Sock's Big 240sx Project Thread

[Sockington]

More work on the rocker.

I got a tiny bit more to do, but it's almost all done. Jesus, rocker panels suck.

[Sockington]

Update involving a motor? Hot Damn!

First off, boring rocker panel work.

Wheel well work.

Sealing in patch on passenger side.

Whoa? What is the forklift doing? Dare I work on the engine? I dare.

Building the stand.

Went to the local Fastenal (awesome nut and bolt store. I know where I'm getting my motor mount bolt.) and picked up some Grade 8 bolts and nuts to hold the engine on the stand.

All tied up and ready to lift.

The god damn starter died in the forklift. I could hear how it wasn't extending and grabbing the flywheel, but rather just spinning. ****.

So, I decided to do some more body work. Whilst sanding, I accidently dropped the can of primer and punctured a hole in it. Dammit.

Moved outside. Still spraying.

I decided to antagonize Mr. Miller some more.

And one for you guys.

After closing the hatch, I really started to see things come together (hatch is being replaced, too rotted to work with). I'm getting all excited about the project again. Tis' a chore no more.

I wanted to put the engine on the stand because I noticed that it seemed really clean once the dirt was removed. It looks as if the head and block were re-painted a high-temp black, which I hope means that they were apart and new interals and porting were done. Odds are they just painted it inside the car.

[eds13]

so is all the rust work about done then?

[Sockington]

so is all the rust work about done then?

Rust work? About 95% done. I've got to weld one jack point on the rear subframe area (I hate pinch seams) and then there is no more rust/welding.

As for body work, I've got to sand down the car, new fenders, new hatch, fix all little tiny dents and such, then it's paint time.

[continental_drift]

awesome. and crack open that motor!

[babowc]

abuot the rocker panels..

i know this sounds half-assed, but how come yuo didnt just put a sideskirt over it? :P

[kamikazeee]

Holy **** you did a lot of work on that car! Men I wish I found this thread a long time ago , lot of haters tho, oh well. And if ur car Is falling apart u can just look around for the first pole or tree and floor it, everybody is fine and dandy (except u, but u can live with that). Can't wait till next post

[KoalaEatingTree]

This is amazing to follow. Inspirational is an understatement. Can't wait to see it after it is painted!

[slow s13]

I have the same idea as bab^^ weld in the new metal for the rockers seal it up and throw some oe sideskirts on there and it would be hot, but skirts go for 2 times the price of the car maybe thats why he didnt hheheheh.

Keep up the updates it realy makes me want to get after my rust, mild in comparison, gota love that midwest salt.

[DJPyro]

For all the haters, bugger off... Sweet work man, lovin' it.

As to safety of the vehicle... I've seen some scary **** out there, I'd put money on it that this car is going to be safer than 40% of the vehicles on the road in N. America today. No, I'm not joking...

Welds are a bit rough, but you're new, and I'm biased, my dad lays some of the most gorgeous welds I've ever seen in my life, and I'm no slouch... But, they have definatley improved since the start, and they're not nearly as bad as some people I've seen who're actually ticketed welders.

Can't wait to see it finished man, keep it up.

I agree with what some of the people have said so far about the haters, not everyone has a mommy and daddy that'll buy us a car.... Y'gotta work with what you get, and you're doing a great job of it! Keep it up man!

[240fstbak]

I truly do commend you for being as persistent and thorough as you have been thus far in your monstrous project. I would have quit before i even purchased the car. Your story and pics have been very entertaining, please be sure and post all of your progress till the end. Remember there will be an end, and i am sure everyone who has read this thread cannot wait for it to come. Keep up the good work!

[roplusbee]

Looking good Sock. I am glad you kept going and didn't let your project just die out like some folks I know back home. One of my boys just gave up on his 2.5RS project and bought a minivan . I'm looking forward to the wrenchwork (I know you are too). Keep it coming dude.

BTW, KoalaEatingTree, your sig is hot.

[ca18datsun510]

hah, that kinda funny.

its cool though, my cars are nice.

[Badfish]

And one for you guys.

Wrong forum, you jerk!

On a serious note, I've been watching your project from the beginning and I'm amazed at your dedication to bring that car back from the dead. I can't wait till we see progress on the motor.Keep up the good work!

Also tell You Am I that I'm glad you never listened to him because it's an awesome thread.

[Sockington]

Wrong forum, you jerk!

Doh!.

I tore into the motor today. I guess my hopes of having a slightly modified motor is gone.

Hanging out.

On the stand.

Grabbed some baggies to label and store bolts and platic wrap to wrap up the head when it's apart.

I choose you to come off first, Mr. Throttle Body.

God damn. That's an awkward as hell nut to get off.

Be gone foul 40mm throttle body.

Goodbye upper intake manifold! (Was hoping the lower would be ported. It was not.)

And farewell to you lower intake.

You're next, crappy turbo.

The coolant line that did the turbo in. See the little crack? That caused coolant to no longer enter the turbo and to spew everywhere.

And the exhaust manifold is off.

