My Swiss 1972 S30 240Z rebuild project

[Colbino]

holy shit dude, your dedication is unwavering!

[JDMjunkies.ch]

holy shit dude, your dedication is unwavering!

Thanks mate, i'm trying my best :)

[JDMjunkies.ch]

Yeah i know - the pace is quite slow lately, but im still working on the project silently in the background. But today is the day i have som GREAT news for you. I got a Package delivered from Japan with some parts i've been looking for over two years now until i recently stumbled across them finally :)


I'm talking about the Sumitomo MK63 brakes. But what's so rare about them you might ask? they pop up every now and then on the internet. But this is not your standard MK63 for vented disk, but the very rare first gen. version for OEM Nissan disks, which are FIA homologated and were used in various ex works racing cars. I've even been told that nissan asked them back after the races from their teams.. wow :)

Here's a comparison between the standard brake (Also sumitomo manufactured) and the MK63:

I plan to restore / rebuild the new brakes before they go in.

And here's some specs from the NISMO homepage and the old Datsun performance catalogue:

Later NISMO offered the same brakes under their brand but they're obsolete since a few years..

Oh and while ordering parts from japan anyway i decided to order all available maintenance and refurbishing parts for the brakes from the NISMO / Nissan catalogue and got them delivered from a local Nissan dealership from Yokohama :)

[revlimitbounce]

I just clicked through this whole thread. Amazing work and patience; schoene!

 

Want to know something crazy and kleine welt? I just bought a Swiss-market 240Z here in the USA. It was imported to Germany in 1983 by the then-owner. Was then imported to the USA in 1986 from Germany by the same owner when he moved to the USA from Germany. He ended up garaging it in the US for 14 years, though. He died about two years ago. His daughter finally decided to sell the car recently and I bought it here in Arizona. The original owner (as far as I can tell) was a Rene Galatti (Oberdorf, 8735 St Gallenkappel, Suisse), with Thomas Faulkner (Switz., Germany, USA) before me. So, I think I'm the third owner. I have a 6-inch tall stack of paperwork that came with the car. Papers from Switzerland, Germany, the TUV, the US government, even the bill of sale, the check, and a letter from Nissan in Japan when Faulkner inquired about equipment he'd need to make it US compliant.

Anyway, great stuff and I'll be watching. 

 

Here's mine:

[JDMjunkies.ch]

I just clicked through this whole thread. Amazing work and patience; schoene!

 

Want to know something crazy and kleine welt? I just bought a Swiss-market 240Z here in the USA. It was imported to Germany in 1983 by the then-owner. Was then imported to the USA in 1986 from Germany by the same owner when he moved to the USA from Germany. He ended up garaging it in the US for 14 years, though. He died about two years ago. His daughter finally decided to sell the car recently and I bought it here in Arizona. The original owner (as far as I can tell) was a Rene Galatti (Oberdorf, 8735 St Gallenkappel, Suisse), with Thomas Faulkner (Switz., Germany, USA) before me. So, I think I'm the third owner. I have a 6-inch tall stack of paperwork that came with the car. Papers from Switzerland, Germany, the TUV, the US government, even the bill of sale, the check, and a letter from Nissan in Japan when Faulkner inquired about equipment he'd need to make it US compliant.

Anyway, great stuff and I'll be watching.

Haha, really "kleine Welt" - so funny :) Never knew Swiss models would end up in US, as mostly US-Z's get imported here - but nice you got it! Seems like the previous owner had to install the rear side winker lights for getting it setreet legal :)

Let me know if i can help you with the swiss paperwork figuring out stuff and so on and thanks for sharing the story :)

[revlimitbounce]

Haha, really "kleine Welt" - so funny :) Never knew Swiss models would end up in US, as mostly US-Z's get imported here - but nice you got it! Seems like the previous owner had to install the rear side winker lights for getting it setreet legal :)

Let me know if i can help you with the swiss paperwork figuring out stuff and so on and thanks for sharing the story :)

A lot of the non-factory stuff on the car was from when it got imported to Germany, like the wheels, etc., but the terrible sealed-beam headlights are USA Crapola-spec. Wondering where I can find some Hella laps that also have that small running light inside. The seat belts are either Swiss or German and the driver's side ratchet will not unlock. Have to take it off to figure it out. Interestingly, this car's glove box liner also has "SUI" in addition to the Japanese characters. Haven't taken the dash apart; it's in quite good shape, just the gauges need a little cleaning and detailing. I like the idea of using some JDM or rare aftermarket bits on the car, too. Cheers!

