scotty-2-forty's Never-2-Late Build Thread (56K beware)

[scotty-2-forty]

I made my first post as a noob back on September 4th, 2002 in which I sought recommendations regarding muffler replacement. Yep, typical first timer question! I was brought up in the V8 crowd and modified many cars with my father. High performance 4-cylinders were something I needed to learn more about. Fortunately, I had been surrounded by extremely knowledgeable people in the few years prior to acquiring this 240SX. Anyway, throughout the years during my build I posted many pictures and I’ve had many inquiries but really never had an organized/official build-thread as NICO did not have this back in the day. So here’s the breakdown of my build probably lacking in some smaller detail due to memory lapse such as dates, but pretty much in order spanning the greater part of two years. While I do have future plans for this car, I am not including them as this is an up to date build spec.

Virgin Spec:
1996 Nissan 240SX SE – KA24DE, circa August 2002, found on a CarMax lot; untouched/unmolested and bone stock … Aw, just look at her.


Plans:
Retain overall stock body look, beef-up suspension and stance (or should I say down?), full-blown custom turbo the 2.4 liter KA. No thought whatsoever about swapping the KA for the SR. Goal = Fun street car and awesome 1320 ride!

Original Build List:
(** = updated/changed since original build; see updates way down below) Oh, and my deepest apologies if this doesn’t match up to the almighty JDM expectation ...

- KA24DE valve cover, polished
- KA24DE head race port/polish and gasket matched and cryo-treated
- JWT cams (.390L/275D)
- JWT adjustable cam sprockets
- Chrome-silicone dual valve springs w/ titanium retainers & custom seat locators
- REV Stainless steel valves (oversized intakes)
- ARP Head studs
- Cometic HP multi-layer metal head gasket **
- KA24DE engine block honed, blueprint & balance (crank, pistons, rods, flywheel & pressure plate)
- CP pistons (8.5:1)
- Wiseco piston rings
- Pauter forged rods
- Top Line rod and main bearings
- ARP Main studs
- Oil pressure regulator shimmed
- Oil pan modified for return and temperature gauge
- GReddy T67 compressor w/Mitsubishi 25G turbine
- Blitz blow-off valve (cold side)
- HKS blow-off valve (hot side)
- HKS race waste-gate
- Custom intercooler piping silver ceramic coated
- Custom down-pipe and extension, high-temp black ceramic coated
- Custom equal length exhaust manifold, high-temp black ceramic coated
- Custom large FMIC w/modified end-tanks
- Koyo aluminum radiator
- Flex-a-lite dual 12" electric fans **
- KA24DE OEM intake manifold ported & polished
- K&N cone filter
- GReddy oil catch can
- MSD ignition w/modified distributer **
- GReddy eManage piggyback ECU **
- Custom fuel rail
- High-pressure SS braided fuel lines
- Custom fuel injectors
- 300ZX turbo fuel pump
- Aeromotive fuel filter
- SX fuel pressure regulator w/FP gauge
- ACT Xtreme pressure plate
- JUN chromoly flywheel (modified for step height)
- Custom 4 puck ceramic "double-sprung" hub clutch disc
- Infiniti J30 VLSD
- APEXi GT Spec stainless steel cat-back (95mm (3.74 inch) mandrel bent w/115mm tip)
- SafeCraft 10lb Halon on-board fire extinguishing system
- RCI transmission blanket **
- Lakewood driveshaft loop
- Taylor aluminum battery box
- Optima redtop battery
- Tein HA coilover system (16 way adjustable damp)
- Tein pillow ball upper mounts
- Tein adjustable camber plates (front)
- Whiteline rear sub-frame suspension bushings
- Whiteline front and rear control arm bushings
- Cusco OS front strut tower bar
- Goodridge stainless steel brake lines
- OZ Racing Futura Modular 17x8 three piece wheels (front) **
- OZ Racing Futura Modular 17x10 three piece wheels (rear) **
- Ventura tires, 235/40R17 (front)
- Marshall Power Racer II tires 275/35R17 (rear) **
- Custom fiberglass eyelids
- Kouki side skirts
- Kouki tail lamp assembly
- Stripped decklid badging
- Cut out crosshair in center of front bumper cover
- Autometer Phantom boost gage **
- Autometer Phantom air/fuel ratio gage **
- Autometer Phantom exhaust temp gage
- Autometer Phantom oil temp gage
- Autometer Phantom oil pressure gage
- Autometer dual A-pillar pod
- Custom 3 pod gauge bezel below head unit **
- HKS Turbo Timer II **
- APEXi AVC-R boost controller **
- B&M T-shift knob **
- MOMO Millennium steering wheel
- MOMO Grand Prix pedals
- MOMO real leather shift boot
- Katzkin leather interior w/matching door inserts; dark graphite w/pearl centers


