S15 conversion complete. Problems I ran into.

[Tr0uble]

DIY S15 Silvia Front End on 89-94 240sx (S13)

I completed my S15 conversion on my S13 after 2 days of work.

Ran into a few problems along the way.

Parts used:-S15 Oem Urethane Bumper-S15 Oem Steel Fenders-S15 Core Support-S15 Oem Style Seibon Carbon Fiber Hood-S15 Oem Headlights-240sx Oem Steel Fender

S15 Core support installTrip to parts store (purchased cobalt drill bits & air hammer )I removed the S13 core support and attempted to install the s15 core support. I went in to this with the mindset of everything being just about bolt on with some minor mods. WRONG!Bumper core support will need to be altered to allow the S15 Oem Bumper Cover to fit. Easier to get a welding shop or yourself to fab up a new one with some steel. (Summit Racing carries a spot weld remover bit which helps alot.)

*Note: Most of the problems with installation can be avoided if you use only the top half of the S15 core support and weld that to the car and the bottom half of the s13 core support. Or Just use 180sx headlight brackets, a dremel to cut holes for the headlights and patience to properly align the headlights.When removing the 240sx core support your tensioner rod brackets will most likely shift backwards. This could possibly be due to the weight. It may help to lift front end off the ground by crossmember or jackstands under rockerpanels.

The bottom section of the S15 core support is slimmer than the S13 core support. So don't be alarmed if it doesn't weld in exactly where the old one came out.

Next - Tension rod bracket will not bolt to the s15 core support for 2 reasons; bracket will not reach the bolt holes. Bolt holes on the support are farther apart than the holes on the tension rod bracket Fixed by pushing the s15 core support farther back and also wallowing out the holes on the tension rod bracket. Also FYI old tension rod bracket bolts will not fit,(14mm) too small. Had to buy 17mm bolts. sigh.....After you attach the tension rod brackets to the core support you need to pull the bottom of the core support and make the brackets shift back forward to original position. Ram Jacks can be used or a simple rope to the tree. See my pics.

Pull each side one at a time until the bumper support holes line up and put the 14mm bolt back in there. (Don't put on the bumper support just put the bolt in the hole). After both sides are done you can weld the core support the the frame rails only at this point. Upper adjustment still needs to be done for fenders and hood.

S15 Hood InstallFirst off the S13 hinges doesn't work at all.I searched and searched online for a place to buy s15 hinges with no luck.The Nissan Parts Dept. in Cali imports various JDM Nissan parts from the Japan Nissan regulary. Intensepower.com could get ahold of some S15 hinges if you called them since they deal with the Nissan store regularly.S14 hinges will work. Not sure how much better the S15 ones would be.

Come installation time no surprise the hood is unable to be mounted using the stock hinges from my car.2 choices modify/fab s13 hinges cut weld etc etc to make them work, or check on a rumor of s14 hinges working.Trip to salvage yard.Found a 95 240 with the hinges still in place. Removed, purchased and went home. They looked similar to pictures of s15 hinges. For me they lined my hood up using the front hinge bolt hole on the rear bolt hole of the car.However with the s15 core support in place the hood cant close, hence the reason not to weld the top half of the core support yet. Adjust the core support until it closes properly and clamp the core support in place to be welded. Playing with the 3 bolts that hold the hood latch to the core support will get you some adjustment out of it as well. Weld in place. Also the S13 hood prop no longer fits. Get S15 Hood prop or order hood struts. Tein and Cusco both make them along with various other companies.*cheap fix= put s13 hood prop in vise and bend it in a couple places to make it fit in the s15 holder.

S15 Oem Steel Fender InstallThese fenders need to be cut and welded (converted) to fit the car.Below are pictures of the cut/welded fenders courtesy of RPS13.5Notice where marks were made to help alignment during cutting/welding.1. Side view of where sections are cut and welded together.2. Close up of lower half of the weld.3. Top view of hood and fender section near windshield.4. View of Side from another angle.5. View of alignment for front.6. Process Finish.