[JDMjunkies.ch]

A lot of the non-factory stuff on the car was from when it got imported to Germany, like the wheels, etc., but the terrible sealed-beam headlights are USA Crapola-spec. Wondering where I can find some Hella laps that also have that small running light inside. The seat belts are either Swiss or German and the driver's side ratchet will not unlock. Have to take it off to figure it out. Interestingly, this car's glove box liner also has "SUI" in addition to the Japanese characters. Haven't taken the dash apart; it's in quite good shape, just the gauges need a little cleaning and detailing. I like the idea of using some JDM or rare aftermarket bits on the car, too. Cheers!

Thanks for the Info. Is it possible to PM me a pic of the seatbelts? i got two different types of (strange) seatbelts in my car. I guess they where equipped by Datsun switzerland to fuilfill some regulations back then and are not sure which one is original. would be great.

I guess Hella is still selling those lamps. they're quite famous in the european classic car scene and still sell a ton of products for old cars. Check your American Hella Dealer or the international website ;)

Interresting with the "SUI" lettering. But maybe just was a dififerent guy marking the cars that day yours was made :)

Have fun with your car (Your kids seem to approve :D)

[revlimitbounce]

Thanks for the Info. Is it possible to PM me a pic of the seatbelts? i got two different types of (strange) seatbelts in my car. I guess they where equipped by Datsun switzerland to fuilfill some regulations back then and are not sure which one is original. would be great.

I guess Hella is still selling those lamps. they're quite famous in the european classic car scene and still sell a ton of products for old cars. Check your American Hella Dealer or the international website ;)

Interresting with the "SUI" lettering. But maybe just was a dififerent guy marking the cars that day yours was made :)

Have fun with your car (Your kids seem to approve :D)

Sure, will take some photos of the seat belts. Just started looking for headlights; haven't found any with the extra small bulb, but I recall them distinctly. Yes, kids liked that day. This project will serve as a teaching moment about tools, mechanics and putting time in on a major project. I'm also going to write about it for one of my outlets, Boldride.com. (I'm an auto journo.) 

[JDMjunkies.ch]

that would be great, thanks already and ssorry for the late reply. just came back from tokyo auto salon :)

[anth]

What is the plan for 2016, Nils? Will we see this car complete?! :)

[JDMjunkies.ch]

 

 

what is the plan for 2016, Nils? Will we see t his car complete?! :)

Thanks for asking. if you check out my blog (www.JDMjunkies.ch) you may have noted i was to tokyo Auto Salon and on a Long vacation that's why i was off a bit.
- However i'm currently collecting the last missing bits for the Body (have some things on the way to me).
- Then my Buddy Stefan will visit me once again soon and help me out with a few things and taking away my Rotisserie, which will give me a lot of extra space in the Garage.
- I'm just collecting some more Money for the bodyshop (feel free to donate, guys :D)
- The bodyshop just wrote last week that he's planning to start working on the Chassis again this week, but haven't got any updates yet.  hope soon.

 

However i had a really busy last year at the Office and it seems like everything is calming down a bit now, so as soon as i got some last things sorted out i hope i can Focus more on my fairlady Project again, but it will definitly not be completed by this year - there's still too much work to do :)

[Eagle_Adam]

Still at it and Still detailed as hell!!

[JDMjunkies.ch]

After i was on a long vacation and visited tokyo auto salon as well (see tons of pictures on www.JDMjunkies.ch) im finally back at the project..


Good news guys. I thought it's about time to get the project rolling a bit faster again. that's why i'm currently preparing a few things. However thanks to my buddy stev (big thank you again, buddy!) i was able to get hands on another NOS piece: A New-Old-Stock Datsun Front lower center valance Panel thingy. Probably the last Bodypanel which was missing. Well i had one but it was rustend and totally crushed so this came in handy :)




With partnumber and everything :)


Oh and last week i got this picture from my bodyshop, letting me know that the car is back at the main workspace and ready to crank work up again. Hope to get some updates from him soon :)IMG-

[soundboi]

some extremely epic parts used.

 

what carbs? also what ignition system?

[JDMjunkies.ch]

some extremely epic parts used.

 

what carbs? also what ignition system?

