally getting around to documenting my build. Will continue to update the text as I go. Happy to answer any questions. Feel free to also follow along on instagram for more frequent updates. 

 

I fell in love with the S30 chassis at around the age of 13 and tried to buy one or two as my first car. Unfortunately, being from the north east, anything I could afford had rust holes in structural areas you could put your hand through. After watching the price trend over the last few years, I decided I better act before I missed the boat.

 

-Purchased sight unseen in October, 2018 from another member here.

-The car started it's life in California, was shipped to Florida by the P.O., and then I shipped it back to California. I was living in Germany at the time, so the plan was to store it with my family and make trips to work on it whenever I found the time. 

-I purchased it as a roller since I'd always planned to do a swap anyway. It came with a lot of T3 and AZC suspension bits already in place, most of which I sold. 

 

 

Link to comment
Share on other sites

Day 1. The car arrives. A little rough around the edges and lots missing, but seemingly little rust:

IMG_5414.jpg.14ee86a54ce4aaa0e40c600e33e13277.jpg

 

A quick wash to see what we're working with.

635423378_WhatsAppImage2018-10-25at19_55.28(1).jpg.c780bc63f4a0c4dbc45112d07246facb.jpg1363208128_WhatsAppImage2018-10-25at19_55_27.jpg.f24051c3efaf85a4c2d48360437803d5.jpg2085932975_WhatsAppImage2018-10-25at19_55_28.jpg.2a8fcde717fda945a093325d70412e31.jpg125199350_WhatsAppImage2018-10-25at19_55.29(1).jpg.95dec584ff7c607ae1b2ede792eb25be.jpg64904375_WhatsAppImage2018-10-25at19_55_29.jpg.f7f8e1f4d01eeea0bb477564dffa2a5a.jpg1261805222_WhatsAppImage2018-10-25at10_05.04(1).jpg.a458eea32ea07bcabd59e52142a4a6bf.jpgIMG_5420.jpg.d8683b279016c0f91b7a9e83c2f6406c.jpg

Parked it next to my brother's expensive Volkswagon. 

 

In a strange coincidence, this guy who came to buy some parts off me said he had seen one being trailered recently in the area... he took a very grainy video of it and send it to me and it happened to be mine on its way home from Florida. 

 

 

Edited by artishard116
Link to comment
Share on other sites

Teardown begins:

DSCF0705.jpg.d852b0bf5f7956f9e76d0e421dc32d99.jpgDSCF0874.jpg.22d9c13a5782714d0d063ecbe2f0d45f.jpgDSCF0704.jpg.7830595a1bab52a55e234c29e6367a6a.jpgDSCF0707.jpg.8b9b100f0c6d3cab2ca4a947d64a9518.jpgIMG_5509.jpg.9861b37e8a399816d07856d979546260.jpg2641F90D-B457-40D0-9837-DB9827BDD27A.jpg.ef166b55e48566c7626e88d734e30eaf.jpg

 

Lots of POR15 in the floors and spare tire well, slightly concerning.

DSCF0890.jpg.7288349bd92100ca76bde3ad3a3a3fc3.jpgDSCF0893.jpg.0347ae1626e736d488af6076a4332b4f.jpg

 

Many extra holes for weight reduction(?).

DSCF0742.jpg.ff8540152aa7555d141c8a6c70338ecb.jpg

 

Kept a couple things and sold a ton of parts. I wanted to ditch the stub axles all together and wanted an e-brake integrated with the calipers. 

DSCF0926.jpg.1bd322b630ddb2e69a8ab264881635f9.jpgDSCF0929.jpg.4f9c18dfb71837763c8000a3e8108373.jpgDSCF0891.jpg.bb260fc5775338d31857878531a9ce37.jpgDSCF0925.jpg.811eeeb764b1ffa098b364a70d2b26c7.jpg

IMG_5573.jpg

Edited by artishard116
Link to comment
Share on other sites

Fabrication/metalwork starts thanks mostly to my friend BDR Fabrication.