S15 Headlight InstallNo instructions, no plugs, no bolts.....Found a wire diagram, No plugs off any of my spare harnesses fit the headlights. Basically either make your own plugs (Summit Racing sells materials) or go to Nissan near you and get a list of plugs that fit the S15 headlight. Take that list to your nearest salvage yard and go cut them off yourself and splice them into your headlight harness.Here's wiring diagram courtesy of Yoshi.

If you want to help strengthen the front end you can also check with Intense power to see if they can get ahold for you the bracket that supports the bottom of the headlights. S15 Headlight Support Bracket (this one runs horizontal, don't let them confuse it with the s13 brackets that run vertical to the core support) This OEM Support helps to strengthen the portion where the bumper attaches as well as supports the lights. Without these ordered from japan the bumper will only be held on with 4 bolts and 2 plastic fasteners. 2 on each side and 2 on the core support.

S15 Oem Bumper install(Oem Fenders come with hardware{screws, fasteners, plastic ancors})Pretty easy install. Push the plastic bolt ancors into the square hold on the underside of the fender and bolt the bumper to the fenders. Put the 2 plastic fasteners in to attach the bumper the headlight bracket.

In my opinion if anyone is planning on doing the conversion spend the money on the metal fenders, take your s13 fenders & s15 fenders to body shop, have them cut both of them in half and weld the s15 front portion of fender to rear portion of s13 fenders. This is the proper way to do the conversion without all the rest of the headache. Also DON'T use the S15 core support. Instead use 180sx Headlight brackets. S15 core support is a little lighter, but your car will be weakened, and will run into alot of problems with alignment. Wish I would have done it that way. And STAY AWAY FROM EXTREME DIMENSION!! I tried to return the fenders. However, I would have had to pay shipping costs to return and shipping costs to receive another set which probably woulda been the same. Friend of mine ordered about a week after I did and when he got his they were the same effed up mold mine was from. Shipping btw was over 90 bucks due to freight shipping. They dont even fit properly around the headlights.... And I KNOW the headlights arent deformed .

Finished ProductHope this information helps.

Modified by Tr0uble at 3:55 AM 9/24/2007
Modified by Tr0uble at 3:59 AM 9/24/2007

[180fan]

the s15 hinges could have been sourced from phase2 or jspec.

the fenders, yeah you get what you paid for. I've seen kazama fenders from superior line up just about perfect on the s13's. pretty penny though, about 500-600 for a pair with plenty of time needed to order em.

Otherwise awesome write up.

[RPS13.5]

I do weld S15 oem fenders for $200 plus shipping, and forget about fiberglass. OEM is the best let me know if you itrested.

[Tr0uble]

All info segmented and added to original post.
Modified by Tr0uble at 2:09 AM 4/25/2007

[RPS13.5]

Thats a good price for the fenders in your area. I have to say that I am located in the BAY AREA CA. everything is expensive here; I am just going to the flow, and this is cheapest you can find here in NOR CAL. Especially I am using TIG weld not MIG. I had done one using S15 RAD. core support, and the rest are S13 & S14. What I did is using the Top HALF part only for the S15 RAD. Core Support which I read from a Japanese Car Magazine.

[Suicide.Veteran]

rofl at money and time spent!

*goes back to money pit engine*

[redtop91]

rofl at money and time spent!

A lot of work for cosmetic purposes. I'll pass.

[RB260sx]

hope this help ya http://www.360realms.com/S13-S15/

http://www.cardomain.com/ride/2346356/5

[Tr0uble]

All info segmented and added to original post.
Modified by Tr0uble at 2:10 AM 4/25/2007

[RB260sx]

first link shows how you can adjust the fenders buts since your getting metal. i just thought first link might help you out if theres any info you might need, guess not. second link was my car when i did a conversion b4 i did a rb swap, that link will be updated soon

[MagikDragon]

I did mine a little different, but my car was totaled, relocated the stock hood hinges with grade 8 boltsrelocated the hoodmounting bracket on my s15 core supportwelded my core support to the Power BraceWent to Nissan for a list of connectors that fit the s15 headlight connectorshad a body shop work my fenders...

I know it wasn't the greatest job in the world, but it functions properly..

[RB260sx]

is your fender metal?

