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GTR-240Z
07-02-2012, 12:29 AM
After 3 months of parts collecting I thought it was time to start a thread on my updates for 2012 since I'm only 2 weeks away from starting to actually fit stuff and I thought it might be of interest to some of you.
To give you a background on the car I spent 5 years restoring and modifying the car starting way back in 2003 and there was always areas I felt uphappy with as I had to compromise due to time and money. I've been slowly making improvements to the car to address these areas and decided after a great 2011 going to shows, track days, and the drag challenge I thought it was time to address the remaining areas in one big hit.


So my upgrades for 2012 are:

Fit power steering, going to use the Subaru STI rack with a Citroen Saxo electrohydralic pump. Terry (Tel240z) will be doing this conversion for me as he has come up with a nice little package for me.
Redo brake lines so they run on inside of wing to give a cleaner engine bay, also going to fit a line lock (two can play at that one Tel :)). Also going to replace the dreadfull brake pads Arizonia Z Car supplied with my wilwoods as they create huge amounts of brake dust and squeal like a banshee.
Remake the gearbox mount as the current one is horrible and requires me to upbolt the mount from inside the car if dropping the box which really annoys me.
Replace worn Exedy single plate clutch which has terrible judder at slow speeds with a Nismo Super Coppermix twin plate clutch which is apparently a nice streetable clutch, doesn't have the usual twin plate jingle, and can handle 660bhp so more than enough for me. Also going to replace the clutch master and slave cylinder as I'm getting contamination of the fluid from one of the seals.
Fit 300ZX TT R230 LSD using the Modern Motorsports mounting brackets, Modern Motorsports custom 300ZX TT CV shafts, and Modern Motorsport billet 39 spline stub axles and matching companion flanges. Suppose to be used regularly on 10 seconds zeds so hopefully no more broken drive shafts also hoping the R230 is nice and smooth with none of the backlash I seem to suffer with the current R200.
Aluminium fuel tank to replace current one which will have some decent baffles and internal collector so it can run an internal fuel pump and do away with the surge tank setup. Hopefully with a simplier system I will have a more reliable and robust fuel system. Still need to decide on a fuel pump will run either twin walbro or Bosch 044, or prehaps a single Toyota Supra IV or Automotive Stealth 340 need to make my mind up soon before tank arrives.
Fit prop hoop for added safety
Rewire whole car, will just tidy rear harness as its actually in good condition just needs better ground wires, repair interior light wiring, the fuel pump wiring is already beefed up. Going to use a US front harness as my one is in poor condition but will replace headlight, and parking light wires, and will add fan, and power steering pump wires in will also strip out all the wiring for the ye olde coil, ballast resistor and all vintage engine stuff :p. Dash harness will be completly redone as its had 40 years of messing about done to it and I think it can be simplified and tidied up also going to fit a more modern fuse box.
Redo oil cooler pipework, replace worn tyres at rear, replace heater valve, replace leaking rear oil seal, get those damn heater controls to work, replace turbo elbows with correct R33 ones so I can re-enable my o2 sensors.
Reupholster transmission tunnel, sills, and behind seats I'm not a big fan of that diamond stitch vinyl and I hate the carpet replacement I current have. Will leave this as a surprise to the end.
Rewire engine harness, fit Injector Dynamics ID1000 injectors, replace air flow meters with RB25 ones which flow better, and a retune.
Fit slightly stiffer rear springs and some adjustable camber mounts to rear so I can run a little negative camber.
So not really much planned :rofl:. And for those of you that get all excited at car part pictures here is what I have cluttering up the house ready to be fitted soon.

http://desmond.imageshack.us/Himg705/scaled.php?server=705&filename=dsc04851tu.jpg&res=medium
Modern Motorsport Custom 300ZX TT CV's

http://desmond.imageshack.us/Himg51/scaled.php?server=51&filename=dsc04853i.jpg&res=medium
Diff still a work in progress on kitchen floor. Pipes where for original oil cooler.

http://desmond.imageshack.us/Himg813/scaled.php?server=813&filename=dsc04854z.jpg&res=medium
Very shinny clutch shame they've gone to all that trouble making it look so nice as your never see it once fitted.

http://desmond.imageshack.us/Himg94/scaled.php?server=94&filename=dsc04860p.jpg&res=medium

http://desmond.imageshack.us/Himg197/scaled.php?server=197&filename=dsc04861nl.jpg&res=medium
Modern Motorsport 39 spline billet stub axle.

http://desmond.imageshack.us/Himg109/scaled.php?server=109&filename=dsc04859o.jpg&res=medium
Modern Motorsport mounting brackets

http://desmond.imageshack.us/Himg708/scaled.php?server=708&filename=dsc04857b.jpg&res=medium
Lots of various boxes in spare room like this, it's stuff like this that you fail to budget for and actually costs a small fortune. 140 for gearbox, diff, brake fluid, and somewhere power steering fluid!.

http://desmond.imageshack.us/Himg607/scaled.php?server=607&filename=dsc04862d.jpg&res=medium
Work in progress on front loom really early progress which I need to start working on again.

http://desmond.imageshack.us/Himg69/scaled.php?server=69&filename=dsc04863kl.jpg&res=medium
Freshly painted crossmember in my kitchen. Hard to see Terry's modifications in this picture but the paint is still drying.The smell is drifting into the living room and making me light headed :unsure:.

