Project Daily Driver: SleepR 240sx's Build Thread 56k VERY UNFRIENDLY

[SleepR 240sx]

Okay so it was probably about six months ago that I decided a Mazda Protege didn't have nearly the capabilities I wanted. At our local car meets each week (300+ cars) there were lot's of 240's, all of which I knew the owners. Decided I wanted a 240 and searched around for a local shell. Just so happens that on 240sxforums.com I found Zach's240sx who was selling his 240 and had just moved to my town. Went over looked at it and fell in love. It's a 91 fastback, some body damage but nothing bad, rust free, and already gutted rear interior. Saved me some work lol. The KA was still sitting in it, though not running. I bought the shell for $600 and had it towed to my house.

PICS:

http://i133.photobucket.com/albums/q51/Jester236/IMG_0019.jpg

http://i133.photobucket.com/albums/q51/Jester236/IMG_0012.jpg

http://i133.photobucket.com/albums/q51/Jester236/IMG_0011.jpg

http://i133.photobucket.com/albums/q51/Jester236/IMG_0006-1.jpg

http://i133.photobucket.com/albums/q51/Jester236/IMG_0004-1.jpg

http://i133.photobucket.com/albums/q51/Jester236/IMG_0001-1.jpg

http://i133.photobucket.com/albums/q51/Jester236/Picture025.jpg

I researched the common engine swaps and decided on the SR20det for it's stock turbocharger, ability to hold 450whp on the bottom end, and the overall reliability and ability to modify it. So I ordered my motorset, and then ordered some parts.

Initial Parts List:

S13 SR20det Blacktop
Greddy Intake Manifold
Greddy Type RS BOV
Greddy Turbo Timer
Greddy M-Spec FMIC
Megan Racing Turbo Manifold (Not used as the motor came with a nicer one.)
Apexi N1 Evo Exhaust
Used Unknown Brand 3' Downpipe
Air Intake
Exedy Stage 1 Clutch
Walboro 255lph Fuel Pump
Koyo KA Radiator (Sitting in the hatch when I bought the car. Perfectly good, used with the SR)

PICS:

http://i133.photobucket.com/albums/q51/Jester236/Picture043.jpg

http://i133.photobucket.com/albums/q51/Jester236/Picture041.jpg

http://i133.photobucket.com/albums/q51/Jester236/Picture038.jpg

http://i133.photobucket.com/albums/q51/Jester236/Picture037.jpg

http://i133.photobucket.com/albums/q51/Jester236/Picture035.jpg

http://i133.photobucket.com/albums/q51/Jester236/Picture034.jpg

http://i133.photobucket.com/albums/q51/Jester236/Picture042.jpg

It was at this point I was forced to make a decision I didn't really want to. Due to the fact that the 240 was to be my daily driver, I needed the swap done quicker than I was capable of doing myself. Seeing as how I have school on top of working an average of 50 hours a week doing it quickly simply wasn't going to happen. Why did this matter? I had to take out a loan to buy the parts and motor, which I would pay off by selling my Mazda. This is why I chose to have NSP put the motor in for me, allowing me to sell my Mazda and not having to make two car payments. I really wish I had had the option of putting it in myself however it simply wasn't feasable.

[SleepR 240sx]

Before giving it to NSP I saved myself the $125 they would charge for putting the battery in the rear by doing it myself. $20 in 2 gauge wiring and a battery box and about 30 minutes of work saved me a bunch of money.

http://i133.photobucket.com/albums/q51/Jester236/240008.jpg

I got the car up to the guys at NSP and about a week and a half later I had my car running.

SR20det Installed:

http://i133.photobucket.com/albums/q51/Jester236/240001.jpg

http://i133.photobucket.com/albums/q51/Jester236/240002.jpg

http://i133.photobucket.com/albums/q51/Jester236/240004.jpg

http://i133.photobucket.com/albums/q51/Jester236/240006.jpg

http://i133.photobucket.com/albums/q51/Jester236/motor003.jpg

So now that I had her running what else could go wrong? Hmmm well that was a bad question to ask. Less than a week after the finished install I found I was leaking coolant pretty badly. Found the culprit a coolant line with a hole the size of a quarter. Replaced it only to be confronted with another problem; my clutch was slipping very badly. Which didn't make sense considering it was brand new. First I adjusted the pedal to make sure it was engaging/disengaging completely, however that was not the issue. Jacked it up, found my clutch slave cylinder, marked where it was and then detached the clutch line. Upon seeing the cylinder move forward, I realized it must be bad headed to Advance Auto (2 miles from my house lucky aren't I?) Installed the new cylinder, bled the line, and voilah my clutch didn't slip anymore.

