Project 92 Hatch

[yellow2000SR]

I've been working on getting the 240 together. I bought it around 3 months ago for $500. It is sitting on K-Sport Coilovers, has a mtx swap, and 15% tint. The #2 rod was through the block hence the oil on the trans in the below pictures. I got an engine and a spare transmission for $130.00 picked up.

I already snapped a damn bolt for the head and started ripping out some threads in another hole... think I need to get my torque wrench checked / calibrated. :blech: Now I need to get some helicoil inserts and fix my mistakes.

Plans for now:Replace windshieldGet fender, bumper, headlight onRegistrationInsuranceInspection

Future plans:Build up engineTurbo~350 hp / tq rangeLSDPaint entire car blue from STI or 350ZRimsFender flares or wide fenders

Engine and transmission as they sit now all cleaned up and painted.





And my 92 240sx.



I forgot to take a before pic of the engine w/ oil all over the pan, bottom of block, and timing covers... below is a pic of how I got the transmission and then below that is after the engine was cleaned.

It was so greasy you can see a reflection on the bell housing of the sky and clouds...



Gave up scrubbing by hand. I busted out the pressure washer and finished the trans and got the engine to the point it is in the above pictures.

Pic of what I got done by hand...

Others







Valve Cover glass beaded and painted, needs some work, the clear didn't come out good, might glass bead it again and use the good clear.

[yellow2000SR]

I glass beaded the manifold also and put that high temp paint on it but I hear it sometimes bakes off and docent last long, I decided it has to look better than rust...

ARP head studs arrived, waiting on a new head gasket. Then i need to drill out at least 2 of the holes in the block and helicoil them since 1 bolt snapped in one and threads were popping in another.

I also got a F1 Sage 2 clutch and racing flywheel (off e-bay). Decided to give them a try, if it doesn't last long I can always upgrade. Just need them to last at least 7 months.







THE BADPulled the fenders, headlights and bumper cover off the front... the upper passenger fender support is snapped from the front getting run over. The front end of the car flexes up like 3/4 inch before the passenger compartment starts raising when I jack up the car... That's No Good for a daily car and eventually drifting. I'm going to get the chassis measurements from collision class and see how much everything is out of whack. The end 10" was bent down along with the radiator support at the corner...

[yellow2000SR]

What I did this weekend (not that much really, to hot and humid.)

Got the car up on stands and started pulling stuff with a little help from some friends

You can see the engine was abused, there is oil leaks everywhere.

Cut up the cubby from the ZX2 that had the APEXi SAFC in it and molded it into this piece on the dash (used to be a cubby where the SAFC is now) and sprayed it all semigloss black.

Previous owner gutted the rear

[yellow2000SR]

I knew there had to be some "bad" rust somewhere on this car...

I noticed a little flake on the bottom of the car, picked at it, then stabbed it with a screw driver a few times... Then inside, the carpet was moist (have a leak in the hatch or door / window somewhere.

End results



Where I'm cutting it out

Started cutting it but stopped for the night (been up since 5:30)

A little on the drivers side in the same area:

Need to remove 1 more engine mount, AC compressor, and power steering pump...

Pulled the Trans from under the car...

What I did last weekend...



Framed opening, cut hole in wall, ran 220, and installed the 15,000 btu AC

[yellow2000SR]

Went to a car show in Lebanon for a few hours then came back and worked on the car more. From 6:40 till 11:30, this is what I accomplished...

Cut more of the rust out and heated/scraped off OEM sound deadening

And finally pulled the engine! Need to get an exhaust, the header, downpipe, and cat were rusted to a solid piece. Had to kick a flanged joint a few times till they seperated...





And the rod...

[amolao]

You are handy...that's lots of work. What are your plans for body paint and rims???

[yellow2000SR]

You are handy...that's lots of work. What are your plans for body paint and rims???

Im debating between flares or full out overlay fenders...

As far as paint, Im most likely going a color similar to this.





Ive only been actually working on the car for the past 5 or so weekends. Im in WyoTech still taking ASM class right now. Ive finished Trim/Upholstery, Collision/Refinishing, and after this class, I'm taking Chassis Fab.

Heres a few pics of some of my work (not much, School takes up a lot of my time, and it doesnt help its 3 hrs from home)

ZX2 Seats



Old Mercedes seatsAfter and Before

Fixed a friends bumperBefore

After

[homeslicej2]

Project is looking good. How much for one of those shifter trims you molded up and painted? Looks nice. Also, can you make an overlay for the center console plastic? My re-finishing job didn't come out too well, and I'm thinking an ovelay glued on will be easier and look cleaner. GL with the build and keep us posted.

[yellow2000SR]

Project is looking good. How much for one of those shifter trims you molded up and painted? Looks nice. Also, can you make an overlay for the center console plastic? My re-finishing job didn't come out too well, and I'm thinking an ovelay glued on will be easier and look cleaner. GL with the build and keep us posted.

Thanks man.

As for making parts right now, quite frankly, I dont have the time. Between school, getting up at 5:30, and being ready and there by 7, until 4:10, and being at a dorm with no place to work on this stuff, hurts bad.

I have almost 12 people lined up for work, and would like the money, I just need to get my 240 on the road first so I can get back to having transportation and getting my ZX2 on the road.