Will keep you posted as I start fitting this stuff.

IbanezDan51
07-02-2012, 09:35 AM
Should the R200 not have handled the power with a decent LSD fitted plus its lighter?

Interested in the power steering rack idea!

Mr.G
07-02-2012, 10:06 AM
Great stuff Darren, glad your posting this, it will make for a very good read.:thumbs:

With regards to the fuel tank, I like the idea of a custom made tank. There is another route you might have already looked at, that involves using your existing tank and fitting an ATL Black Box inside it. I've dove a bit of research on this and looks like the route I'll be going for. The black box has a self contained fuel pump within it and the box helps to reduce the fuel splashing around and letting in air from the pump inlet.

Rob Gaskin
07-02-2012, 10:19 AM
Sounds like some really useful upgrades and practical solutions to existing issues eg gearbox mounting and wiring reliability/efficiency which is so important.


Rear camber comment is interesting. With my standard but lower set-up I have negative camber without trying.

GTR-240Z
07-02-2012, 10:48 AM
R200 can handle the power and is lighter but I wanted the strongest driveshafts which using the MM kit also means replacing the diff. I actually think a little extra weight in the rear is not a bad thing should be interesting to see how that pans out.

George I have looked at the ATL black box and did consider it but my tank has been lined with the tank sealer stuff which apparently is impossible to remove once in the tank. I like the idea of an alloy tank so no more rusty tank to worry about in the future and I've ordered a custom tank with a nice big sumped area for the pumps to sit in and big baffles to keep fuel in that sumped area will post pictures once it arrives.

Rob I know everybody else that has a lowered zed seems to have a nice amount of negative camber on the rear but looking at my rear wheels they sit perfectly upright not sure why my setup is any different.

Wyn
07-02-2012, 07:17 PM
Nice collection of bitties you've acquired there :D

Wyn
07-02-2012, 08:15 PM
btw, unless you already have you wanna check what wheel studs are fitted to those rear stub axles
Mine came with 12x1.5, so means I need to change the rear wheel nuts to fit, or change the studs back to 12x1.25 :unsure:

GTR-240Z
07-02-2012, 09:12 PM
btw, unless you already have you wanna check what wheel studs are fitted to those rear stub axles
Mine came with 12x1.5, so means I need to change the rear wheel nuts to fit, or change the studs back to 12x1.25 :unsure:

Yeah I seem to recall his site says there 12x1.5 I was going to buy a new set of wheel nuts as I want to get his aluminium front hubs at some point which have the same ARP studs. Should order them now will probably take 3 months to get here :D

datsfun
07-02-2012, 10:06 PM
Darren I assume that you work for RBS and are now spending some of the Stephen Hester bonus that has been re-distributed to staff :D...

The planned upgrade ^^^ is simply awesome and trulytaking the whole build to the next level. Bet it aint cheap either;)

I need to visit the Northwood mansions soon...:thumbs:

Rob Gaskin
07-02-2012, 10:15 PM
Yeah I seem to recall his site says there 12x1.5 I was going to buy a new set of wheel nuts as I want to get his aluminium front hubs at some point which have the same ARP studs. Should order them now will probably take 3 months to get here :D

You could try Rallynuts for some studs. I've used them twice, they get delivered in a couple of days. However you really need to push one out to see what spline dia they are.

Competition Wheel Studs | M12 x 1.25 Metric Fine | Hardened Steel Motorsport Studs | Rallynuts (http://www.rallynuts.com/wheel-studs/m12-x-125-metric-fine-wheel-stud.html)

GTR-240Z
07-02-2012, 11:06 PM
Darren I assume that you work for RBS and are now spending some of the Stephen Hester bonus that has been re-distributed to staff :D...

The planned upgrade ^^^ is simply awesome and trulytaking the whole build to the next level. Bet it aint cheap either;)

I need to visit the Northwood mansions soon...:thumbs:

haha no RBS can't afford me. I like to think I'm doing my bit for the trickle down effect keeping all these car parts manufactuers in a profit during the recession.

