IM BACK!!! Fenris's New Build

General discussion forum about the 240sx, and a great place to introduce yourself to the board!
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Fenris
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Car: 2011 Subaru WRX
1989 Nissan 240SX
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My old project, Sold off to fund college in '08:
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The new hotness:
1989 240SX SE Hatch,
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The Goal:
2011: Auto-X/Time Attacker as well as semi-reliable commuter
2012: Auto-x/Time attack serious contender.

Came with:
175,xxx

HKS Exhaust
180SX Diff
Kouki tails
Nardi Wheel
Q45 Brakes
180sx chuki side skirts
MagnaFlow cat
4-2-1 header
STK adjustable Tension Rods
Circuit Sport Rear Toe Rods
Intense Power RUCA's
New water pump
New Thermostat
New alternator
Optima Battery
SPL braided stainless steel Clutch line

All very nice.

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Issues:

Rust, a fair amount of it.
PS leak, pretty bad.
Cracked radiator.
Interior dirty
some wiring issues
Sitting on SE wheels with no tread
(makes it interesting to drive onto a trailer in the snow)

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The Build!!!

Freshly in my garage.
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Fenders stripped and new wheels test fit.
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17" Elbrus 105's (17x7.5) wrapped in Hankook 205/50R17 V12 K110's

Parts!
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Interior stripped:
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Found: 3 dead mice, one snake skin, and random ground wire for an amp, pile of half eaten acorns. As well as... cancer.

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New parts inbound:

PS Pump
PS Rack
Energy Suspension Steering rack bushings
KYB Shocks
PDM Superior Sport Springs
Greddy Strut tower bar
New engine belts


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bigbadberry3
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Had rust in the same exact spots. Under the pedals is annoying to get at just cause of the area. the passenger side isn't bad at all though :)

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Fenris
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1989 Nissan 240SX
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Update:

More of the wheel testfitting

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Was told that the radiator was cracked so i got to work on that.

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Then i started finding loose things.

SO! Can anyone tell me what these are:

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Then i found this broken thing on the side of the block....

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Hmmm.... old rad was a koyo... and i cant seem to find a crack, will have to have someone look at it...

All cleared out
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Fenris
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1989 Nissan 240SX
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update: Broken mount was the AC compressor, or lack there of....

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Fenris
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1989 Nissan 240SX
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Update:

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New PS pump and PS rack :D

laxands13
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Car: 93 240sx Hatchback - Sold and missed
80 280zx - sold
83 Honda Civic Wagon - Current DD, soon to be CA16 powered
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Nice dude, i really like it. That rust is crappy though, whatn are you planning on doing for that?

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Fenris
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1989 Nissan 240SX
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Have a shop cutting it out and welding new in. Will be fresh and new.

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PapaSmurf2k3
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Car: 2017 Corvette, 2018 Focus ST, 1993 240sx truck KA Turbo.
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I was gonna say, all those random wires and absence of stuff on the side of the block looks like AC related hardware.

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Fenris
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1989 Nissan 240SX
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could the loose pigtail in the front be related?

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Fenris
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1989 Nissan 240SX
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Update again!!!

Remember:
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??

Prep work for some cuttin and weldin:

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Still needs to be cleaned up but its coming along nicely. Would be easier with dry ice if i could find the stuff, but stubbornness and elbow grease can go a long way.

Driverside will be done tomorrow :D
And maybe i can get the high pressure line off the ps pump. Darn thing wont come off.

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PapaSmurf2k3
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Yeah... I don't know if they changed from the pignose to the DOHC, but I think mine had 2 connections going to it somewhere. One went to the AC fan, and I think one to the evaporator or something... I can't quite remember completely though, I pulled mine in like, 2002.

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Fenris
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Update:

Pulled the header out today, having a buddy deffo makes this easier. Interesting bolt setup.. but eh.

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Now just a bit more sound deadening to remove before its ready for the shop of goodness.

Oh... and this came to my door today....

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What could it be?

Perhaps....

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My new KYB GR2's woo! Now the springs just need to get here from Canada-land.

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Fenris
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1989 Nissan 240SX
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Another update!:

More parts came in today!

My PDM springs and Greddy strut tower bar.
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Re-installed my kouki tails as well as the lock bit. either i did it wrong... or it no fit good... come to think of it, i think i did it wrong lol, as it sits rather sunk in.
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Then i have to rewire them.... will do that at a later date after studying some wire diagrams...
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Fenris
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Update kinda:

Car is back with the fine folks at Fuji SPL, getting its much needed cancer treatment.

