OFFICIAL: NicoClub's Rally 240SX, by Finnish Fury Rallysport

[IanS]

firstly, this build is awesome and it's one of the reasons I still lurk around here (I don't even have a Nissan, I drive an '85 Celica, hah)

secondly, have you considered making the tie rod ends double shear? I lot of the amateur rally guys do it because the single bolt simple breaks off.

here's an example

Thanks.

I dont plan on modifying the steering knuckles yet. Id rather snap a tie rod off, then destroy the steering rack.

Are you upgrading the brakes? Those look stock correct? Also, are moog ball joints better than oem or remanufactured or just better all together?

I will be sticking with stock brakes for now. On gravel, massive braking power isn't as important. If I find the car needs more braking, I will do a Q45 swap.

I do plan on getting some nice sport pads, and I have new rotors. I just didnt want to put them on yet, so they can sit and rust.

Moog ball joints are top stuff. They are best OE style BJ you can buy.

if you didnt know you can replace your rear s13 LCA ball joints with b12 sentra ones instead of buying a new set of arms

I was aware, but I dont think I will be changing the rears just yet. I did the fronts because the were haggered looking, and the boots were torn.

[DMan II-40]

That brace is sexy as hell. I wish you could make one for my S14. Beefiest thing evah!

[Razi]

If you want, you can buy a bolt in one!zerothread/266824Look at bottom of page 3 for S14 brace pictures.

I demand more updates Ian!

[IanS]

If you want, you can buy a bolt in one!zerothread/266824Look at bottom of page 3 for S14 brace pictures.

I demand more updates Ian!

No doubt. I had a Jonnie Fraz brace in my S14. I loved it to death. I even did the write up on how to install it. zerothread?id=325591

Sorry man, only update I have is, I pulled the trigger on a steering wheel. Ive been debating what I want, and after lusting after another Nardi, I decided I couldnt afford it, so I split the difference, and ended up with a deep dish 350mm leather sparco wheel.

Classic and stylish.

[DMan II-40]

Yeah I was planning on getting one of those, and yeah I have read your write up. After I do my clutch I was gonna get new bushings, that brace, and then look into brakes. I really want to do the Koni Yellow with GC but I don't know If I want to spend that much. I have it all written down and stuff, but I don't know if it is even worth it for me. guess time will tell.

Nice wheel btw, I was gonna just get one of those knock off nardis on eBay with the blue stitching. Have heard from people that have have had real nardis that they cant tell the difference.

Keep up the good work man. This is such a cool build, and I like that you keep updatung and progressing. Makes it stay interesting.

[lbreevesii]

Yummy wheel. wish mine was that nice.

in regard to brakes. why would you go Q45 vs say the Z32 swap? I looked into it once but the lack of high end pads turned me off.

[Ajax]

FWIK Q45 is an easier upgrade due to the banjo fittings. Though with the stock 7spokes he got from me, he could do the Zswap (I do believe mine had the proper clearance).

[IanS]

in regard to brakes. why would you go Q45 vs say the Z32 swap? I looked into it once but the lack of high end pads turned me off.

For multiple reasons. First off, is wheel clearance's. The Z brakes severely limit the wheels I could run. Not to mention they are expensive, and really throw off the braking balance. I plan to have at least one spare set of calipers, and Z binders are spendy.

All that, and Q brakes are more than I could ever need.

[lbreevesii]

Its true you won't need massive braking.

Since you don't want to be running big wheels the size is a factor I suppose. No need to worry about brake balance though. I mean c'mon, if you're going Z32 you're going Z32 bmc anyway.

[mekta3]

super epic.

i'm honestly rethinking all of my decisions about my ride height...

stop it.

subscribed

[elchoccolatte]

[IanS]

Ok, Ive been slacking on the updates. I picked up a wicked cold that left be battered and useless for the better part of last week. Added to fact that work is busy, and I just am not getting stuff done the way I need to. The June deadline is fast approaching, and at this rate, its not going to happen. I need help bad, and Im not sure where to get it. Everyone I know who is mechanically inclined already has a project going.

On to updates.

Pulled the cover off the diff.



Ring gear is in good shape.



Guts out.



Case. In need of a cleaning, but otherwise in good shape.



Shims and bearing races.



Case cleaned and primed.





And the color. I know its bright, but it should be visible even with the car on the ground, because of the high ride height.



Back to the guts, cleaned up.



I put some axle grease on the ring gear mating surface to keep slag from sticking.



Then I welded the heck out of the spider gears. No more one wheel drive.



I was a little worried about the strength of just the 8 weld points, so I decided to go heavy duty.



Plates solidly welded to either side mean the case will break long before the spiders spin. And I can still remove the stub shafts.



Cleaned all the grime off the cover.



Primer.



And blue. On my S14, I polished the cover, and it looked really good, too bad the fins make that impossible, or I would have done it again.



With paint drying, I reinstalled the ring gear, and put the diff back into the case. Since I didnt change anything, I used the same shims. The pinion lash is still within spec.



And the cover back on. The flash makes the blue look much lighter, its darker in person.



Like this.



The brake booster was all rusty, and it had lots of overspray on it from the previous owner.

Sanded down, and primed.



And the color. I wanted to do black, but Cale insisted on green. We will see how it goes, I may decide to go over it with black later.