I'm only renting in Northwood thanks to the crazy 25% deposit needed to get a mortgage these days, instead I have to pay my landlords mortgage:rolleyes:.

GTR-240Z
07-02-2012, 11:08 PM
You could try Rallynuts for some studs. I've used them twice, they get delivered in a couple of days. However you really need to push one out to see what spline dia they are.

Competition Wheel Studs | M12 x 1.25 Metric Fine | Hardened Steel Motorsport Studs | Rallynuts (http://www.rallynuts.com/wheel-studs/m12-x-125-metric-fine-wheel-stud.html)

I dont mind the switch to 1.5 thread nuts the stubs have nice ARP studs so would be a shame to not use them and replacement nuts are cheap enough.

Mr.F
08-02-2012, 12:31 PM
Competition Wheel Studs | M12 x 1.25 Metric Fine | Hardened Steel Motorsport Studs | Rallynuts (http://www.rallynuts.com/wheel-studs/m12-x-125-metric-fine-wheel-stud.html)

Also in stock at MJP. The 14.3mm spline is bigger than S30 stock, so once used you are stuck with them.

GTR-240Z
20-02-2012, 10:31 PM
Started work today on the zed at Terry's workshop even had John there for company. We stripped the rear end down and changed the springs, top mounts, and stub axles. Ran into clearance issues with the diff which held us up but after checking on Hybridz it seems the norm to have to notch the rear of the chassis to allow the diff to sit high enough in the shell. Hopefully more progress tomorrow and some better pictures.

http://desmond.imageshack.us/Himg11/scaled.php?server=11&filename=dsc04864d.jpg&res=medium


http://desmond.imageshack.us/Himg545/scaled.php?server=545&filename=dsc04866f.jpg&res=medium


http://desmond.imageshack.us/Himg3/scaled.php?server=3&filename=dsc04868b.jpg&res=medium
DOH!

Looking forward to tomorrow roll on 8.30 if only my day job excited me this much!

GTR-240Z
21-02-2012, 11:14 PM
Made some more progress with the car today

http://desmond.imageshack.us/Himg848/scaled.php?server=848&filename=dsc04880p.jpg&res=medium
Tel cut a section out of the chassis for the diff to sit high enough in the car.

http://desmond.imageshack.us/Himg267/scaled.php?server=267&filename=dsc04882ht.jpg&res=medium
This gave us the clearance needed

http://desmond.imageshack.us/Himg12/scaled.php?server=12&filename=dsc04896y.jpg&res=medium
Welded an L shaped piece back in and then sprayed with underseal

http://desmond.imageshack.us/Himg19/scaled.php?server=19&filename=dsc04887ct.jpg&res=medium
View from another angle

http://desmond.imageshack.us/Himg580/scaled.php?server=580&filename=dsc04906w.jpg&res=medium

http://desmond.imageshack.us/Himg803/scaled.php?server=803&filename=dsc04910a.jpg&res=medium

http://desmond.imageshack.us/Himg163/scaled.php?server=163&filename=dsc04912q.jpg&res=medium
Then reassembled the rear suspension and axle. Still needs finishing but coming together nicely now.

http://desmond.imageshack.us/Himg192/scaled.php?server=192&filename=dsc04890am.jpg&res=medium
Time to replace the clutch, and gearbox mount. Also discovered the oil leak I thought was the rear oil seal is actually from one of the semi circular seals in the rockers which was seeping down the back of the block so saved some time there.

http://desmond.imageshack.us/Himg685/scaled.php?server=685&filename=dsc04891k.jpg&res=medium
Fitted the Nismo Super Coppermix twin plate clutch

http://desmond.imageshack.us/Himg842/scaled.php?server=842&filename=dsc04911cv.jpg&res=medium
Tel has started to make a new gearbox mount using the old ears and x-member. Will be welded in tomorrow.

Rob Gaskin
22-02-2012, 10:23 AM
Looks like you are progressing well and improving lots of things. :thumbs:

Car lifts and space to work are so useful, plus a helping hand and encouragement from a friend/engineer.