The Pics:
- KA24DE valve cover, polished


- KA24DE head race port/polish and gasket matched and cryo-treated





- JWT cams (.390L/275D)


- JWT adjustable cam sprockets




- Chrome-silicone dual valve springs w/ titanium retainers & custom seat locators


- REV Stainless steel valves (oversized intakes)


- ARP Head studs


- Cometic HP multi-layer metal head gasket **




- KA24DE engine block honed, blueprint & balance (crank, pistons, rods, flywheel & pressure plate)



- CP pistons (8.5:1)




- Wiseco piston rings

- Pauter forged rods



- Top Line rod and main bearings

- ARP Main studs


- Oil pressure regulator shimmed

- Oil pan modified for return and temperature gauge


- GReddy T67 compressor w/Mitsubishi 25G turbine



- Custom equal length exhaust manifold, high-temp black ceramic coated



- Blitz blow-off valve (cold side)


- HKS blow-off valve (hot side)


- HKS race waste-gate


- Custom intercooler piping silver ceramic coated
- Custom down-pipe and extension, high-temp black ceramic coated
- Custom large FMIC w/modified end-tanks


- Koyo aluminum radiator



- Flex-a-lite dual 12" electric fans **



- KA24DE OEM intake manifold ported & polished


- K&N cone filter


- GReddy oil catch can


- MSD ignition w/modified distributer **

- GReddy eManage piggyback ECU **


- Custom fuel rail
- High-pressure SS braided fuel lines
- Custom fuel injectors
- Aeromotive fuel filter
- SX fuel pressure regulator w/FP gauge



- 300ZX turbo fuel pump



- ACT Xtreme pressure plate


- JUN chromoly flywheel (modified for step height)


- Custom 4 puck ceramic "double-sprung" hub clutch disc


- Infiniti J30 VLSD




- APEXi GT Spec stainless steel cat-back (95mm (3.74 inch) mandrel bent w/115mm tip)




- SafeCraft 10lb Halon on-board fire extinguishing system



- RCI transmission blanket **


- Lakewood driveshaft loop


- Taylor aluminum battery box **



- Optima redtop battery


- Tein HA coilover system (16 way adjustable damp)
- Tein pillow ball upper mounts
- Goodridge stainless steel brake lines


- Tein adjustable camber plates (front)


- Whiteline rear sub-frame suspension bushings
- Whiteline front and rear control arm bushings


- Cusco OS front strut tower bar


- OZ Racing Futura Modular 17x8 rims (front) **
- OZ Racing Futura Modular 17x10 rims (rear) **
- Ventura tires, 235/40R17 (front)
- Marshall Power Racer II tires 275/35R17 (rear) **



- Custom fiberglass eyelids
- Cut out crosshair in center of front bumper cover


- Kouki side skirts
- Stripped decklid badging


- Kouki tail lamp assembly



- Autometer Phantom boost gage **
- Autometer Phantom air/fuel ratio gage **
- Autometer Phantom exhaust temp gage
- Autometer Phantom oil temp gage
- Autometer Phantom oil pressure gage
- Autometer dual A-pillar pod
- Custom 3 pod gauge bezel below head unit **
- HKS Turbo Timer II **
- APEXi AVC-R boost controller **



- B&M T-shift knob **
- MOMO real leather shift boot


- MOMO Millennium steering wheel
- MOMO Grand Prix pedals


- Katzkin leather interior w/matching door inserts; dark graphite w/pearl centers





Updated/changed items since original build:
- Cometic HP multi-layer metal head gasket – Also o-ringed block
- Flex-a-lite dual 12" electric fans – Motors went bad; went back to OEM clutch-fan set-up
- MSD ignition w/modified distributer – Axed in favor of stand-alone management; covered distributer hole with XS Engineering plate



- GReddy eManage piggyback ECU – Replaced w/ EMS 8860 stand-alone engine management system


- RCI transmission blanket – Actually never installed; still new on my shelf (I’ll get to it)
- OZ Racing Futura Modular 17x8 rims (front) – Replace w/ Rays Engineering Volk Racing GT-7 17x8
- OZ Racing Futura Modular 17x10 rims (rear) – Replace w/ Rays Engineering Volk Racing GT-7 18x10
- Marshall Power Racer II tires 275/35R17 (rear) – Replaced w/ BFGoodrich g-Force drag radials 275/35R18







- B&M T-shift knob – Replaced with Momo
- Custom 3 pod gauge bezel below head unit – Removed exhaust temp; relocated to ashtray location
- HKS Turbo Timer II – Replaced with GReddy full auto turbo timer
- APEXi AVC-R boost controller – Replaced with GReddy PRofec Type-S boost controller

[Touge_Drifter]

Nicely done. Liking the build

[breadbox]

Very nice.

Can ask what the true purpose of a transmission blanket or whatever it is?