So I was still to encounter more problems however. My power steering line was leaking pretty badly. Here's the line that was leaking, and where it was leaking down onto.

http://i133.photobucket.com/albums/q51/Jester236/lines005.jpg

http://i133.photobucket.com/albums/q51/Jester236/lines003.jpg

Good news came though and I sold the Mazda for $5700, leaving me about $150 left over after paying off the loan. Not too bad huh.

So after fixing that, I was finally ready to solve some of the more mundane problems that I knew of. Starting with my rear brake pads. Simple right? Not quite. The rear pads hadn't been changed in a LONG time, so when I went to get the caliper off, the bolt sheared. Now this is the bolt that holds the caliper to the pad and disc. There was no way I could get the bolt out, so I got lucky and Advance had 1 set of what I needed. Not sure I explained what happened here real well, but anyone who has replaced their pads on a 240 should know what I'm talking about. Replaced the pads and off to more business.

My suspension is absolutely SHOT. I"m getting ready to order some Tein springs, and new tie rod ends. Here's a pic of the front:

http://i133.photobucket.com/albums/q51/Jester236/lines004.jpg

Now I wanted to get rid of some of the vibration. After jacking up my car, I noticed my exhaust was scraping against a bolt. This was where 90% of the vibration noise was coming from. Used a small hack saw to try and cut it shorter, though it wasn't working well so I unbolted that portion of the exhaust and used a dremel cutting tool to get shorten the bolt, fixing a lot of my vibration problem. Not sure how well you can tell in the pictures but this is where the bolt was hitting the piping.

http://i133.photobucket.com/albums/q51/Jester236/lines002.jpg

http://i133.photobucket.com/albums/q51/Jester236/lines001.jpg

Now of course I couldn't go on forever without music right? I wasn't looking for anything fancy just something to listen to, and I had pulled out my pretty nice Pioneer Head Unit out of the Mazda before selling it. So I inspected the stock 240 speakers, not expecting much, but not expecting them to be this bad either.

http://i133.photobucket.com/albums/q51/Jester236/speakers001.jpg

http://i133.photobucket.com/albums/q51/Jester236/speakers002.jpg

[SleepR 240sx]

Went to Wally World, bought 4 Pioneer's. Not amazing speakers but good enough to listen to. Of course the speakers didn't fit the mounts for the 240 even though they are 6x9's. So drilled holes to make them fit, and mounted and wired up the rear ones. Come to figure out the wiring for the rear speakers doesn't work, and I was forced to run my own wiring.

http://i133.photobucket.com/albums/q51/Jester236/speakers003.jpg

http://i133.photobucket.com/albums/q51/Jester236/speakers004.jpg

http://i133.photobucket.com/albums/q51/Jester236/speakers005.jpg

Of course I had to run over a nail and was left with a flat tire on my way out of work one night. Patched it up for $15 the next day though.

Finished the speaker install tonight:

http://i133.photobucket.com/albums/q51/Jester236/speakers.jpg

Put the door covers back on and I have the head unit harness all wired up. Too tired to mount the head unit tonight though...I'll do it tomorrow.

[ATLspeed]

nice msglength

[GuardianLlama]

reminds me of my car haha

[Farzam]

Welcome to s13 world...

Enjoy finding random problems with your car that make no sense!

[alindeman1989]

Sweet car. I love sleepers.

[SleepR 240sx]

Thanks for the comments. I'm going to keep updating this as I move along. The thread is a little misleading on the time scale. I've had the car back and running for about a month and a half now, in which time everything else above has taken place. The speakers I really did finish tonight though lol.

I'm definitely keeping with the mostly sleeper look, only outward modification will be a front lip if i can find one I like, and lowering it which should happen very soon.

Here's a youtube video I made of the car...contains both footage from before the SR and from about after a week I got it back...http://youtube.com/watch?v=4nfpBLOtJQ8

[opponheimer]

I've noticed theres been an increasing number of build threads on this forum... its awesome!

Keep up the good work.

[driftage240]

nice.........

[initial_drifter]

use the macro on your camera...

[PhAtXSuMo]

now thats a bad ass Daily Driver!!

glad to see a thread about a car thats not stolen! haha jk

[d*star180]

I noticed you havent said anything of what the SR feels like.
How do you like it? Powerful?

[jackjack]

nice start. have fun. damn i love working on cars.

[blasting_speed]

Woo. That's nice. I like it. I was never a big fan of the s13 but that one is going to be real nice. Take care of it. How's the SR treating you?? Take care of it.

[IIIXziuR]

Car looks pretty clean in those shots, minus the interior.
Nice work bro, have fun with it.

[theronin]

im not a fan of putting more power in a car before you do the susp, but to each his own. good luck on the build.

[sd8ted]

grats on everything man, I know david from NSP, they do some good work there. You said you local car meets, you talking about hobby lobby?