Ian Patmore
22-02-2012, 02:02 PM
Good to see mods in transition

Mr.G
22-02-2012, 06:55 PM
Coming along nicely, you must be pleased, roll on 22nd April....:)

GTR-240Z
23-02-2012, 07:47 PM
Forgot my camera in the workshop yesterday so I didn't provide a quick update so for the last 2 days we have done the following.

http://desmond.imageshack.us/Himg812/scaled.php?server=812&filename=dsc04923y.jpg&res=medium
Fitted the prop made by JW Engineering in Barnehurst,Kent.

http://desmond.imageshack.us/Himg703/scaled.php?server=703&filename=dsc04936b.jpg&res=medium
Fitted to car with Tel trying to take a crafty pic.




http://desmond.imageshack.us/Himg851/scaled.php?server=851&filename=dsc04925hg.jpg&res=medium
Built up a new set of control arms with new bushes, balljoints, and original steering knuckles to replace the short ones I was running.

http://desmond.imageshack.us/Himg855/scaled.php?server=855&filename=dsc04943a.jpg&res=medium
Tel finished the gearbox mount

http://desmond.imageshack.us/Himg23/scaled.php?server=23&filename=dsc04945o.jpg&res=medium
Subaru STI rack attached to modified x-member ready to be fitted

http://desmond.imageshack.us/Himg708/scaled.php?server=708&filename=dsc04915ko.jpg&res=medium
New x-member and rack will be going to be replacing this tomorrow

Tel also made up a power steering pump bracket but no pictures till tomorrow of that.

johnymd
23-02-2012, 08:36 PM
Getting there Daren. Missed not going to the workshop today :(

GTR-240Z
23-02-2012, 09:08 PM
Getting there Daren. Missed not going to the workshop today :(

Yeah after the initial day of feeling like no progress was being made its really exciting seeing it all come together now. I cant wait till its running again so I can see what the diff, clutch and steering feel like.

johnymd
23-02-2012, 09:18 PM
I'll pop over tomorrow and you can take me for a drive. What time should I get there?

GTR-240Z
23-02-2012, 09:36 PM
lol lets not hold are self to a time just yet it may well be Saturday if Terry kindly opens his workshop :rofl:

Pop over though and see if you can make use of them studs.

tel240z
23-02-2012, 09:44 PM
I'll pop over tomorrow and you can take me for a drive. What time should I get there?

Iv'e missed your uncontrolable witt John ! lets say about ten past eight in the morning before Darren gets there give it a blast then we can tell him all about it :lol:

GTR-240Z
24-02-2012, 09:19 PM
Finished bolting up all of rear suspension/axle today also added the rear diff brace bar which means the swirl pot will need to be removed. This isn't a big deal as a new tank is being fitted soon and the swirl pot, lift pump, and external pump was going to be junnked then anyway.

http://desmond.imageshack.us/Himg844/scaled.php?server=844&filename=dsc04959eo.jpg&res=medium

http://desmond.imageshack.us/Himg513/scaled.php?server=513&filename=dsc04965u.jpg&res=medium

Fitted the new x-member with rack, I'm really impressed with this part of the update the rack looks great in there.
http://desmond.imageshack.us/Himg842/scaled.php?server=842&filename=dsc04967px.jpg&res=medium

Refitted control arms
http://desmond.imageshack.us/Himg198/scaled.php?server=198&filename=dsc04968o.jpg&res=medium

Fitted new tension rods
http://desmond.imageshack.us/Himg694/scaled.php?server=694&filename=dsc04969a.jpg&res=medium

Fitted power steering pump where battery tray use to be located. The battery will need to be relocated to the rear of the car.
http://desmond.imageshack.us/Himg829/scaled.php?server=829&filename=dsc04971l.jpg&res=medium

Power steering reservior attaches on bulkhead, wiring will be done when I get the car home.
http://desmond.imageshack.us/Himg851/scaled.php?server=851&filename=dsc04972o.jpg&res=medium

johnymd
24-02-2012, 09:49 PM
So, is it drivable yet?

Rob Gaskin
24-02-2012, 10:34 PM
It's looking great Darren, hope it performs well at Mallory - still just you and me!

Not being pedantic here but why do folks (including Arizona Z) call the Compression Rods, Tension Rods? Surely they are never under tension, if it was front wheel drive I could understand it.

They help to locate the TCA/Lower Arm and stop it being forced backwards under braking.

Where is your battery going - behind the seats?

GTR-240Z
24-02-2012, 10:35 PM
Almost just need to fit exhaust, put fluids in, and various tidy up jobs hopefully will be driving home haha

GTR-240Z
24-02-2012, 10:52 PM
It's looking great Darren, hope it performs well at Mallory - still just you and me!

Not being pedantic here but why do folks (including Arizona Z) call the Compression Rods, Tension Rods? Surely they are never under tension, if it was front wheel drive I could understand it.

They help to locate the TCA/Lower Arm and stop it being forced backwards under braking.

Where is you battery going - behind the seats?

I'm afraid I have a habit of using the American terminology hence Tension rods but your correct the proper name is Compression Rods.