Thanks mate, appreciate your feedback :)

 

Haven't really spent too much time planning the engine, as it's probably still a few years away until i start tinkering with it :) However plans included a Ultra nagaidenshi Ignitino system and Mikuni triple carbs, but havent thought about the details yet and this plan might be subject of change :)

[JDMjunkies.ch]

The 240Z Project has been really cooking on a low flame last year. I was too busy with my Job and travelling. Luckily this year started out smoother and i'm really working to get back on the Z-Project. I Ordered one expensive part which will show up in a few months but so far i started reading a lot about the Z, because i forgot most of the things i knew maybe two years ago since i never used them :) However im starting to make plans for the next small projects of the Project and i'm super excited about it. However before i started to work on car bits, i had to get rid of the mess in my home-workshop (aside from my garage i have a little hobby-room for small work and parts-storage at home). So i bought some new shelves, moved everything and this is how it ended up. I'm super happy with it :)

I can finally work without searching for the right parts and tools for half of the time :)

Then it was time to complete a simple but not-so-simple job i've started a while ago. Before i had the Door locks replated a while ago i removed the old damper rubbers and after i never figured out how to get them back in, i never did it.

Today i decided it was time to complete the job :) So took an old toothbrush and scalpel to remove old glue from the rubber. then washed it in the sink with some warm water and dishwashing soap. worked fine :) Then took me quite a while to figure out how to get the Rubber back in without damaging it, but finally got it after 30mins of fiddling around. Added some of the Super glue like it was from factory, but the rubber sits so tight, i doubt the glue is really needed. Just a small job, but one more box ticked on the 2-do list :)

[Eagle_Adam]

Every little thing adds up ;)

[JDMjunkies.ch]

Got a bit bored from all the reading an investigation in front of the computer, so decided for my own pleasure to test-assembly my rebuild steering colum together with the HKB Steering boss kit and the RS-watanabe falcon steering wheel (Horn button not installed). Nothing big, but enjoyed how it ended up. Now trying to figure out how i can clean the multifunctional steering wheel switches to get them back on the column :)

 

[JDMjunkies.ch]

I Decided to visit my Bodyshop and talk to my Panelbeater Yves about the progress of my car. Remember it was more than 15 months since he last worked on it, because it's still a side-project. Lucky me he just began working on the car today. Not a lot to show you but i hope for some updates soon. And i'm more than happy with any progress :)

As you can see he just started work on the floorpans. And the good thing is i already have another apointment with him for the next week. so pretty sure there are some nice news :)

[JDMjunkies.ch]

Today i spent a wile rebuilding / refurbishing the headlight switches. The problem with the Original wiring design is that the full headlight current runs through the steering wheel multifunctional switches. This causes contacts tu burn, specially when upgraded to H4 headlights. I decided to refurbish them before putting it back on the steering column.
In future i will run a relay, because the original design is not very long-lasting, nor is it very safe to have 20 amps in your hands when switching on the lights :P
Started with choosing the best of all four switches i had (one beeing a later model or something different):

Disassembled everything following This great manual:
http://www.doyouevenhoon.com/datsun-240z-gtr/how-to-rebuild-datsun-240z-headlight-switch.html and ended up like this:

Removed the old contacts and as you can see they're pretty urnt and carbonized:

Used some "relay contacts cleaner" Fluid and after a bit of rubbing looked like this. Also but the switches back in reverse orders to make sure the "weak" part will be on the opposite side and last longer ;)

Will continue with the rest of the switch next week. need to buy smaller pliers first :D In the meanwhile i got an update from the bodyshop. Before:

after:

Now work on the passenger side floorpan and rear quarter as well as the small storage compartment started. More rust than expected. but yeah. t hat's how life is :)

 

Also ordered ordered the rear lower valance and rear corner valance so basically i will have an almost new chassis at the end *lol*. more updates soon i hope ;)

Edited February 27, 2016 by JDMjunkies.ch

[JDMjunkies.ch]

Made some progress again :) First i cleaned all the switches and buttons by hand so the white texture finally came back to life and is visibla again. worked surprisingly good with an old tooth brush and some dishwashing water ;)

Well and then assembled everything back together. not factory fresh but as nice as an 44 year old switch can get :)

Then started with the turn signal switch on the other side. seems a bit more tricky...

The contacts had massive burn marks

So this is after cleaning :)

Who needs puzzles when you have cars? I never realized how complicated these switches are until i took it apart :)

Then got some updates from the bodyshop. Rear lower side cowls (before):

And after:

And that "triangle piece" inside the rear fender well...