****ed turbo? Check. I can probably take off the impeller and housing and sell it to MX-6 GT Turbo guys for upgrade.

Exhaust ports.

Pulled the plugs - they all look good. Nothing too serious to worry about.

Closed up for the day.

Tommorow I'm going to pull the head and see how things look from there. If the block is all right, then I'm going to start sourcing out some good performance parts for it.

[Sockington]

I'm looking at what I'll be doing to the engine. It should be at least 280rwhp and well over 320ft-lbs.

Should be a hoot.

[Sockington]

Captain Obvious here, but a rebuild is certainly in order. Where/how long did that thing sit to pick up that much rust?

Rebuild, eh? I wasn't even thinking about doing that.

Don't forget the TurboFord forums for great 2.3L turbo awesomeness. Lots of good info there.

Can't wait for the next update and to see what your buddy Mike has to say.

I owned a Merkur. I know all about them forums - they rock.

Time for the teardown. This is an update for yesterday (I was too tired to post).

Valve cover off. Damn, it looks brand new.

The head. Nice and clean.

Goodbye alternator.

Timing cover off.

SOOO clean. Damn, I thought things were doing to be worse. Head bolts all loose.

Head bolts vs. 1/2 Drive Socket wrench. Big bolts.

OH SNAP! Timing belt is gone. Good old non-interference.

Oh, the first three look good.

Oh ****. Cylinder #4 was crap.

The head.

Cyl #4.

Cyl #3

Cyl #2

Cyl #1

Well there's your problem right there. A bee in Cyl #2.

I guess there was still a bit of oil left in the engine.

Coolant and oil in the pan. I'm guessing the headgasket failed in #4 as there was a slight crack in the gasket.

The end for today.

Packed up. Good old cling wrap will keep crap out of the cylinders for the night.

[Sockington]

Today's work.

The start.

Oil pump and pickup removed.

Rod cap #1 removed.

The rest removed.

Crank caps removed.

Everything bagged and tagged.

Crank out.

Hello pistons.

Crank all wrapped up. I don't want any damaged too it as it's going back in.

Pistons out.

The bad piston (#4).

The block.

The bad cylinder.

Water pump removed.

Now you see the dizzy.

Now you don't.

Pulling the dizzy crank gear.

Dizzy gear and shaft out.

The almost clean block.

Weird *** thing. It has to do with the PCV system. I suspect it will be hard to find a replacement/replace.

Engine stripped.

Body work!

Bagged, tagged, and removed parts.

Closed up for the day.

The block is going to be bored over 30 over to clear out that bad spot on cylinder #4. Then I'll be picking up some Crower Sportsman rods, ARP bolts, Pistons (probably Weisco or Diamond depending on reviews on TurboFord), A237 Cam (a little more performance) or just a Ranger Roller cam (better than stock), some home head porting, and a few other things.

[amolao]

Damaged cylinder??? Aww....c'mon, a little sand paper and elbow grease and you should be back in action in in time......Ps. love your shop, you have all kinds of room and laundry facilities.....

[mrzabala]

you selling ur 280z? Looking for something to do a full restoration. LMK

[Sockington]

Damaged cylinder??? Aww....c'mon, a little sand paper and elbow grease and you should be back in action in in time......Ps. love your shop, you have all kinds of room and laundry facilities.....

Sand paper? I'm getting it all machined. I want it to be nice and clean when the new forged pistons go in.

[Sockington]

Most the bits out.

Bottom of head.

Intake Port #1

Intake Port #2 and #3

Intake Port #3 and #4

#1

#2

#3

#4

More bits coming out.

So god damn clean.

[Neri]

Dude really nice work, I'm always watching this out for an update. Good luck and congrats on doing all of your work and not letting somebody else do it. This way you get exactly what you want.

[LiteraryCannon]

Great job so far, keep it up, I am checking back daily

[Sockington]

Work on the wheel well.

Taking apart the rear subframe.

Looking pretty comfy in there, Mr. Diff.

To the corner with you!

All taken apart.

I dropped off the subframe to be sandblasted. It should be done by the end of next week.

[Sandy sx]

I don't get it. If you like rust so much and your choice of engine... why didn't you just buy a rustang?

[Sockington]

I don't get it. If you like rust so much and your choice of engine... why didn't you just buy a rustang?

I dislike rust. I hate rust. I wish to never do this again.

I have the 240 because I like the chassis - it handles much better out of the box than a Mustang. Also, the upgrades available will help it ride like rails.

I'm not going to argue about "why the 2.3." It was in the first post:A) I got the engine for freeB) Lots of experience with the engineC) Can make tons of power for little investment.

[mrzabala]

Hey Im following your thread. Keep at it and I know great things will come out of your 240 project. I think you would get sponsored if you want free things and have a limit in budget. Only thing is you'll have to advertise them like no other but thats up to you. Have fun with the rust.

[captainfalco]

wowo awesome project, love the originality, and cant wait to see how it turns out. I vote everyone on the forum chips in like $1-$5 for your hard work and your forthcoming tetanus shot

[~4N~]

Weld that diff while you're at it.