As for the battery I'm thinking of having the passenger toolbin behind the seat modified into a proper box shape and hiding a smallish battery there. I did think about fitting a racing battery due to there small size but I'm under the impression they dont like slow drains like alarms/immobilisers so you have to disconnect the battery if left for a while and I'm not into all that malarky. Will need to give it some thought really when it comes back this weekend.

johnymd
24-02-2012, 11:00 PM
Hope it all goes well. Just remember I'm working all weekend setting up a server and network so I can't take your Z back home on the trailer....................unless you want to swap places and setup the network for me.

johnymd
24-02-2012, 11:01 PM
Call them tie rods and everyones happy?

GTR-240Z
24-02-2012, 11:20 PM
Hope it all goes well. Just remember I'm working all weekend setting up a server and network so I can't take your Z back home on the trailer....................unless you want to swap places and setup the network for me.

lol keep your phone handy we may have to swap jobs for the weekend :D.

Mr.F
25-02-2012, 12:37 PM
Call them tie rods and everyones happy?

Unfortunately, some people call track rod ends tie rods...
Nissan officially call the diagonal rods compression rods.

GTR-240Z
25-02-2012, 09:45 PM
Got the car running today but no pictures as I left the camera at home but probably nothing to exciting to photograph anyway. Car will now be coming home so I can crack on with all the other work now.

Initial impressions are good the clutch has a lovely bite and very light and smooth with no judder like the other one. It's even lighter than the clutch in my misses 3 series so really happy with that purchase.

Diff seems quiet and smooth with no obvious backlash and chatter but will need to test that at speed. Was nice reversing out of the workshop and it being like a normal car no stupid chattering from the LSD clutches and no more backlash when accelerating/deaccelerating that made it look like I was having an epileptic fit.

Power steering is nice it's quick and light without being to over assisted will need to see how it drives long term but can now turn the wheel in the palm of my hand at slow speeds like a modern car no more looking uncool huffing the steering wheel around when trying to park.

So on the whole very happy just need to do a shakedown test and crack on with the still large list of mods.

GTR-240Z
03-03-2012, 09:13 PM
Got the car home today its return was delayed as my cam angle sensor was foobar so had to wait till a replacement arrived so I could get home. Was very nerve racking at first driving the car home as I had to drive around the M25 but there was no need the car was perfect.
Really pleased with the clutch, diff, and power steering one of the best mods I have done so far. The car feels much smoother and nicer to drive I could never go back to the original rack and r200 now.
Would also like to thank Tel again who without his help I could never have done these mods. Now time to get on with more stuff in my garage.

morbias
03-03-2012, 09:18 PM
That rack looks like a pretty tight fit! How did you hook up the speed sensor for the power steering?

GTR-240Z
03-03-2012, 10:11 PM
That rack looks like a pretty tight fit! How did you hook up the speed sensor for the power steering?

Saxo pump is constant flow so no speed sensor like an MR2 pump for example. So just wire in the relay and off you go. I will probably fit a switch inbetween the ignition switch and relay so I can turn the pump off if required.

Mr.G
04-03-2012, 08:56 AM
Really pleased with the clutch, diff, and power steering one of the best mods I have done so far. The car feels much smoother and nicer to drive I could never go back to the original rack and r200 now.

I may have missed this but what were the issues you were having with the R200?

GTR-240Z
04-03-2012, 12:44 PM
I may have missed this but what were the issues you were having with the R200?

I always thought my R200 was noisey and not particularly smooth especially when suddenly deaccelerating. Most people said this was normal for an old R200 but I wanted something more refined.

Rob Gaskin
04-03-2012, 02:33 PM
I always thought my R200 was noisey and not particularly smooth especially when suddenly deaccelerating. Most people said this was normal for an old R200 but I wanted something more refined.

I've had two R200 diffs and they gradually get noisey when reversing is this common too? Pretty crude items IMO.

tel240z
04-03-2012, 06:16 PM
Well these diffs can be 33 odd years old and all probably well ove 100 thousand miles even with new bearings in they need setting up right the crownwheel and pinnion will never be in exactly the same mesh pattern as before, guess i must be lucky mine just makes a quiet whooshing noise at speed but i must admit darrens diff was silen t:thumbs:

Ian
28-04-2012, 04:27 PM
Any more updates?




Apart from the ****** pads how do you find the AZC front brakes?

I want to fit an LSD to my 260Z but I want something that will still be suitable for when(or if) I put an RB26 in her and theres no point in me putting a Kazz or something into my R200 (I'm assuming my car has R200 being a late 260Z) if thats going to have to be changed for another diff later on. Would you definitly reccommend not using an R200 or would it be ok for me as I don't plan to run as much power as you (I'd be happy with 350 - 400hp)

Do you know how much heavier the R230 was over the R200?





Sorry for all the questions.