Big shout out to Tom, James, and Will.

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Fenris
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While the chassis is away getting cancer treatment figured i would work on the fenders and hood. Paint was peeling and mismatched so i figured i could at least make it match. Hopefully its the same as the body :D looks pretty close.

I also hammered and bent the fenders back into shape, should fit much better now.

Then i ran outta primer lol, will have to pick up more.
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Hood was sanded, primed, sanded, primed, sanded then painted a semi gloss black. Hoping for a sylish-ish low glare option as i drive into the sun in the morning and into the sun after work on my daily commute.

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Fenders are in the process of being primed, until i ran outta primer lol...

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Fenris
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Fenders have their first coat of red:
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I also decided that just a flat black hood was boring, so i spiced it up with some awesome. The paint was still wet, and it is gloss so it will always shine up in a pic.
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Fenris
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bah wont be any updates for a while, garage space got commandeered till early next week. And fenders need more coats! -shakes fist-

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Fenris
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Back in the hanger and back to work.
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She has returned to me from Fujii and they have worked their magic.

Before:
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After:
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Before:
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(That pic doesnt do justice to how much was rotted away really)
After:
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Also the rear rocker on the drivers side was pretty much gone, now, its sexy:
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Also, new powersteering pump and belt installed.
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And old yucky shocks/springs were yanked.
PB blaster is my friend.... Seriously.

To-Do List:

Yank Power steering rack and replace with new one
Refill PS Fluid and bleed.

Install new radiator + fluid + bleed

replace brake fluid + Bleed

reinstall header

Reinstall fenders/bumper/hood

reinstall interior

Drive :D

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Peach.
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:popcorn:

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Fenris
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Been a while with no update, but ive been busy.

Hard to remember to take pictures when you are up to your arms in 240sx...

Further details to come.

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>:D

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PapaSmurf2k3
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How much did the weld shop end up charging you? I can do all the hidden stuff myself, but my rocker panel is pretty much gone, and I probably wouldn't be able to do as good of a job as a specialty shop.

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Fenris
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Work cost ~650, got basically a new driver side foot well, passenger floor under the seat, front frame rails and running board on the drivers side. Then painted and undercoated. Very top notch work and would recomend the guys at Fujii any time.
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Took it outside today for some photo's

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So, since the last update:

Shocks + Springs installed
New PS rack and pump installed
New OEM bolts+hardware to attach hubs and shocks
header installed with all new gaskets and ARP hardware
Interior steam cleaned, better but not perfect.
New OEM style outer tie rod ends.
Chuki bumper reinstalled as i couldnt for the life of me get my piggy bumper to fit.

Things on the todo list:
Proper alignment
install new oem reverse sensor
bleed brakes
new windshield
figure out a horn button
figure out my CEL.

Register then cross my fingers for an inspection sticker.


Daily and weekend in harmony:
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Fenris
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Figured out the CEL, Automatic ECU i put in didn't like not finding the transmission, learned this by swapping the manual ecu back in.

Now have a horn switch :crazy: Til i can track down a proper button. Works just fine but looks silly as all hell.

Bled the brakes only to find i have a leak in the passenger side banjo line. I'm hoping its just a bad crush washer or something and not a busted line.

Alignment is most definitely wrong, i can turn muuuch sharper to the right than the left.

But i did take it for a quick spin around the neighborhood.

>:D do like

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Fenris
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Introducing the latest craze in NYC the horn SWITCH! now you don't even have to press it down to keep it blaring! Or, the car i got didn't come with a horn button so i went MacGuyver on its a**. Take that inspection requirement!

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Also, since each sticker adds 30-50 HP, i must be rocking an extra 90 to the wheels with these babies!

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PapaSmurf2k3
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Fenris wrote:Take that inspection requirement!
:rotfl
F em! :chuckle:

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Fenris
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gah, no matter how much i bleed it, my ps fluid turns to froth, then it foams out of the reservoir and i have to refill and bleed it again >.>

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PapaSmurf2k3
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What are you using for fluid?

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OutToWinPAHC
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horn is epic

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Fenris
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Royal Purple Max ATF.
I bleed it for 45 mins, take a 5 min drive, pop the hood and fluid all over again.

New horn is indeed epic. Wish i had a button of some sort in my random electronic components box, all i had was that switch lol.
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New windshield today! :D
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Fenris
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Well.... I guess i forgot to update my thread..