IMG_5877.jpg.c6448af1f85af9828dc64c46ad23a78c.jpg

 

POR15 in the seatbelt pockets

IMG_5878.jpg.45f9bd5174d118136019d70be9ffe57f.jpg

 

Pockets welded shut and standoffs for the main hoop added in 1/8" steel. It was tight, but managed to keep the stock seatbelt bolt holes accessible. 

DSCF1258.jpg.e9d1981de9b55b3fe304a48552cb550d.jpg

 

Test fitting main hoop. We used the diagram floating around on this forum and it fit great. 

DSCF1282.jpg.c702a44ec20635307bb71547ac20c8d8.jpg

 

DSCF1285.jpg.d9b563a24e7051ba3d181569792ff419.jpg

 

DSCF1283.jpg.2bba138c4419a50cd3bc737425517f07.jpg

 

I hadn't welded since college, so I practiced by filling some holes. 

DSCF1339.jpg.e03da80339bab85e4a5f9c9e1ad3d6e5.jpg

 

DSCF1341.jpg.d645f1beec3587ea3c359352fe3f0b67.jpg

 

Removed some plates that were welded over the original sway bar holes by a previous owner on the front frame rails.

DSCF1342.jpg.37e9852535a5db23425f2c28095ee2cf.jpg

 

Parts start to trickle in.

DSCF1259.jpg.d3a48052b6c2fbf6df303e0950868a8f.jpg

 

IMG_5890.jpg.e7a2194a4a8ea4a1d4b27772dcebdae6.jpg

 

DSCF1346.jpg

 

Edited by artishard116
Link to comment
Share on other sites

  • 2 weeks later...

Had some downtime while waiting for my fabricator's schedule to clear up so I kept myself busy by restoring the original tail lights and installing Dapper led boards.

 

Cleaned the grime off.

DSCF1277.jpg.599554eb097ada28b32537231a0e445d.jpg

DSCF1278.jpg.413d1f7dd761e0f049e1934e8c507e07.jpg

DSCF1288.jpg.c5711b93abe328207cd902b445689fc7.jpg

 

Pried open the lenses.

DSCF1279.jpg.4bec537220ec5c5a1c6cdd3765cba03e.jpg

 

Dapper lighting boards wired up.

DSCF1290.jpg.1538b89b8827085c0ad5771fd24af56c.jpg

DSCF1293.jpg.2910294b27579706116b67212c4e4a6c.jpg

 

New sealant added.

DSCF1423.jpg.2ecb16d0ce29b877d9e591059fe4ee39.jpg

 

Polished up the lenses with a buffing wheel on a power drill. 

DSCF1360.jpg.3a9d211c7d640a452bedf777cbf9b7dd.jpg

 

Added some clear coat.

DSCF1365.jpg.a785966c0487b04d2b08035dbe6bffe9.jpg

 

DSCF1451.jpg.865387b6e2c97fe235507ddbfa553cb3.jpg

 

Painted the worn out chrome trim black.

DSCF1453.jpg.809b03099cc7498f8be41bb789962105.jpg

 

Testing. Doesn't appear I'll have any trouble backing up at night...

DSCF1458.jpg.ffd76fc4bc0354059d2a4cadb02b8d4d.jpg

DSCF1456.jpg.750d87cb9c5e0e0000b50ec4095eeeba.jpg

 

 

Link to comment
Share on other sites

Next I tackled the headlights and installed Dapper led 7's.

 

40+ years of grime.

DSCF1348.jpg.2eb3a5a1817ed89d0c06d9643ccec711.jpgDSCF1349.jpg.27e30c655819d74213ef8b17cbc8e837.jpg

 

Cleaned up with a wire wheel.

DSCF1366.jpg.61ee44594855962b9c859044a2dca595.jpg

 

Replaced all the old hardware, trim, and inserts. Used some Camaro parts or something because I couldn't find direct replacements. It required cutting the adjuster holes to squares, but otherwise went smoothly. 

DSCF1408.jpg.8954d3e32600dde0d0757ead180f3401.jpg

 

Painted the buckets.

