MoulaZX's Build Thread

Discussion in 'Member's Garage' started by MoulaZX, Sep 17, 2011.

  1. MoulaZX

    MoulaZX #TEAMROB

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    So after 3 long years of owning my dream car (both with my share of highs and frustrating lows), it's finally my turn to do something I've been wanting to do since I was a child, after the passion for Zeds at 5 years old was ignited, then a few years later watching my father meticulously rebuild a Datsun 260Z over 6 months bolt by bolt, wanting to do the exact same thing to my baby.

    This link will take you to my Garage page on the forums, for a complete list of the mods at current on the Zed: Linky!

    The plan:

    By priority.

    1. To take out the old aged (and now damaged) motor, drop in a freshly built monster. 220-230RWKW was fun for about the first year. Now I want more... LOTS more and after having the previledge of driving Sav's (CUSTOMTT) Zed, its been absolutely confirmed. Also during this stage, a lot of the engine bay deletes will be done, including EGR, AIV, PRVR, will also generally be tidying / simplifying the engine bay. Also any and all hoses, including intake piping, will be replaced for my piece of mind. Will also be replacing Master Brake & Clutch cylinders with new ones as well as Slave Cylinder, just cause I'm picky and want that 'new comfy-to-drive car feel', and toying with the idea of going with SS Braided lines for Brakes as well.

    2. Strip the entire interior down to bare metal. Install (probably an excessive amount lol) sound deadening material to reduce as much outside / road noise as possible. Also during this stage, replace any broken / worn / missing interior pieces. The end goal being to have the interior feeling like a new car and removing any rattling noises associated with a 20+ year old car. I'm extremely picky about even the most tiny things out of place, from any body panel / exterior issue, to an interior piece slightly out of alignment, to an unusual smell from engine bay to handling and ride comfort. This stage will be to address any and all of these.

    3. Replace Diff bushes. Install complete adjustable suspension components. Theres an odd drive-train noise that I am absolutely determined to solve, thats been there since the day I bought the car that other members have heard, none of would could tell me what it was. Suspecting Diff bushes for now hence them definitely to be changed.

    4. Looking at fixing the old motor and selling it off. But having said this, it will be without a Plenum and without Cams as I will be re-using these.

    Me and my father will be doing most of the work. My father is a mechanic and over the years we've rebuilt numerous OEM engines, but never anything on this scale. I've been speaking to a few of the more knowledgeable members I've met over time I've been with Aus300ZX for advise and am beyond-words thankful for the information I've learned and still am learning. I by no means consider myself a guru of Zeds but I believe I now have enough knowledge, coupled with past knowledge to take this on successfully. :D :zlove:

    The only things I will not be doing are the machining work associated with prepping the Block and Heads for assembly, but we will assemble them, once the Block is balanced and Heads are ready to be mated to the Block. I have spoken to my Heads guy and Engine Block guy and just waiting on the green light from me at this stage.

    Today I drove her into my backyard, where she'll be for the next 1-2 months, perhaps more, depending on circumstances. But this is not one of those 'oh yea, 1-2 months' and turns out being 2 years. I have a deadline on this and since the majority of the work will be by me and my dad. It really comes down to when we have time, and thankfully as I am on a 4 days on, 4 days off roster, I get reasonable amount of time between work to work on the Zed :)

    Main Engine Parts list:

    These are the purchased parts.

    - Engine Block from Zeb (after mooonths of waiting to get it lol, thanks again mate for sticking through): Linky!
    - Ported Heads from Chad (well, really Chad's mate, appreciate the deal he cut for me on this and the extras): Linky!
    - Forged Kit (also includes gaskets, new OEM Water & Oil Pump)from Coz: Linky! (To be ordered shortly)
    - Ferrea 1mm oversized Valve kit (to match extensively ported Heads) from Coz: Linky! (To be ordered shortly)
    - JECS 615CC Injectors from Coz: Linky! (To be ordered shortly)
    - Complete HKS GT2530 Turbo Kit, and will be using the supplied HKS 3" Dumps.
    - AMS Manifolds from GB.

    Things to note.

    - Will be keeping my S1 Cams and Cam Gears at this stage.
    - Already have the larger JAPTEK SMICs installed.
    - Exhaust from Turbo back is already upgraded, but I will be modifying it a little, I want a full 2.5" system, not 3, so will have the exhaust taper down slowly right after the Dumps, toying with the idea of buying a UAS X-Pipe as well.
    - Keeping stock fuel rail, and FPR, if I find out I am having fuel delivery issues, 300 Degree Rails & FPR will be the next immediate step.
    - Will be re-using my polished Plenum from the old motor.
    - Already have an ASI 56mm radiator installed.
    - Already have Nistune board installed and most likely will stick with this method for tuning. Haven't quite decided on who will be tuning her though.
    - As mentioned a little earlier, will be replacing Master Clutch & Brake and Slave Clutch Cylinders with new ones, for added piece of mind.
    - Looking into going SS Braided Brake lines as well.

    More pictures of parts to come in the next few days.

    In the meantime, I recorded the Zed being driven into my backyard as I kinda felt sentimental as this'll be the last time she is in her current state. You can kinda hear the bottom end noise in this vid, that you hear for sure in the next. http://www.youtube.com/watch?v=uiIXaREZj5s

    And finally, the horrendous noise my current motor is making, which pretty much was the last straw and made me decide to finally start this. The sad part is the video doesn't do the noise justice... Its very loud... :( I am suspecting a bottom end bearing has given way at this stage. Will know in about a week when it comes out. http://www.youtube.com/watch?v=jWpM201Vr58

    More then happy for the local NSW members to come by from time to time to check out the progress as a few already have expressed some interest in this. Regardless if some can't make it, the build shall be well documented. Going to be treating this as a diary of sorts lol.

