91 240

I’ve been been a member here for a while and have made enough progress to justify starting a build thread. It's taken a while to get to this point, but married life, a 6 month old, and going back to school for a 2nd degree really cuts down on time to work on the car.

Just a little background, I bought this car after graduating high school in 1997. In 1999, I swapped my first SR and enjoyed that for several years. But, during this time, I ended up going through several motors and 4 different turbo setups, enough was enough.

Here’s a bit of the build list:
2001 LQ4 6.0L
317 heads with mild port polish
Patriot dual valve springs
Callies Compstar H beam rods
Wiseco pistons (4.030")
Brute Speed Blower cam (232/240 duration and .595/608 lift)
Masterpower T76 Q trim turbo
JGS 40mm wastegate
JGS 50mm BOV
And much more

This is the car. I want to start off by apologizing for the picture quality. Lighting in my garage sucks and I don’t have a real steady hand apparently.


And the previous setup. T67 fully built SR


Here’s the motor when I picked it up. Dirty, but I’m tearing down for a build anyway.


Here’s the test fit. I was going to try and use the truck manifolds, but I just didn’t like the clearance issues I was going to have.


So I decided to build my own headers. While waiting for piping and flanges to show up I focused on a few other things. I cut out the hatch floor area and made a new flat floor to make room for a new 16 gallon fuel cell. I also added a polished fuel door for access to fill the cell.






All the piping and flanges finally showed and it was time for me to start working on the headers, crossover, downpipe and exhaust.
Passenger header:



Driver header:



Crossover:


Wastegate placement and the beginning of the downpipe:


Then it was on to the exhaust, all 3” except for where it splits to a homemade 2.5” y pipe that mates to the rear half of my Greddy DD exhaust. I really love the look and clearance of this catback so I wanted to make sure I could still use it.









I can’t weld aluminum yet, so I had a friend take care of the intercooler piping along with the BOV flange and AIT bung. I also mocked up the air filter. It tucks up right behind the vent below the turn signal.

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91 240sx
03 Pathfinder

91 240

I made a couple mounts for a powersteering cooler behind the intercooler.



I was able to finish a 6 point rollbar out of an S&W Racecars 8 point setup (no pics of the door bars).






I made a dump/down turn for my cutout. I'm still waiting on my E cut out.


I also got the majority of my fuel system. Professional Products rails, Bosch 044 pump, Siemens 60lb injectors, Trick Flow 10 and 100 micron filters, Aeromotive 13101 FPR, -8 feed and -6 return.



FPR mounted on the firewall, and notched the pinch weld at the firewall.




i primarily have the pump and pre-filter tucker up behind the passenger rear tire. I'm going to add/build a shield to help protect it.

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91 240sx
03 Pathfinder

91 240

The battery must have exploded before i bought the car back in 1997, there was rust everywhere behind the passenger headlight. I cut the headlight panel and part of the core support out so i could sand blast the rust and weld everything back in. I cut out the front fender wells due to a shady shop's work cutting holes for intercooler piping and welded in new patch panels.

drivers side - still have to finish welding and grinding. it'll be easier to finish after i pull the motor.




passenger side



I also got an Fbody aluminum driveshaft that i had shorted 2" and replaced the u-joints. I also had to use a 1310 to Nissan differential flange to mount to my rear end. fits perfect with plenty of exhaust clearance.



i pulled the motor and tranny from the car and assembled everything on the engine stand.


i needed to add a few things that were damn near impossible to do with the motor in the car. first off was tapping the oil pan for the oil drain line. this looked like a good spot. clears everything inside and out.



Next i wanted to add some support braces to the collectors....all that weight would eventually causing some cracking somewhere.
Drivers side


Pass side


these 2 braces helped out a ton, it's pretty solid now. I'm thinking of possibly adding another one on the crossover pipe and attaching it to the pass side head.

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91 240sx
03 Pathfinder

91 240

A few months ago i dropped my motor off at a machine shop to bore/hone the block .030 over, polish the crank, balance rotating assembly, deck block and heads, and do a 3 angle valve job. I picked everything up a couple weeks later with the plan to start building right away, but that didn't happen as i wanted to be sure everything was good to go. I bought a micrometer set and a dial bore gauge to blueprint the motor and get the correct bearings needed. It took me a while to find a place that had the needed 0.001" undersized bearings (both rods and mains) in stock. Finally got those in and the fun began.

Wiseco 4.030 pistons and Compstar H beam rods


Installing the last rod/piston combo


Installing BruteSpeed's Blower Cam.


New LS2 Timing set


I dont have any pics of the top end going together.