[laxands13]

dude, its so overwhelming to see all the changes you made in a couple years in one post. Or was that just the first time you built it and im interrupting your posts? lol. You must work hard though, thats all quality stuff!!'
Oh and im sure im not the only one wondering, what kind of power do you make?

[OutToWinPAHC]

Very nice.

Can ask what the true purpose of a transmission blanket or whatever it is?

NHRA / IHRH requirement

[breadbox]

And its actual original purpose? Is it like a flak jacket if your trans explodes? Or do governing bodies just want to keep your transmission warm and cozy?

[OutToWinPAHC]

Its for explosion where a shield is not practical. They are also not required for engines in certain classes. Blankets are only approved for auto-transmissions, but doesn't hurt to have. A scattershield is required for a manual.

[breadbox]

Hmm, good to know. Thanks PAHC.

[scotty-2-forty]

Very nice.

Can ask what the true purpose of a transmission blanket or whatever it is?

Kevin pretty much covered it ... For this car it's more about peace of mind and safety. I have seen high revving flywheels fly appart and go straight through the transmission housing, not to mention the thin sheet metal between your legs and that housing. This is also why I refused to have a flywheel "lightened". I have blankets on other cars, and had a custom 1/4 metal scatter shield built for a car we ran back in '99-02. I never got around to installing the blanket because I had though about having a shield made; really not an excuse (for me) ... eh, whatever the case, I need to do something for my own sanity. Eye witnessing an explosion like that aint pretty.

dude, its so overwhelming to see all the changes you made in a couple years in one post. Or was that just the first time you built it and im interrupting your posts? lol. You must work hard though, thats all quality stuff!!'
Oh and im sure im not the only one wondering, what kind of power do you make?

Hehe, yeah it's confusing I guess. The "original build" happened within the course of the first two years after I bought the car ('02-04). The changes and updates happened pretty much between '05 to '10. I have no dyno sheets; I don't even know what happened to them. The skinny is that it made 502whp/495ftlbs on 26-28lbs boost back in '04. Ran 10.53@130mph at Moroso (now PBIR) ... it will always be Moroso to me though. I had a few complications before those numbers though, in that after a few initial dyno passes I had the head mushroom, leading to disassembly and reassurance that the head didn't warp. I also went through two Cometics until having the block o-ringed. I honestly think the engine is capable of more boost, but I'm super reluctant at this point. One divorce, change of job and 3 aging kids will take a toll on your wallet.

[scotty-2-forty]

Nicely done. Liking the build

Thanks! It's by no means done though ... I call it a temporary hiatus.

[Amays U G37S]

Scotty and his two forty are mega hotties!!!!!!!!!!!

Drift vids or track times are a must, Scotty!!!!!!!!!!!!!!!

[scotty-2-forty]

Scotty and his two forty are mega hotties!!!!!!!!!!!

Drift vids or track times are a must, Scotty!!!!!!!!!!!!!!!

Yeah, not a drifter and no vids. ... one day.

[s13sickboi]

Love your car Scotty!

[Gabes13]

Woot, FLORIDA!!!

[Amays U G37S]

I really love your car tho, I would just darken the windows. Looks really good man, awesome whp goals as well. Your interior looks really good, very unique. Definitely turns heads. Awesome work man, For Sale?

What are your future plans? Turn up the boost? Will it see a track? I didn't see mention of a manual boost controller, are you going to run one?

Its 500whp right?

[420sxWETDREAMS]

good job way to keep it KA-T

[costa_rican13]

i will be personally messaging you for info and nooby questions when i start my ka-t. reason being your motor looks sick.

[mixeds14]

thats a bad a$$ ride man.... loving the clean look on it.. its like the ultimate sleeper in my book..

[DanThaMan]

your car has always been one of my favorite s14s on here, super clean man! props to you

[scotty-2-forty]

I really love your car tho, I would just darken the windows. Looks really good man, awesome whp goals as well. Your interior looks really good, very unique. Definitely turns heads. Awesome work man, For Sale?

What are your future plans? Turn up the boost? Will it see a track? I didn't see mention of a manual boost controller, are you going to run one?

Its 500whp right?

Funny you mention darker windows. If you look at the earlier version of the car, I had the windows tinted. Eventually some of the tint was bubbling, so I removed it all and haven't got around to getting them redone. It's not my DD anymore, so right now it's not a neccessity. But believe me in south Florida it's a must!

As for selling the car? Hmm ... no. Not for sale.