DSCF1369.jpg.b78e6b242fe68cbc6049338fb3423eb0.jpg

DSCF1442.jpg.00e5afacd280dd1bb3d6b93aa3c11c71.jpgDSCF1444.jpg.3aa7193af5ab5234054dbddef1714179.jpg

 

The new lamps require cutting holes in the buckets. Hoping water and dirt won't get in there, but may need to close it off somehow. 

DSCF1445.jpg.ec592d0060c0a597d131d70a3d56525a.jpg

 

Lights installed. Actually replacing the glass covers with a more textured version so they look less modern. 

DSCF1461.jpg.38b95aae3731f668bd118ec7a6059062.jpg

 

Testing.

DSCF1466.jpg.40c2ab9854858bde000d8a21a76c2f2d.jpg

 

Link to comment
Share on other sites

  • 2 weeks later...
  • 2 weeks later...
On 7/19/2020 at 9:09 AM, boosted300 said:

Looking good!

 

I love the work you did on the tail lights.  Can you go into a little more detail on how you buffed them?

 

Thanks! Sure, it was pretty simple, just used a plastic polish by McGuires I believe (meant for headlights), along with a cloth buffing wheel attachment on a power drill. Took several passes to get them shiny. You can find similar kits at most auto parts stores. Power tool is a must, unless you want your arm to fall off. Let me know if you have more questions.

Link to comment
Share on other sites

  • 3 weeks later...
  • 2 months later...

Signal and reverse lights cleaned up/painted and new lenses added. Will replace all the wiring later. DSCF1638.jpg.7306c45e87927ef5338730a3598972f3.jpg

DSCF1659.jpg.842b254c1fe92cffeaa47f22ba44b3bd.jpg

 

Made some wheels out of swivel casters, 4x4's and U-bolts so I could push the car around. Also had to move garages which was slightly sketchy. 

DSCF1412.jpg.b0cb030b44ad10f6932a2bb77ac7cbe2.jpgDSCF1409.jpg.058a37dc2de2d03b15c337a3f8eb201b.jpgDSCF1433.jpg.addc643395c8c8059988ae0bd6b4faa0.jpg

 

In the new space with some major garage upgrades.

DSCF1582.jpg.404aa1bcec2b951744a6b7d5f724c808.jpg

 

Finally got the cage in for good. More details to come. Strut towers also cut for weld-in plates. 

DSCF1438.jpg.056cf6f09903390db3fc19afcb9213f4.jpg

DSCF1440.jpg.18e374bcc0c525296d22d219961c460f.jpg

DSCF1441.jpg.274dda907d1c2273f5f2efa160cb9135.jpg

 

Lining up the T3 weld-in camber plates.

DSCF1413.jpg.7e5fa56d7de1885c170190a17eae0af3.jpg

 

Welded on both sides. In retrospect, it would have been prettier if I put them on top of the towers, but it seemed like this would be stronger. They'll be covered by STB brackets anyway. 

DSCF1532.jpg.f7f3659fc1d569b222c81ff6533823d8.jpg

 

A huge haul of parts show up, as well as seats and belts. 

DSCF1666.jpg.15a2670e8276189085f98ca659d4a9d8.jpg

DSCF1672.jpg.650db5130bbb56c01c62a1052c39c3d2.jpg

DSCF1552.jpg.fca13f6881386b134c89abfba66d8fc7.jpgDSCF1568.jpg.f4c215162747544ab49c3ce1c60c7d02.jpg

 

Quick test fit:

DSCF1571.jpg.e6916683af3b4908a6eaa526f71e18d7.jpg

 

 

 

  • Like 1
Link to comment
Share on other sites

Stripped the rails down to metal in order to test fit some Bad Dog parts, only to discover that mine are unusually asymmetrical. Apparently it was a California car thing? One rail is about an inch taller than the other on one side, and runs flat against the floorpan instead of being contoured like the other side. John from Bad Dog was super helpful and offered to make me custom rails if I sent him templates. If anyone else runs into this problem, drop him a line and see if he can make you a set.

 

DSCF1492.jpg.45e955468e2e5a2e7e9696e52cad7059.jpgDSCF1483.jpg.8b39a2fba65fe0839e3345208afbd0b1.jpgDSCF1506.jpg.35fe999d203cf56117b60e5d040529c5.jpg

 

Templates made, and subframe connectors mocked up. Had to do these from scratch as they're a totally different shape than on a 240. 