[SleepR 240sx]

^^^ Yes I'm talking about hobby lobby. In the summer we fill it up, bout 200 plus cars at least wouldn't you say. What do you drive?


Thanks for all the compliments guys. And the SR feels real nice. Really nice as a daily driver, I don't have to hit boost if I don't want to, but when I want to I've got PLENTY of power.

As far as suspension I'm ordering Teins in the near future, I need to adjust the way my exhaust sits before I lower the car due to scraping my muffler everywhere.

Interior wise, I'm going to get molded black carpet, I already have one APC seat and I'll prolly buy another, shift boot/e-brake boot, and new steering wheel.

My manual boost controller and my gauge pod came in today as well.

http://i133.photobucket.com/albums/q51/Jester236/boost6002.jpg

http://i133.photobucket.com/albums/q51/Jester236/boost6001.jpg

Post up more pics when I finish my head unit install. I plan on swinging by somewhere and getting my gauges today as well.

[sd8ted]

^^^ Yes I'm talking about hobby lobby. In the summer we fill it up, bout 200 plus cars at least wouldn't you say. What do you drive?

Drive a Blue S13 Pignose Hatch, haven't been out to hobby lobby in a good 5 months tho, I'm around the berea/cherydale area mostly.

[ECR33S14]

Im curious where you meet that gets 300+ cars each week.

[sd8ted]

Hobby Lobby parking lot on Woodruff Rd. every Sunday Night, weather permitted.

[jyon9689]

If you already have an APC seat thats cool but instead of buying another to match it, invest in something nicer or even an R32 seat etc.

[onehundredoctane]

http://i133.photobucket.com/albums/q51/Jester236/boost6001.jpg

I love it when mom leaves me little notes around the house! JK

[BustedS13]

i can dig it save the 4x6 speakers. just cut some baffles and mount 6.5's up front, it makes a world of difference.

[SleepR 240sx]

I think I remember seeing your 240 one or two times out there....we fill up the hobby lobby and strip mall parking lot that's next to it. Seriously at least 200 cars every week.

Already installed the new speakers just have to install the head unit.

And LOL at that note, I forgot it was there.

[unicoladron]

yay i love builds...i did a similar build. and yeah, if you're taking pictures up-close like that, there is a macro mode on digital cameras. usually a "flower/rose" icon indicating it's selected. use that and hold the camera really still. looking at your pics hurt my eyes lol.

get rid of that crusty old steering wheel and use that left over $150 and get a hub and a used momo or something.

enjoy the sr!

[yota man]

Its good to see another person from Sc on here. What are your plans with the car? If you plan on doing any drifting you should come down to Drift Mb. There are a few guys who come down from around your area. The next one is March 15th.

[SleepR 240sx]

I don't think I could make the March 15th, I know i'm doing something that day, but I can't remember what lol.

As far as drifting, I will not be drifting this car. However my friend recently bought a 240 shell and we are either building and turboing the KA or getting an RB haven't decided yet. We have completely stripped the chassis though. I'll take some pics of that build next time I get over to our shop. We will both be drifting that car.

[yota man]

Well check out southeastdrift.com in the event section you can see the whole Drift Mb schedule. It may also be posted in the regional section here too but I'm not sure.

[SleepR 240sx]

I'll be sure to check it out. Did you come up here last year for elite summer nationals? It was a pretty good event.

[SleepR 240sx]

Ok so I finished up my head unit install tonight. Fit it in tight and securely it's not going anywhere. Not sure if the trim piece is going to fit perfectly yet because I can't find it lol.

http://i133.photobucket.com/albums/q51/Jester236/unitinstalled.jpg

The pioneers sound better than I thought they would. Pretty good base and very good highs. Well that's it for my music setup lol no amp or subs here...never will be.

I know it doesn't look perfect right now, but I"m in the process of fixing it, just not tonight too late.

Also fixed a problem with my intercooler piping knocking against the frame and making a ton of noise on startup and in the higher RPM's. Sounds much better. I've nearly eliminated all noise.

[blasting_speed]

this thing just keeps getting better and better. Awesome pix.

[s13coupedrfter]

Looks like a fun car. Any thoughts on a diff upgrade, seems a shame to peg leg that nice black top. +1 for you

[SleepR 240sx]

I will be getting an lsd in the future...right now I need to get my new suspension and then I'll see what next. I have a good bit of money coming in due to tax return + me and my girl broke up lol...sad about it but means more money for my other baby. Plans for this weekend:

1.) Rebuild my rear calipers-both are in very bad shape
2.) Install A-Pillar gauge pod and boost/oil temp gauges
3.) Set up Manual Boost Controller
4.) Get a new dimmer switch: At night when my headlights are turned on my dash lights turn off...lol it's an adventure at night.
5.) Borrow an SAFC and get my car to stop running rich.
6.) Whatever else I have time for.