[MagikDragon]

nope fiberglass

[KiLo64]

Hey Tr0uble, do you have any pictures of your installation? How far out are you from the city? I'm having RPs13.5 weld my fenders for me soo fitment won't be a problem. DID YOU SEE HIS s13.5?!?! ITS DAMN SEXY . Anyways back on topic, Is there any way to keep the s13 bumper support for the bumper? WHered you get your oem bumper?

[MagikDragon]

I fabbed up a bumpersupport out of 2 inch box, and some styrofoam insulation..

[Tr0uble]

All info segmented and added to origninal post.
Modified by Tr0uble at 2:11 AM 4/25/2007

[RB260sx]

when i did my s14.5 conversion, i custom my steel reinforcement by hacking it and reweilding it to make it fit the frontend bumper. also i shaved down the foam to stiffing it. thats what conversion are made for.

[mwilloughby]

im doing this conversion as well and just finished getting my headlights and hood on. started some fiberglass work on the fenders since i didnt want the sidemarker. i havent mounted the fenders or front bumper yet, but the fenders seem to line up decently well, but the bumper will need some trimming on the opening part in order to clear the intercooler. the wiring on the headlights was quite easy on my 95. just a little splicing, but i used 2 of connectors off of the stock s14 front end and they fit perfectly. i just had to change which wires the actual plug was connected to. i believe it was the accessory lights plugged into the low beams on the s15 lights, and i forget what the other one was.

[Tr0uble]

All info segmented and added to original post.
Modified by Tr0uble at 2:12 AM 4/25/2007

[mwilloughby]

there should be an adjuster knob

[driftneil]

instead of having the hinges welded, the 95 240 hood hinges fit the s15 coversion. all yo have to do is space the hood latch bout a 1/4 inch

[yelnatsch517]

Dude, find your camera already!!!



So how much did you spend total on everything and where did you get the parts from?

[Tr0uble]

All info segmented and added to original post.
Modified by Tr0uble at 2:13 AM 4/25/2007

[Tr0uble]

[All info segmented and added to original post.
Modified by Tr0uble at 2:14 AM 4/25/2007

[Tr0uble]

I did mine a little different, but my car was totaled, relocated the stock hood hinges with grade 8 boltsrelocated the hoodmounting bracket on my s15 core supportwelded my core support to the Power BraceWent to Nissan for a list of connectors that fit the s15 headlight connectorshad a body shop work my fenders...

I know it wasn't the greatest job in the world, but it functions properly..

Think you could get a picture of your power brace where you welded it to the core support?

[TRBOMOFO]

[QUOTE=yelnatsch517]Dude, find your camera already!!!



QUOTE]

AMEN

The hood hinges got to be cut off and rewelded back on to match the S15 hood

Your going to have to knix the bumber support (dont wreck)

and three ALL and i mean ALL fenders for the S13.5 fender conversion are sh*t you will have to make it work with some mad body work

i still got alittle gap on my driver side headlight where the fender and bumber dont sit flush against headlight (gay) but i will get it to work sooner or later (got tired of body work i jsut wanted to drive the car)

[TRBOMOFO]

you can see the lip i got next to my headlight where i cant get it to flow quite right yet

[mwilloughby]

Have you even held a set of S15 Headlights? There is no "adjuster knob".Only adjustment you can get out of the headlights is via 2 bolts. That's right only 2 bolts hold the S15 Headlights onto the S15 core support. And these allow for a maximum correction of only 3/8 of an inch up and down, 1/4 inch left or right. However, if you move the headlight to the left or right you must do the exact same with the other headlight since the bumper bolts to the headlight bracket with the little plastic hardware.

no adjuster knob? so youre telling me the knobs on my headlight where i stick a screw driver in and turn left or right to adjust my headlights arent adjusting it

and yes i have held a set in my hands. actually i have them on my car. i used the s14 support that was on the car and i have 4 bolts supporting mine to the car

[Tr0uble]

All info segmented and added to original post.
Modified by Tr0uble at 2:15 AM 4/25/2007

[mwilloughby]

on the back of the headlight there should be 4 on each, where you can stick a screwdriver in and turn it clockwise or counter clockwise to adjust the beam pattern its on the back of the headlight. ill take pics today once i get out of class. but actually i have 5 bolts supporting each headlight to prevent them from moving. it might be overkill, but nevertheless they arent moving at all