And to finish off my day, I welded new bottom mounts onto the rear shocks, then assembled them. Save for some paint, they should be ready to install.



Later guys.

-Ian

[Razi]

Sweetness!

And blue. On my S14, I polished the cover, and it looked really good, too bad the fins make that impossible, or I would have done it again.

With a dremel you can do anything!

I could've done better, but it took way too long.Painting it was tempting.

Looking cool so far Ian!I was wondering what you'd do for a diff, and guessed you'd go welded.Looks like I guessed right.

[S13AL]

This is going to look interesting with the bright-looking neon colors What else is going to be green/blue?

[IanS]

Sweetness!

With a dremel you can do anything!

I could've done better, but it took way too long.Painting it was tempting.

Looking cool so far Ian!I was wondering what you'd do for a diff, and guessed you'd go welded.Looks like I guessed right.

When I say polished, I mean bright, like a mirror. It can be done on the S13 covers, but there is no flat space for it to be noticeable, so I went with paint. Yours looks good though, I like the black and silver.

This is going to look interesting with the bright-looking neon colors What else is going to be green/blue?

Its a race car, its allowed to be loud.

[lbreevesii]

Awesome Ian. Thanks for the update. I need to get one up myself. I've been cleaning up my diff, rear brakes, and subframe.

What happened to that cars LSD? ::wink wink nudge nudge::

[J14cm7]

+1 on the welded diff ian. Tracked down an engine yet?

[IanS]

+1 on the welded diff ian. Tracked down an engine yet?

No leads yet. Nothing pans out, or if it does, the seller wants a million dollars for junk. I have found tons of SOHCs, and Im thinking more and more, that may be the way I end up going.

Anyone ever done a DOHC to SOHC conversion? Seems kind of backwards.

[Timeless240]

epic epic build. gives city folk like myself motivation to get a move on my own project car. I e-mailed you regarding some of the power steering stuff you hopefully don't need.

[lbreevesii]

It would be a snap to get you an engine here Ian. Too bad you live in a creepy cabin in the woods of minneesoottaa :-)

[IanS]

It would be a snap to get you an engine here Ian. Too bad you live in a creepy cabin in the woods of minneesoottaa :-)

Thats how it was a few years ago. DOHC KAs were everywhere. Now, every 240 I find in a yard is SOHC, or sans engine. Ive called all over, and checked car-part. Though recent developments are pushing me more towards a mild SOHC build. My daily driver has fallen on hard times, and Im debating if I should make the effort to keep it driveable for much longer, or just donate it to the rally project. It would mean a perfect running engine, a transmission thats fine apart from a 3rd gear synchro, a great spare diff, and a full set of control arms. All I have to do is find a new daily that I dont hate. Light RWD, manual, and cheap. Decisions decisions.

Do I slap some high comp pistons and a HG in an SOHC, or do I keep looking for a DOHC?

Either way, I better start looking into a new car.

[lbreevesii]

Keep looking for a dohc or at least a dohc head to swap onto your SOHC. higher comp w/ no work ftw!

You can always buy anoother 240. haha

C'mon man, gotta know what you did with the LSD.

edit: Ian i'm sure you heard about this, but a lot of folks here haven't i'm sure. Check this out for some inspiration!

http://jalopnik.com/5497042/ho...e&s=i
Modified by lbreevesii at 5:05 PM 3/22/2010

[IanS]

Keep looking for a dohc or at least a dohc head to swap onto your SOHC. higher comp w/ no work ftw!

You can always buy anoother 240. haha

C'mon man, gotta know what you did with the LSD.

edit: Ian i'm sure you heard about this, but a lot of folks here haven't i'm sure. Check this out for some inspiration!

http://jalopnik.com/5497042/ho...e&s=i

Modified by lbreevesii at 5:05 PM 3/22/2010

LSD?

Well, my buddy J-Lak went buck wild on bushings tonight. All the bushings are installed, and all the arms and knuckles are bolted onto the rear subframe. I also got the rear subframe mounts stitch welded to the body for better rigidity.

I will need to pick up some new caliper slide pins, and a new ball joint, then I should able to get the diff and axles back in. I hope to have the rear suspension back in, and have the car on the ground some time on Wednesday. Pictures later, I dont have my camera on me.

[lbreevesii]

Its an SE, it should have had LSD... Pretty sure I saw the LSD guts in one of your pix too.

[IanS]

Its an SE, it should have had LSD... Pretty sure I saw the LSD guts in one of your pix too.

Nope, The LSD was an option for every package, it was not standard on SEs, its just rare to find one without it. The only way to know FOR SURE if an S13 has the VLSD, is to decode the VIN. Its a non LSD diff with an ABS sensor, which is very uncommon.

[ChampionSound]

not sure if you have seen this ian

but you will probably like it / take some inspiration

http://jalopnik.com/5497042/ho...acers

[Ajax]

Dude, you just reposted the link to an article that was linked and quoted a few posts above yours.

[ChampionSound]

eff i hate my life

i just saw it on another site and immediately though of this build and posted that

whoops

[OM3GA]

This is pretty awesome

[lbreevesii]

haha beat ya to it chief!

Here are some more tidbits of info from the co-driver.http://jalopnik.com/5500013/i-...e&s=i