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jepherz

Jepherz's Datsun 240z restoration

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Not sure if this is the correct place for this, but I figured since it's a huge amount of body/paint work, it'll do. Mods, feel free to move it if it's not!

I can't believe it's been 6 months since I purchased this car! I figured I'd be done so much sooner... However, it turned out to be in worse shape than I originally thought, and I got hung up on a few things so far. Oh well, at least I'm making some progress. If anyone is interested, I can keep adding pics to this thread.

I started cleaning the interior out, and it was nasty:

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I removed all of the crappy wiring that someone had done:

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Tore out all of the wet, rotten carpet (the previous owner was parking it with the window open in the winter) *puke*:

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I started to remove one of the few panels that I knew had a little rust beforehand. This panel commonly rusts out on these cars. I was looking to learn some about major body repair when buying this car:

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I got ballsy one night when my ADD kicked in. Took out the angle grinder and decided to expose why there was some rust popping through the paint in a few small areas. *eek*:

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At this point, I knew my perfectionism (or anal-ness) would require me to take this project to a whole new level, so I busted out the windshield:

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Another ADD session; decided to cut out the rocker panel on the passenger side. The car had been hung up on some huge rock or something at some point, so this whole side was dented as well as rusted through and bondo'd up:

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Perfectionist again; coating everything in POR15, even the inside of the rocker! Also fixing the dent damage and fabbing up all of the metal that was completely rusted away:

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Prepping the tank for a POR coating. This is the first time I've used POR correctly with all of their cleaning and acid etch products:

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Prepping the new rocker panel to go in. Cleaning and acid etch were done before coating the middle area in POR. Outter edges are coated with weldable primer:

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Marking out some material to cut away and then to fab a replacement:

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And finally tonight, I started welding the rocker panel in:

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For all of the pictures, the album should be public here. Enjoy!

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Nice! Quite a project you got there. Looks like you've got the skills to handle it well.

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What they said! Fantastic man, it's great to see someone getting down and deep and refreshing an old Z from the bones out! Awesome work, keep it up and keep us posted.

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Good question :-) There was a huge crack down the center and it was all yellowed. I found a brand new one (basically) at the junk yard and was able to get it out by pushing it out with my feet from the inside, as there was only a rubber seal. The one that was in the car wouldn't come out that way as someone had used window weld to hold it in.

You can see the crack:

DSC00768.jpg

Edited by jepherz

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Off topic, but is that your M Coupe? I love those cars, and am considering getting one (if I don't get an S2000)!

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That's one of the guys that I share my shop with. They are pretty cool cars; rare and they drive much like the 240 did for me when I bought it and drove it home. His is a '99 I think, so it only has the s50 in it (around 235 hp) but a fun, cool car.

I too have been looking around for s2k's, but they jumped up in price so much since they were killed!

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One of the reasons I like the M Coupe is because it's so reminiscent of the 240Z! It has a similar "swoopy" but muscular design with a sweet straight six under the hood. The S2k also reminds me of the Z, as it's fairly lightweight, curvy and muscular and has a hell of a drivetrain.

Back on topic, looks like you have your work cut out (literally). Keep up the great work!

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Is there an acceptable way to post up a WTB here? Not sure if I need a high post count or anything, but if anyone can help me out on getting the lower grill mount (the one that is welded to the lower core support) mine is cut off and I'd like to actually replace it for the restoration.

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Use the Classifieds for your WTB.

Look on the left margin, under the Menu and select Classified Ads. The same name/password that you use here works there.

E

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Wow you have a lot to do, but so far you are doing a great job! Was the previous owner a pilot, with all of the toggle switches on the (ruined) fusebox cover? haha.

What year is your Z by the way?

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Wow and I thought i had a hard time getting my brake booster out! I also love the M coupe, I always love seeing them drive by me in my 3 series. Keep up the work and photos too!

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I was able to get a bit more work done this weekend. I finished up the welding on the passenger side rocker panel, and got a good start on the driver side. Here are some pics:

Before cutting anything out:

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Removing the paint to expose the spot welds I needed to drill out:

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Process of drilling out the spot welds:

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Expressing some creativity with the grinder while cutting the panel out :-)

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Most of the rocker removed. I decided to just cut things out in pieces and then go back and grind off all of the parts I had access to, rather than spending hours with the spot weld drill bit and doing more damage to the parent metal:

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This picture didn't turn out too well, but if you squint your eyes enough, you can see that I'm not even making a scratch on the parent metal (inner rocker panel). This way is working out much better for me! I hope to have the rest of this cleaned up sometime this week:

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Hope you guys enjoy!

-Jeff

Edited by jepherz

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Had some company in town over the weekend, so I'm a few days behind, but I finally got the entire rocker panel cut out of the driver side.

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I am working on fabbing up the metal portions that are heavily rusted underneath, and cleaning up the entire area for weldable primer/POR15. Should be able to start fitting in the new rocker sometime this week.

It's amazing how much I learned the second time around. It was much easier to remove the old rocker by cutting it into small, manageable pieces. When removing all of the individual pieces, it really helps preserve the material that will be needed to weld the new rocker in later.

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wow! i just scored a 73 240z, and i have it almost stripped down, minus the dash,windshield. motor and tranny. i want to dive in and start cutting rot, but i need to see how bad it really is rotted underneath. the front wheel wells have some holes close to the motor mount thats got me scared. should I be? anyways , keep the updates coming , ill be tuned in.

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Got a bit more work done this past week and didn't get a chance to upload any photos. Trying to cut away to solid metal far enough that I can treat any surface rust that exists:

[ATTACH=CONFIG]48054[/ATTACH]

I assume even any "rust free" Datsun has surface rust like this on the back of all of the panels. It's only a matter of time until it eventually rusts through.

[ATTACH=CONFIG]48055[/ATTACH]

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Wow, it's depressing to see that it has been over a year since I last update this thread! Admittedly, I got caught up in work and burnt out working on the car, so I had some months of no progress. However, I've gotten back at it. A few pics for you guys that are interested:

I got the rear diff all cleaned up and POR-15 coated. I found that it's a 4.11 rear end! It looks good though!

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Some fat bastard must have abused this car, because the seat rails had been broken and cut out

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All fixed!

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Since the front swaybar is about 1" (I'm guessing larger than stock) I decided I needed re-enforcement plates:

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Plates formed and spot welded in. I plan to do some TIG welding around the perimeter just to seal it up

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Got burnt out from doing rocker panels. That was a horrible place to start! So, instead I decided to tackle the floor panels

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Part of the reason I am replacing the floor pans is because they are somewhat rusty. Another reason is the damage that was somehow done to the passenger side of the car. You can see how the floor is punched up in this picture

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You can see in this picture that I cleaned up the undercoating pretty easily by using my needle scaler. I also started to drill out the spot welds on this re-enforcement panel. I later decided to scrap it because drilling out the spot welds wasn't worth it.

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Here I said 'screw it' and just started cutting out the rear seat mount to preserve it

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The rear mount is almost out here

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Edited by jepherz

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