Future plans? Oh I got'em - Everbody's got'em! Strapped for $$ right now, so they'll have to wait. But ..... as for turning up the boost? No, probably not - it's not an experimental car anymore and I'd like to keep my investment within the safety boundary for now. The only track it sees is the 1/4 mile. The old boost controller, the APEXi AVC-R was replaced by my current GReddy PRofec Type-S boost controller. And yes, that was 502 wheel HP. On with the plans:

- TIRES! I NEED TIRES! Drag radials aint cheap for 275/35-18's ... and rare!
- Upgrade brakes to either StopTech (or the like)
- Rollcage (whether a 6-point or more of a harness bar I'm yet to decide on)
- Simpson 5pt harnesses (I've had an extra set new in a box for the past 10 years; a bit past their expiration date, but it's not a competition car; most likely won't use the 5th point)
- Seats (front) will be tossed for Momo, Cobra or Bride - which ever strikes me at the time I'm ready. I've had Cobra Sidewinders before; nice seat!
- Aluminum one piece driveshaft
- Intake manifold (Xcessive or Godspeed - have to research both still - Maybe custom)
- Coilovers (undecided if I'm keeping the Teins; might just explore springrates)
- Might scratch the driveshaft and intake altogether for some sort of "major" engine swap

And thanks guys for all your comments!

[scotty-2-forty]

So, I got my new battery and the battery box relocated. In moving it from the side of the trunk to the center where the spare was, I also took time to level out the floor below the tray. I used the ever so handy expanding foam and trimmed it neatly ...

From:


To:







... it is vented via a tube running down the backside through the floor. I'm going to make a new fabric cover to replace the OEM one. Should give the battery box a 'sunken' look.


I'm also installing a few things I found deep in boxes I had from years ago on one of my race cars - a bunch of Autometer gages and my Smart Racing removable steering wheel adapter. Cool part is, the tach and speedometer were never used. I had them in a mock-up dash; but they didn't get used:








So far, this is what I've done with the gages. I fabricated an aluminum plate, trimmed the OEM bezel just a hair to flatten the backside a bit, and rivited the plate on. The fuel gage and oil temp gage will go down below the radio where the other existing two are now. I need to get a matching oil temp gage as it's the only one in the A/M Ultra Lite silver I don't have:






... they are not operational yet (no I wasn't doing 100mph in my garage). That's my son in the passenger seat - he's starting to be a good helper! Sometimes I want to punch him though ... his singing is horrible!


And I got creative with the hood emblem. Took it off, sanded it, sprayed it ... Now it looks like brushed aluminum w/black accenting:




Oh, and I found my time slip from back in the day!



One last thing - What do you think of the shift knob? I had this one (in my hand) installed when I originally got the Momo steering wheel. It matches nicely, but I like the feel of the round Momo ... stupid little things ... they drive me insane! Yes, for those who remember, I took out the T-handle:

[terry_240sx]

that idea about the emblem is super nice!
clean s14 btw

[OutToWinPAHC]

I like your bezel, but I don't see any indicator lamps. Also what fuel level sensor did you use. I use my fuel cell so I use a 0-90 but I though Nissan was 0-full and 270 empty.

[scotty-2-forty]

I like your bezel, but I don't see any indicator lamps. Also what fuel level sensor did you use. I use my fuel cell so I use a 0-90 but I though Nissan was 0-full and 270 empty.

Thanks Kevin! Hehehe, indicator lamps ... the bezel has been a gradual work in progress the past week when I've had time. I've been finding some spare parts here and there in the garage, so I'm trying to use what I have. I took those pics real early, before doing some other work to it. I already installed 12V LEDs for the signal indicators, and also incorporated my Autometer Quick-Lite. I had to make a sturdy bracket for the tach light in order to retain a clean look from the front. The Autometer A/F gage is not wideband, which is what the AEM one is, so I'm keeping that one in (though today I sprayed the outer ring silver, so at least it's a close match). Also, that original pic shows a water temp gage that is mechanical, so I'll be replacing that with an electronic one. I need to disconnect the oil temp sensor from the pan in order to run the gage through the new bezel, at least until I can upgrade that one to an electrical unit. A lot of stupid work for something so simple, but it'll be pretty clean afterwards. And I really haven't given thought to the fuel gage yet, so that in-and-of itself will be another task. Both the water temp and fuel gages are going down below the radio. Anyway, today I soldered up some extension wires behind the bezel; didn't have coordinated colored wire, so it pretty much looks like Disney World threw-up. I also rerouted my positive battery wire through another grommet on the firewall and also gained some slack back by the battery box which I needed. It's amazing how fast time goes ... I feel like I got nothing done. Here's a few pics from today:

[scotty-2-forty]

that idea about the emblem is super nice!
clean s14 btw

Thank you!

[badbob2121]

aweseome build... kudos

[EnjoiNismo]

Damn nice work scotty!

[KC224]

Love your car, nice build!

[scotty-2-forty]

Thanks for the compliment(s) ... Just an update - I ditched the gauge install (for now) and re-installed the factory cluster. The way I want to do it requires a few more purchases that I can't afford at the moment and I just wanted the dash back together.