GTR-240Z
28-04-2012, 06:48 PM
Lots more updates done to car I just have not updated this thread as pretty much all the interested people see the car regularly anyway or will see it at the pod soon enough. I suppose I should really update this thread.

AZC brakes are great even the **** pads they supplied are good just noisey and create alot of dusting but the car does now stop as quickly as it can accelerate.

Not sure on the weight of an R230 over an R200 it's definetly a big heavy thing but I think a little increase in weight at the rear is not necessarily a bad thing. I went R230 to allow me to beef up my stubs and driveshafts which is really where your weak spot will be, the R200 is more than strong enough and is used in Skyline GTR's upto the R34 in short nose form so its more than upto the job. I think if I was building another car I would look at using the R200 short nose from a GTR or similar with the Technotoy kit and use the strongest shaft/hub combination it could provide which will mean using a 5 lug hub as the 4 lug stuff all have a lower spline count to make it not worth the effort in my opinion.

Ian
29-04-2012, 01:15 PM
Please update this thread, I'm interested in what you are doing but can't see the car in person.


Good to hear the AZC brake setup is good as I'm definitly considering getting it. What pads are/have you upgraded to?




I think I'll plan to use an R200, I'll only upgrade if I have breakage problems. My diff has low milage on it so it should be good but do I keep this and get the parts needed to convert it to cv's and install an LSD or do get a short nose R200 from a R33/R34 and the parts needed to fit it?

franky
29-04-2012, 01:48 PM
+1

Ian
30-08-2012, 05:36 PM
Any updates?




Saw a photo of your car on Speedhunters:

http://1.1.1.3/bmi/cdn.speedhunters.com/wp-content/uploads/2012/08/SH-RRG12-26.jpg

GTR-240Z
31-08-2012, 11:48 PM
Just got back from a long drive from Germany and not taken any pictures of more recent mods. When I'm refreshed in the morning I'll take some pictures and update my thread.

tel240z
01-09-2012, 12:09 AM
The oil burner made it then :cool:

GTR-240Z
01-09-2012, 12:38 AM
The oil burner made it then :cool:

Yeap 1400 miles in total without a hicup including about 180 miles each way on the A2 at a nice constant 115mph it even managed to get better MPG than I ever got driving in blighty :)

GTR-240Z
01-09-2012, 01:31 PM
Right been ages since I actually updated this thread properly and to be honest forget where I left off. I think the original plan was to have the car done ready for summer but after rushing the larger parts of the project like the diff, steering etc it was apparent I would not be finishing the large list of stuff I wanted to do and saving for a house has meant I have had to budget any bits for the zed so progress has been somewhat slow.

Here is what I have done since the last update some of the pictures are not great as they were done on a mobile phone camera.

Fuel Tank:
Fuel tank was replaced with the help of Terry the old tank was sound but I really didn't like the swirl pot setup the lift pump was noisey and when at brand's doing a track day I could actually drain the swirl pot and cause fuel starvation when entering the straight which is not ideal :(.
I decided to have an alloy tank made which would have internal baffles to restrict fuel slosh and a lower sumped area in the bottom which within an ATL surge tank can be mounted with a fuel pump then mounted inside this.

Here is the outside of the tank showing the sumped bottom which can hold about 4 litres, the whole tank holds approx 70 litres.
http://zclub.net/forum/attachments/s30-240z-260z-280z-tuning-upgrades/10363d1334857654-fuel-tank-options-011-jpg

Here is the internal baffles to prevent sloshing of fuel
http://zclub.net/forum/attachments/s30-240z-260z-280z-tuning-upgrades/10364d1334857687-fuel-tank-options-013-jpg

And here is the ATL surge tank which can hold .6 gallons and has trap doors to keep the fuel inside. It's been modified to fit to the top of the tank's lid much like a modern car.
http://zclub.net/forum/attachments/s30-240z-260z-280z-tuning-upgrades/10360d1334857550-fuel-tank-options-005-jpg

The fuel pump is a Walbro 400LPH fuel pump, at the time a fairly new pump but I have been very happy with my previous Walbro pumps and this flows 400 litres per hour which meant I could keep a single pump setup and mounted inside the tank its whisper quiet.

The tank uses a VDO dip sender and will work with a programmable autometer fuel gauage which I still need to buy so still running the older one at the moment.

GTR-240Z
01-09-2012, 01:52 PM
Battery:
Battery had to be mounted to rear of car as the original space was now taken by my power steering pump. I decided to use a traditional battery mounted in the rear passenger side just behind the wheel well. I really didn't like stories of the gel type batteries not liking slow drains like car alarms as I need to have an alarm for insurance purposes so went to Halfords and found the smallest battery I could find on the shelf which I think is an 063 commonly used on BMW E46 316i/318i so should be easy to replace in the future.