IMG_6204.jpg.226bbe9e570c6483c9602ecc74a7bf16.jpgIMG_6168.jpg.827eb1b82a6623ed4acd837781048f1b.jpgIMG_6171.jpg.d08b5f8e9add81f6be5de1818d61ea3b.jpgIMG_6210.jpg.c958f3165f9c69576b7523966a3e5d41.jpgIMG_6208.jpg.f618e9845bc7323da54a4a9a0d37b332.jpgIMG_6205.jpg.e3860127580ee6773b351e647c25cec9.jpg

 

Determined that the stock seat mounts would have to go unless I wanted my seats to be at a severe angle (and too high). Messy job. Kept ripping holes in the thin floors when trying to remove the spot welds. 

DSCF1595.jpg.d64d15831898363d6c70b7360b5e870d.jpgDSCF1597.jpg.29e1ef75f303497b5161ca60a79211a3.jpg

 

Sank some tubes through the frame rails and sandwiched 1/8" plates on either side to strengthen the sway bar mounting points. 

DSCF1521.jpg.9aa20e9eb03a35197582ea23b9c7c9fd.jpgDSCF1543.jpg.01740ac13bfba18337931177754b9138.jpg

 

Had a little tube left over from the cage and figured it couldn't hurt to brace the front frame horns. 

DSCF1542.jpg.95f0ae7cf21e71980f6faac3b5643387.jpgDSCF1547.jpg.90450705d1338530129f07e5c980f9b4.jpg

Link to comment
Share on other sites

Finished products:

B4042218-F576-4704-AED2-BB0CC0E8DC45.jpg.c13095eec86bcfabe669fdffb53c270d.jpg56D0B3F8-B1D9-419A-B193-397B6354AD7A.jpg.82e513a86af41679c24095c4572e6c2b.jpg4905574B-5FDF-42B9-908A-6C813B96B8EA.jpg.099664711798f73ff6c0c4f5c6230dc0.jpg89FA9052-8788-4AD7-A5AB-85C0512B374F.jpg.61831b398777439640980a65b9ceb63a.jpg

 

"I'll just do a couple stitch welds around the inside of this strut tower" (Famous last words). 

CE4CE2A8-5595-4C51-A3D0-8DE432DA17FB.jpg.c9e6341cfa73a338cfacaf31067d2a47.jpg

 

Some details of the cage and attachment points. Avoided the stock belt mounting holes so I could use them for my harness lap belt. Not sure if the angle will work out though. 

DSCF1526.jpg.61b7f7ad970c104cbab62d401b9d3767.jpgDSCF1524.jpg.c09e1cf9a35371c4c3957f832c42cf67.jpgDSCF1523.jpg.a8b7fca9583b64bdd4b4c2f26ffbbcf8.jpgDSCF1534.jpg.40ab52fba01e94442280956cfaecec0a.jpg

 

Bashed the hump in the transmission tunnel with a hammer to try and get enough seat clearance but it was a lost cause. Went full Flinstones. 

IMG_6422.jpg.60284559d5f669093798aa59325a82fb.jpgDSCF1655.jpg.a421a0a707874970de05f9e352b96299.jpgDSCF1704.jpg.401723b3269867b81efc54c5e44b3a8b.jpg

 

Filled the bumper holes using some Skillard pieces and warped it pretty bad in the process. Will let the body shop sort that one out. 

2522FD76-D88C-48E5-8607-7615AF04077A.jpg.0fcf2fcb7bab5d08d340b4a3ff9bd186.jpg

 

 

Link to comment
Share on other sites

On 10/22/2020 at 11:55 PM, grannyknot said:

Hey, looks good.  Don't forget the brace between the T/C rod mount and the rocker, it really stiffens up that whole area.

 

 

DSCN0828.JPG

DSCN0858 (1024x768).jpg

 

Thanks for the tip, nice idea. I do have the Apex crossmember which has bars that brace the TC boxes somewhat. 

Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

×
×
  • Create New...