Look for updates Sunday or Monday. Appreciate that you guys appreciate my carr.

[beastka101]

hey i know you.. sup todd how s the sr treating you?

[unicoladron]

I will be getting an lsd in the future...right now I need to get my new suspension and then I'll see what next. I have a good bit of money coming in due to tax return + me and my girl broke up lol...sad about it but means more money for my other baby. Plans for this weekend:

1.) Rebuild my rear calipers-both are in very bad shape
2.) Install A-Pillar gauge pod and boost/oil temp gauges
3.) Set up Manual Boost Controller
4.) Get a new dimmer switch: At night when my headlights are turned on my dash lights turn off...lol it's an adventure at night.
5.) Borrow an SAFC and get my car to stop running rich.
6.) Whatever else I have time for.

Look for updates Sunday or Monday. Appreciate that you guys appreciate my carr.

hey i have a few suggestions, but first...nice move with breaking up with the girl. sr20 hatch build > girlfriend!!! plus your car will attract plenty of women (lol not!, it will most likely scare them away)

1. i just rebuilt my rear S13 calipers. MAKE SURE you have snap ring pliers with REALLY LONG pins on the end. (you know....the piece that you insert into the two holes on a snap ring). i didn't have the super long snap ring pins and could not reach a snap ring inside of the piston.

2. i was gonna go with the A-pilliar pod and found a few reasons not to. A. it attracts thieves/fanboys. B. it's kinda bandwagonish.

3. i decided to get rid of my center vent in my dash and get a triple gauge bezel. it looks much cleaner and is harder to notice than the pilliar pod.

just thought i'd voice my opinion lol

[SleepR 240sx]

Thanks for the tip about the calipers.

As far as the gauges...i'm unique in the SR world in that I have AC so I need the vents lol. A-pillar is prolly where I'll end up having them.

beastka-is that brandon or devaughn? Anyways she's running good...well whichever you are see you sunday night.

[sd8ted]

get rid of ur little cubby hold and mount ur gauges under the radio, thats where i have mine mounted.

also, im gonna try and roll out to hobby lobby sunday night, haven't been out there in months tho. look for me!

[SleepR 240sx]

Nice...be sure to go to Sonic across the road though we got kicked out of hobby lobby and we pretty much chill at either Sonic or Jeff Lynch down the road when the crowd starts showing up.

Going to install my turbo timer and hopefully rebuild my calipers today. Depends on whether or not I can get it done before work.

[khoadogg]

sweet build and good move w/ the gf!!! girls will come and go man. the times spent laying on the garage floor because you're so damn tired wrenching are priceless... just remember to eventually get another girl one day! hah

[SleepR 240sx]

Okay so I got my turbo timer installed today along with rebuilding both of my rear calipers.

http://i133.photobucket.com/albums/q51/Jester236/turbotimer003.jpg

http://i133.photobucket.com/albums/q51/Jester236/turbotimer002.jpg

http://i133.photobucket.com/albums/q51/Jester236/turbotimer001.jpg

I had hoped to buy and install my gauges today but I just didn't have time before work...prolly Monday when I get to that.

[dori_sil8t]

clean car. keep up the good work

[JVD]

im not a fan of putting more power in a car before you do the susp, but to each his own. good luck on the build.
It's an SR... Haha. Don't get me wrong. It's a lot faster, but it's not like your spinning your tires in 2nd gear in a straight line. LOL.

[KA24DESOneThree]

Aren't sleepers supposed to be sleeperish?

Big silver intercooler? Check.
Atmospheric BOV? Check.
Loud, canister style exhaust? Check.
A-pillar gauges? Check.
Ricer seats? Check.

Yup, you don't have a sleeper.

[Jspec603]

Nice looking project! Looks like you went crazy with the Greddy catalogue! LOL

[SleepR 240sx]

Aren't sleepers supposed to be sleeperish?

Big silver intercooler? Check.
Atmospheric BOV? Check.
Loud, canister style exhaust? Check.
A-pillar gauges? Check.
Ricer seats? Check.

Yup, you don't have a sleeper.

Thanks for critiquing my name however I'd appreciate it if we stayed on topic about the build. I'm not sure how s13 seats are really ricer either...

[KA24DESOneThree]

What build? You have an SR with bolt-ons. Half the board has the exactly same build already completed.

You are not a unique snowflake.

PS- APC seat.

PPS- This is not a build yet. You had other people install your parts, therefore there has been no real build. It's a waste of bandwidth. We have a picture thread for a reason.

[SleepR 240sx]

APC seat that my cat sits in in my room...yeah I guess that is ricer. If your not interested in my build don't comment...other people obviously are interested in this thread...in the very least there is no reason to go off on me for no reason...