The battery was mounted in an alloy frame I bought from ebay, It's mounted at this angle so the battery is easier to remove from the frame without having to remove trim or hit against the body.
http://img580.imageshack.us/img580/4962/img1192h.jpg

The negative battery cable is grounded against rear body and then a 2nd cable goes along the inner rear wing down the inside of the sill and is grounded a 2nd time on the bulkhead where most of the wiring loom and engine get grounded to prevent any issues with poor grounds throught the shell.
The postive cable goes to a 200A maxi fuse ontop of the battery tray which protects the circuit incase the battery cable gets shorted with the body. The postive cable then runs the same way as the negative cable and then onto a bulkhead terminal. From the otherside of the bulkhead terminal it goes to the starter motor.

http://img40.imageshack.us/img40/2485/wp000165.jpg

The fuel pump relay and fuse box is also mounted here so any voltage drop to the pump is minimal, The only fuel pump wire the runs the length of the car is a white wire used by the ECU to ground the relay. I still need to make a battery cover to hide this away.

GTR-240Z
01-09-2012, 02:22 PM
Wiring:
Removed all the wiring and gave it a good overhaul with hindsight I wish I had just made a completly custom loom as I could have made a better loom from scratch but I will save that for the next project.
Things I did to the loom include:
Remove insulation tape, clean off gummy ****

Remove unused wires

Repair or replace damaged wires so no more scotch locks, insulated crimp connectors or two wires just twisted together and wrapped in insulation tape!

Placed loom in convoluted tubing which I prefered the look off and was easier to position in the car using the tubing.

Fitted modern fuse boxes that use blade fuses, one inside the car to replace the old fuse box and another in the engine bay which powers the fan, power steering relay, alternator sense wire, headlights, and ecu.
Also replaced the fusable link from the starter with a midi fuse box this then feeds the 2 fuse boxes and power steering pump.

Completly redid headlight wiring with new beefier wiring, no more scotchlock heaven there.

Replaced older style relays with modern style ones also added in relays for gauages, flashers, and junked my old ACC relay harness which was a complete dogs dinner and is now feeding seperate relays for the wipers, blower, and rear demister circuits. Also replaced the flasher relays with modern electronic versions.

Got everything electrically in the zed working I now have a working map light, demister, even the interior light comes on when I open the day :D

Dash harness during the refit
http://img801.imageshack.us/img801/5206/wp000275.jpg

Everything got its own nice little sub harness with a proper multiconnector etc
http://img99.imageshack.us/img99/1939/wp000283.jpg

Part of front harness mounted as cleanly as possible
http://img213.imageshack.us/img213/1453/img1206yf.jpg

Tidy the engine harness
http://img685.imageshack.us/img685/5549/img1210ma.jpg

Even got it looking alright under the dash, dropping resistor for the injectors is also hidden hear but will be removed when I replaced the injectors
http://img163.imageshack.us/img163/5152/img1180jx.jpg

GTR-240Z
01-09-2012, 02:44 PM
Interior:

Removed the old carpet and decided to fit some heat insulation to cut down on heat coming into the car from the transmission tunnel. It should also cut down on some of the road noise.

http://img443.imageshack.us/img443/6492/wp000208.jpg

The decided to reupholster in black alcantara as I was not that keen on vinyl or carpet on the transmisison tunnel or sills. The cloth is black but in bright light and from camera flashes does have a purplish/grey hue which is a shame as a like my interiors dark dark black but I'm still happy with the end result.
Never done anything like this before but was pleased with the result, I tried to cut the material in such a way the joins where typically under things like the seats and at the ends I folded edges over and glued to give the impression of seams etc.

http://img20.imageshack.us/img20/6797/wp000268.jpg

Picture showing sill

http://img440.imageshack.us/img440/8452/wp000277l.jpg

Drivers footwell

http://img35.imageshack.us/img35/7205/img1168oo.jpg

another picture of drivers area and also showing most of wiring etc back in car.

http://img96.imageshack.us/img96/1920/wp000285t.jpg

Passenger side, also shows cigerette lighter socket I have mounted for powering sat nav etc

http://img839.imageshack.us/img839/3872/img1175tla.jpg

Then redid doors as these were looking dog eared in the corners, may only issue is it really needs something to break up this large area like the chrome strip or a line sewn in. Also replaced the brush along the top of the door cards with window felt material as I broke the brush strips when trying to remove from the door.

http://img441.imageshack.us/img441/2126/img1174ks.jpg

datsun dave
01-09-2012, 03:02 PM
Looking very nice Darren.