Tomorrow i will visit a shop to repair my wing and on friday i'll drop by the bodyshop again. hoping for some updates again ;)

[JDMjunkies.ch]

One popular upgrade for the 240Z seems to be swapping out the lame Original Heater blower motor to the one coming from some 80ies or 90ies Honda. Unfortunately all the manuals i found for this swap mentioned a different Honda model as source for the Blower motor so i was confused. They all looked the same in the pictures and some guys on Ebay even sell the Blower swap for around 90$ + shipping. I thought that's too expensive and did some research and figured out the one blower everyone is using is the TYC Genera Model 700077 which is an aftermarket replacement for the aforementioned old honda motors. Funnly this blower is sold for only 23 Bucks so i went the direct route and ordered it :) This is the old Nihon Radiator / Hitachi Blower:

 

And here we have the new one. Brand new and factory fresh :)

 

As you can see the shape is slightly different (left new, right old), but it wil fit perfectly.

 

I compared with the drawing on the TYC website and many people in the internet told this is a 1:1 swap except for the rubber gromments which need to be changed due to different mounting hole diameters (other people probably will enlarge the holes). Also i recommand to paint the now Silver motor cover black as this is installed right in the foot compartment of the passenger and will stick to the passengers eye ;)

 

According to the poeple in various forums the advantage of the new Blower is: Much more powerful, much more silent, lighter (Due to the plastic squirre-cage compared to the metal one in the old design) and draws less current. Overall it's much more effective. can't wait to install it. Of course i will write about it once i get to that point ;)

[JDMjunkies.ch]

Last friday i spent a visit at the Bodyshop. Mainly to bring him the Passenger side door so he could check fitment after he's done with welding in that area (some parts may have moved a bit and need adjustment). I also asked  him to close the original door mirror holes in the door as i will switch to the JDM Fender mirrors ;) And i had to bring  him some cash as well :)

And then i have some good and bad news. The good news is that work in the front right (passenger) sode is almost completed and the work looks fabulous. To the untrained eye it may look a bit patchy but after everything is primered and has the same colour it's almost factory-work - maybe even better since factory welding from datsun was really crappy in some areas :P

Now the bad news. Specially in the passenger area behind the seat there has been copious amount of cheap patchwork repairs and way more rust underneath every panel which was removed, than initially expected. So well - yeah. the whole thing will be a bit more expensive and take maybe another two years at the bodyshop until completed.. but i'm still happy with the fact i will save one of these fairladies...

Inner wheel well has been removed and he's currently fitting the new one from tabco..  

Also the old sparewheel well has been cut out and the new one placed inside just to save some space. hasn't been welded yet...

The car looks a bit like a swiss cheese currently :)

Here's a good example. I wouldn't have noticed but as the bodyshop explained and showed me the patchwork under the gas filler thingy i understoud where there has been cheap repairs in the past. so this one has to go out as well and fixed nicely... many small bits which will take up a lot of work at the end...

Anyhow, looking forward for updates. And while i was there i also ahd a look at this almost finnished (has been in the works there for a while now as well!), Toyota KE70 Corolla "Kesser Sport spezial". This was a swiss homologation special as far as i understoud (wasn't able to find anything about it on the web..) in all it's early 80ies boxyness. Love it and i'm pretty sure this will be a rare gem once completed!

[JDMjunkies.ch]

This post is going to be a little summary of the weeks happenings. I have some more good and bad news from the bodyshop first:
The good thing: My Panelbeater yves put the door back in for aligment and thus it still has a lots of panels missing, a door already makes the car look like - ummm - a car again :)

Then the bad news: Someone crashed into his car (the one below is the one who hit  him), so he's currently suffering from a whiplash injury and of course his recovery his priority first. Not sure what that means for my car. probably will not be worked on for a while again...

The very next day my Buddy Stev visited a guy who is currently selling a lot of NOS datsun parts:

He brought this little Oil pressure Sensder unit for me, but i have to check if it's really for the Z since i have the feeling my ones look more cylindric istead of this "Church-bell" design.

And then i reworked the new Blower motor (See last post), to fit my needs. First removed the old Motor cover which was silver.

Painted it black with some rattle can spray:

Ordered some new rubber grommets which will fit since the old blower has different hole sizes.

Here i have them installed together with the metal sleeves from the old blower inside:

Here you can see the old insulationg foam ring and i wanted to recreate something similar.

And here's my result. boaght some foam-tape and installed it. Doesn't look as nice as the original one but since it will not be visible once installed im fine with that :)

And last but not least i had a little running-test with a 12V DC supply just to see if everything's fine. and it is :D - Blower motor: Completed!

[Eagle_Adam]

You have quite the tolerance for set backs :) deffanitly not a bad thing when dealing with 35 year old metal ;)