My ZX2 and what is done to it: http://www.endlessmotorsports....2.htm

Most of the work goes to the previous owner. I bought the car in late December after totaling my previous ZX2. Plans for it is Starfire Pearl (white) paintjob (Lexus) and cleaning it up overall. Restoring and bracing the subframes (for now), and running a 2.25" exhaust.





Modified by yellow2000SR at 12:34 PM 8/13/2007
Modified by yellow2000SR at 10:01 PM 12/16/2008

[homeslicej2]

That's cool. Had to ask. How long do the Wyotech programs take? I've thought about going through them or UTI for years, but never really looked too much into it.

[yellow2000SR]

That's cool. Had to ask. How long do the Wyotech programs take? I've thought about going through them or UTI for years, but never really looked too much into it.

I've been up here since October. The core class is 6 months, and you have to take 1 elective class which takes 3 months, then you can be done. I added 2 extra classes (ASM, and Chassis Fab) so Im here for a total of 15 months and is putting me back around $46-50k...

[Spiffy240]

nice work man, really nice

what kind of rims are those on the s2k???

[homeslicej2]

....so Im here for a total of 15 months and is putting me back around $46-50k...

OMG! It's like grad school! Well, if it helps you get a good paying job doing something you love, then it's worth it.

[yellow2000SR]

OMG! It's like grad school! Well, if it helps you get a good paying job doing something you love, then it's worth it.

LOL, yea... it’s a lil bit of money. One guy that I had Upholstery class with that I am still in contact with, got a job in Cleveland Ohio starting at $25 an hour for 90 days, then a raise of $.50 and switched to flat rate. He is quite efficient so he should make it off good with flat rate!

Towards the end of this year, I’m going to get a business license amongst the other items to run legally to make money on the side. If it takes off good in the first few months, I am going to look for a garage or something to run out of for a year or 2, then if plans go accordingly, move to a larger facility.

[homeslicej2]

Sounds like a good plan. Stick with it bc it will be difficult, but with hard work, good planning, and good choices, you should do just fine. I'd be nice if I made $25+ an hour . I make pretty good, but not that much.

[lbrowne]

Did you paint your center console trim piece? It looks nice, alot better than the factory shiny black plastic.

[yellow2000SR]

I primed it then painted it with SemiGloss Black (the engine enamel stuff you find at AutoZone and the similar)

[homeslicej2]

Edited bc wasn't talking to me . lbrowne, love the tah-tahs in your sig btw.

[lbrowne]

I primed it then painted it with SemiGloss Black (the engine enamel stuff you find at AutoZone and the similar)

Good stuff. BTW I just noticed that you have the exact same CD deck as me, werd! lol

[yellow2000SR]

Good stuff. BTW I just noticed that you have the exact same CD deck as me, werd! lol

LOL, I dont even know the quality of the head unit... I'll most likely upgrade it later...

Anyhow...

Another Rust problem...

Cut out rust, welded in some plate, and then welded some seams. Welded seam around strut tower...

Ground welds, smeared a thin layer of filler on everything and sanded down. Then put a wet coat of paint on to see how reflections are to see if I am satisfied yet or not (and am not).

[crash n burn]

did you just volunteer to fly down at your expense and fix my rust and seam weld my front end?

i had hoped so : [

looks good though, i had a little rust that big on mine, i was luck enough to grind it down level and got beneath it for now. how big was the hole in the tower

[yellow2000SR]

did you just volunteer to fly down at your expense and fix my rust and seam weld my front end?

i had hoped so : [

looks good though, i had a little rust that big on mine, i was luck enough to grind it down level and got beneath it for now. how big was the hole in the tower

LOL, starting more customer work next year...

Anyhow: Engine bay

Flat black, SemiGloss Black, or Gloss black?

[nwmrkt]

i vote gloss black.Anywho, where else are you going to stitch if any?What do you think of welding the whole car? Any negetives?

[yellow2000SR]

i vote gloss black.Anywho, where else are you going to stitch if any?What do you think of welding the whole car? Any negetives?

I plan on doing most of the seems along with making fender braces and a front strut bar and possibly a rear "strut bar" but to double as a harness bar until I get my cage in.

As far as negatives... dont wreck it, because all the welded seams would make it harder if you plan on welding on a new clip (dont know why you would since shells can be had for cheap...)

[nwmrkt]

I plan on doing most of the seems along with making fender braces and a front strut bar and possibly a rear "strut bar" but to double as a harness bar until I get my cage in.

As far as negatives... dont wreck it, because all the welded seams would make it harder if you plan on welding on a new clip (dont know why you would since shells can be had for cheap...)

well lets not thing that way (crashing) . anyways looking forward to the rest of the welding process, post pics please!

Thanks

[tigerpawkc]

post pics please!

I agree! I'm enjoying this!

[m tr4nch]

awesome stuff man all those parts cleaned up really nicely, the block/head/valvecover look

what kind of paint did you use on the strut tower there?

[yellow2000SR]

awesome stuff man all those parts cleaned up really nicely, the block/head/valvecover look

what kind of paint did you use on the strut tower there?

I just used some black automotive primer in a rattle can to check the reflections to see where the shaving needed more work.

[nwmrkt]

hmmm i read your first post in the thread about the tourqe wrench problem, needed to by calibrated? Im going to buy one soon...is that something i have to look out for even if its new? how do i calibrate it?

[yellow2000SR]

Got some supplies for relocating / shortening/lengthening hiding the harnesses

Got some Rage Gold to continue the shaving process and then the body work...

Pulled electrical tape and loom off harness...