    The clock has started gentlemen. Just can't wait to do this for real... :br: (oh, that first skid... being in 2nd gear ;) :rofl:)

    MoulaZX
     
  2. Pepper

    Pepper 1991 N/A Slicktop

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    that EL panel green now?

    when'd u change that.
     
  3. Anti

    Anti 14.7 x 14.7 = 44.1

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    IN for coming to help! from that list... I can pull out trim, and fit suspension lol. that's something!
     
  4. pennyarvs

    pennyarvs New Member

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    You know I'll be there. Ready to get my hands greased... with fried chicken oil! :p


    Arvin




    P.S. So, that HKS dumps which came with the package is 3"? Thought I was told they're 2.5"?!
     
  5. zedboy

    zedboy Active Member

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    Sounds like its going to be a good build Emile. Where did you get your 2530's from, I thought you also missed out on them?
     
  6. MoulaZX

    MoulaZX #TEAMROB

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    I didn't change it. It just faded over the year after I installed it! :mad:

    The night I finished doing the mod (22/03/10):

    Please excuse the crack in my Infill panel, have long since replaced it :D

    [​IMG]

    [​IMG]

    After (04/05/11):

    [​IMG]

    I never touched it. It just slowly faded to that bluey / white color. I mean it doesn't look so bad... but I wanted a red one :(

    MoulaZX
     
  7. MoulaZX

    MoulaZX #TEAMROB

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    Hrm, sounds eerily just like this... http://www.youtube.com/watch?v=d3YTIWu6YOw&feature=related, looks like it just may be a simple bearing issue. Hopefully Crank is fine too.

    MoulaZX
     
  8. Chad_

    Chad_ Well-Known Member

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    going to be an epic build :eek:

    hope u end up finishing it :br:
     
  9. BLACK BEAST

    BLACK BEAST SLICKTOP TT R-SPEC

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    looks good .

    but one thing .

    big ports and big valves with stock cams isn't a good combo .

    get a set of R4+ cams at least.

    you cant just drop in JWT cams later .. JWT cams need to be checked for lifters/lash spec because of reduced base circle .

    or machine the head for cam clearance now so the JUN will be a drop in later.. (If you can afford them) But you will need upgraded valve springs in now
     
  10. MoulaZX

    MoulaZX #TEAMROB

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    The original plan was to go those R4+ but decided to hold back as Sav's build is still running stock cams as well. Though having said that, he doesn't have over sized valves. Ugh, I wouldn't mind going R4+ but as always, it all comes down to $$$$.

    I am not against pulling the motor out again to have further down the line head work done again to fit the R4+. I'll be running in the engine for about 10000Kms, which is going to take quite a while (as now that I've been using my EXA as a daily and seeing first hand how much bloody cheaper it is to run, the Zed is going to be relegated to a weekend toy). After the motor has been run in, I'm hoping to shortly after... if I run into any sort of performance bottlenecks because of the Cams, go R4+.

    Question, can I use the Stock Cam Gears with the R400+ Cams?

    Also, when you say not a good combo, is that from an engine safety perspective or just performance perspective?

    MoulaZX
     
  11. MoulaZX

    MoulaZX #TEAMROB

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    Oh it will. Not only am I stubborn but in between helping me, my dad will be on my ass to finish it and get it out of the backyard lol.

    You ought to come up to Sydney sometime after its run in, more then happy to take you for a spin. :D:br:

    MoulaZX
     
  12. BLACK BEAST

    BLACK BEAST SLICKTOP TT R-SPEC

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    Yes but you need JWT adaptors for the series 2 cams to fit S1 Gears

    performance perspective ....assuming they are the huge ported heads from AVO that chad had.

    bigger isnt better if it isnt a complete package
     
  13. ProckyZ89

    ProckyZ89 Senior Member

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    SOOO.. when am i coming up for a tech day haha ;)

    I can help with electrical.. fitment, interior alteration lol.
    getting hands into tiny bits on engine bay..

    moral support..

    and fitment haha.

    P>S i also thought they were 2.5"dumps :S ...
     
  14. MoulaZX

    MoulaZX #TEAMROB

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    Crap! :mad:

    Fair enough.

    What exatly would need to be done if I did stick with the Std Cams for now, then later on go JWT +400 Cams?

    Also, you mentioned I would need upgraded springs, I was under the impression the springs included in the full Ferrea 1mm oversized valve kit I am ordering are upgraded?

    MoulaZX
     
  15. MoulaZX

    MoulaZX #TEAMROB

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    I'm thinking about throwing like a mini BBQ day in a few weeks time for some guys to come around when I get all the final new parts, and the old engine is out and when the interior is being taken out. No real reason to come around other then to poke around, would appreciate any help though! lol

    MoulaZX
     
  16. Chad_

    Chad_ Well-Known Member

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    lol thats what they all say at the start of a project. hopefulli u stick to it though lol
     
  17. MoulaZX

    MoulaZX #TEAMROB

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    Care to make a wager? :D

    MoulaZX
     
  18. Chad_

    Chad_ Well-Known Member

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    yup build it, or hand over everything for free and ill finish it :D
     
  19. BLACK BEAST

    BLACK BEAST SLICKTOP TT R-SPEC

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    you've got the best valve kit ..

    just save $1000 for the R4+ cams and do it all once ..save in the long run by not pulling heads off again .

    silly not too
     
  20. MoulaZX

    MoulaZX #TEAMROB

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    I hate you man. I really do lol. You just gave that little voice inside my head a fairly large decibel boost... I need to think it over again, again. :p

    MoulaZX
     

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