GTR-240Z
01-09-2012, 03:02 PM
And the rest of the smaller jobs

Tried to relocate as much stuff from the inner wings as possible, the fuel filter was relocated, and the boost solinoid and alarm were tucked up out the way.

http://img694.imageshack.us/img694/9956/wp000151a.jpg

Moved the screenwash bottle to the otherside as my power distribution box, fuse box, and boost soliniod took the space up.

http://img268.imageshack.us/img268/4979/img1203ep.jpg

Fitted a coil pack cover, I've bought some 3M scotchpads just need the bottle to rub all the polished bits and go for the brushed aluminium look.

Also upgraded the coolant system by fitting a header tank which is in the bottom right of the below picture. This is now the highest point of the coolant system so makes it easier to bleed and has had a noticable improvement on cooling as it now runs about 10 degrees cooler.
http://img16.imageshack.us/img16/5338/img1194ox.jpg

Replaced my tach as it didn't match the rest of the gauages and redid my warning lights. Since my cowl was in poor condition I decied to recover using the alcantara I had left over

http://img441.imageshack.us/img441/2132/img1171bd.jpg

Also redid the oil cooler pipework which now runs low along the chassis rail as before it was bit too long and took a poor route throught the engine bay.

Still need to replace the injectors, air flow meters, get it retuned, and possibly do some upgrades to the diff. Unfortunately all this is on hold while I wait to buy a house but am visting the bank on Monday to see if I'm worthy enough so hopefully progress will resume in the next couple of months.

Rob Gaskin
01-09-2012, 03:26 PM
That's a very impressive 'refresh' Darren and I like the fact that most of the work is to make the car neater and reliable.

Congratulations, a great 'mini' project, well executed.

Good luck with your house purchase.

Mr.G
01-09-2012, 03:47 PM
Very nice Darren I especially like how everything's been really well thought out and executed.

Ian
01-09-2012, 05:19 PM
Great work, nice upgrades. Fuel tank should work well.

New trim looks good but I think something to break the door up a bit would improve it.

GTR-240Z
01-09-2012, 11:56 PM
Thanks for the comments guys

Great work, nice upgrades. Fuel tank should work well.

New trim looks good but I think something to break the door up a bit would improve it.

I think your right, I was thinking a few double rows of stitching running diagonally in the top left area would break up the large blank area here.

IbanezDan51
04-02-2013, 11:38 AM
Unfortunately the fuel tank pictures arn't working and it was one of the main interests of mine!

Can you get them uploaded again? Would be a great help!

Who made the tank for you?

Regards,
Dan

tel240z
04-02-2013, 02:28 PM
Unfortunately the fuel tank pictures arn't working and it was one of the main interests of mine!

Can you get them uploaded again? Would be a great help!

Who made the tank for you?

Regards,
Dan

Dan They work on my antiquated laptop :confused:

IbanezDan51
04-02-2013, 04:21 PM
Works now! Very odd... sorry. Looks great!

Do you have it fitted yet? I assume you will you cut the spare wheel well out?

Who made it up for you? As I could do with something identical but with a filler tube going towards to petrol cap.

Cheers,
Dan

GTR-240Z
05-02-2013, 11:59 AM
The tank was fitted last spring and required the wheel well to be cut out. I used BA Fabrications who made the tank there web site is www.bafabrications.co.uk/contact (http://www.bafabrications.co.uk/)

I basically sent them a picture of what I wanted them to make and provided measurements and turn around was a few weeks, I was very pleased with there work.

datsun dave
05-02-2013, 12:40 PM
Hi Darren how is the Z enjoying its new home ?

GTR-240Z
05-02-2013, 01:03 PM
Hi Darren how is the Z enjoying its new home ?

A little lonely in the garage as its a bit small and jammed full of stuff I need to tidy away. Very difficult to remove the car at present but hopefully will resume my updates next month once the new house type stuff has settled down.

Ian
14-06-2013, 06:57 PM
Done any more work on this recently? Any more updates?



Do you know exactly what type of calipers your front Wilwoods are? I have the same ones waiting for me at home and I want to order pads for them but I am not 100% sure which pads fit, I know they are 4 pot forged superlights but they don't seem to appear on the wilwood site anymore.


I want Hawk HP+ pads because they work really well on my civics setup (apart from loads of dust) so I think these are the correct pads, can you confirm?

HB101.800 - Wilwood LC-GT, Superlite II & Superlite III LC-GT - Cambridge Motorsport Parts (http://www.cambridgemotorsport.com/HB101800---Wilwood-Calipers)





What pads are you using on yours now?

Ian
19-11-2013, 09:53 PM
Hows this going Darren?


Also, your inbox must be full as I tried to send you a PM but it won't go through.