============================================================================================ 8-6-11

figure out a horn button - done, had a switch there for a while, then got donated a proper button.
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Swapped the KYB's and Springs that were 4 months old for a set of coils, am now lower, and handle so much sharper, which makes it easier to dodge the potholes now.

Since last update, been on a few drives, KA24E is like a Steve Rogers pre-Captain America. It tries so hard, it give it all its got, then kinda falls on its face.

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At Wallis Sands beach north of Hampton, NH.

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One Swap meet in Holden Mass.

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Now then, the new stuff, and whats coming soon.

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Old School Volk's 16x7 and 16x8 Staggered.

But, as they are five lug, i also have a 5-lug set that needs to go on.

And the biggie, will be going in next spring or over the winter:

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Oil Cooler and remote oil filter block.

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Super JDM side mount intercooler. I am well aware of the benefits of a FMIC setup, but i plan on a more subtle sidemount setup, with a nice quiet recirc bov. Want to try and make this as sleeper as i can. As is, the hood will be getting a repaint in red, too many red/black civics in my area...

Also, sleepy co-pilot #2 Maggie the GSD.

Will be doing some custom ducting for the SMIC, or mounting a fan to it, or both.

Did more driving. Hit the Kanc with some friends.

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KA24E's and 9% grades, not the best of friends. Glad its SR time soon.

==================================================== 8-29-11

Well now, this build thread has certainly become a bit of a drive thread as the issues got hammered out.

The hood is red again, from far it looks great, but up close its blotchy and meh. It does its job for now, but will pull it apart and redo properly this winter. The Volk GR-C's look great on the car, and the new rear tires have more grip than a KAE can handle.

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Did some Auto-X This last weekend, my 240 is set to under-steer naturally right now, this gives it a little more predictability for road courses, but doesn't really help much in Auto-X. Brand new Yoko Advan AD08's in the back with toasted Hankook all seasons in the front means every hard corner is a push under-steer. But, after a few runs, and since i don't care about my front tires, i just went with it and used the under-steer to keep revs up. I beat the piss outta my KA and it loved it, no temp spikes rough running or anything, actually seemed to pull a little harder later in the day, or that could have just been me getting more familiar with the car.

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Up next in the handling department is certainly new front tires, but other expenses are all going to putting the SR in by spring.

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Have a flywheel for my SR20, parts starting to roll in...
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=========================================== 9-21-11

Pile of parts came in/were picked up today on project stockish sr20!
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Got an igniter from a Q45 at a U-pull yard, yard people didn't know what it was, so i got it for free :D, as i remember, this one is same part number as sr20 :D
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New DOHC dash cluster, so i can have a working tach~
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Turbo lines!
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CA18 injectors. My fuel rail is top feed and i have 720cc injectors, but im trying to get away without a tune at first so i needed something top feed and 370cc... CA18 it is.

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Mad rusty turbo elbow, but it is needed, will deal with rust at some point in coming weeks:

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Down Pipe of some aftermarket type, a little dented and scuffed but i cleaned it up a bit, will be getting some high temp paint to protect the metal.

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And last but not least, a supposedly great condition T25, we'll see.
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Oh, and last and certainly least... Stock intake pipe with spring thing!

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================================================================ 1-25-11

Well, its been a while since I've updated. I picked up that bell housing i needed, sourced a power steering pump, bracket and pulley; and Ordered a mess of parts.

Also, my trusty KA-E has gone the way of tray of tacos at a fat guy convention:
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Have my T25 mounted to my SR, with the ceramic coated manifold:
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Got this for Christmas:
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And this just came today:
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It's ebay-tastic, and i have concerns about the BOV, but the piping looks solid, the core looks great, and is much larger than the stock side mount i was thinking about using.

============================================== 1-28-12

And now for something completely different...
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============================================= 1-29-12

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Bam, Sil40 time.

About that hole:
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Backed with 1/8" weldable steel wrapped with saran wrap to form a base:
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And the first layer of fiber glass:

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Needs more resin, then more fiberglass, then more resin, then sanding and paint. Will be red to match the car, stealthy carbon fiber.

==========================================2-4-12

Today i built a wire harness for the silvia lights, made some leads for the fogs, which will be wired into the pop-up motor harness, so the pop-up button turns them on. And test mounted everything and pushed the car outside the garage for the first time in months.

Disregard the taped out rectangle, that's around the area im still patching.

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==========================================2-5-12

Fiberglassing done, body filler in, now for it to dry and then sand down. Then some paint and will be good as new...

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===========================================2-13-12

And now, the hole is patched, and the hood is one color.
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