Since my last update I’ve finished assembling the motor, I’ve installed an ACT 6 puck clutch kit, new slave cylinder/lines and mated the T56. Before putting the motor and trans back in the car for the final time, I wanted to take time and clean up the engine. This started as a simple cleaning project that turned into stitch welding, shaving and re-painting the bay. All the time spent welding and grinding and adding body filler was brutal, way more than I had expected. Hopefully it will pay off in the long run. I don’t have any pics of the shaving process, but here are some pics of the first few coats of primer (iphone pics, sorry)

2 coats of Epoxy primer




Here it is after 2 coats of high build primer/surfacer


This weekend I’m hoping to get another coat or 2 of primer/surface laid down and block sand to get ready for the base coat.

I’ve been brainstorming on how to make my car different visually to help separate it from other 240’s and make it different. I’m not a fan of body kits or big wings. I’ve been intrigued with the hood scoops from the Toyota Tacoma, 4runner, and Rav4 and thought that might a way to spruce up the looks. I came across a hood from an early 90’s Toyota Celica GT All Trac locally on Craigslist for $75 so I jumped on it. This scoop is functional and could help with under hood temps, whereas the Tacoma/4runner/Rav4 are non-functional. I’m planning to cut the scoop out and weld it in to my stock hood. The lines and shape are very similar so hopefully after body filler it will all look good.


the only other thing I’ve been able to do has been to get a new set of wheels/tires. Nothing special, but they are Mustang replica FR500 in a matte black finish (17x9 and 17x10.5) with Sumitomo HTRZ3’s 245/40 and 275/40.




Hopefully I’ll have more updates in the next few weeks.

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91 240sx
03 Pathfinder

corby_baby

aggie in austin? you live dangerously lol. builds look good, hope to see it one of these days.

91 240

damn straight! being in Austin the last couple of years as they've fallen apart is nothing short of AWESOME. Us Ags have needed something like this past year for so damn long, hopefully we can keep it going!

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91 240sx
03 Pathfinder

91 240

I got some work done over the last week or so, not as much as i would have liked but fate had something else in store for me this weekend.

last week i was able to wet sand the primer/surfacer smooth and get it ready for base/clear.

today i wanted to get 3 coats of base and 3 coats of clear, but i was able to get 2 full coats of base before my compressor decided to crap out on me.

Here are a couple pics of Summit Racing's single stage Jet Black base. Honestly, i think it turned out ok for my first time painting using a Devilbiss Starting line gun.




Now on to what really ruined my day/night. I was just starting my 3rd coat of base when clanking from my compressor. I quickly shut it down and took off the plastic casing around the compressor motor.

Some how I was able to snap both connecting rods and shatter the cooling fan in my Craftsman 60 gal 6.5hp compressor. Not sure how, but now i get to track down a rebuild kit to hopefully try again next week.



I'm calling this damn car Jack Stand Rocket, cause it's apparently never going to get off these jack stands.

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91 240sx
03 Pathfinder

speedracer601

Holy hell.

Fable

wow man sick build you got going on here with some awesome fabrication

Kwolfe

Craftsman products have lifetime warranties? Just get a new one?

bc.

wow, you are a psychopath.

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* S14SR22 * 9.0 c/r * GT3071R *

Oakville

Holy fap that bay paint looks awesome.

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BNR32 connoisseur // 1990 GT-R

Nissansota240

Nice build, looks like its coming along nice, are you making a shroud for around the intake filter? I had a similar setup on mine but any extreme amount of driving in the rain would allow it to suck in ridiculous amounts of water.

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DLG - DIRTYLOVE

BlewByYou

Sweet build

iStubz

loving the wheel choice, different but sick.
and you crazy to boost an LS!

slow92

Wow looks good keep up the good work

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Sr22 in the works

91 240

I got some work done over the last 2 weeks. I got my replacement parts for my compressor and was able to finish painting the engine bay. 2 more coats of base followed by 3 coats of clear. Then i was able to get the motor and tranny back in the car for the final time, hopefully. I plan to get the rest of the front suspension and front wheels back on over the weekend. it'll be so nice to have it back on the ground. Now i can start the fun process of putting everything back together. i think i can see the light at the end of the tunnel....faintly.

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91 240sx
03 Pathfinder

revenn

Looking awesome man keep it up!

ryans523

something ive always wanted to do, looking good!

ShadowMan

Damn, that's some really nice work on the headers, and the entire exhaust for that matter. I'll nkeep this in mind if I ever go with an LS. Awesome man.

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in any situation....thou shalt blaze

Royal_T

Wow very sick build and you are not far from me at all.. Might have to check it out one day..

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http://zilvia.net/advertise.html

91 240

Well, I have another bit of an update. I don’t have too many pics to go with this but a good amount of work went on behind the scenes.

Here’s a little bit that went on since the last update.

- Dropped differential to replace seals
- changed differential flange on driveshaft from Nissan to Infiniti to mate to Q45 differential
- assembled complete rear end (axles, hubs, ISIS adjustable suspension links, Suspension Techniques sway bar, 300zx ebrake, 300zx rear calipers and all lines)
- fabbed DIY Power Brace
- assembled front suspension (Ground Control coilovers, Suspension Techniques sway bar, ISIS adjustable tension rods)
- assembled front brakes (300zx calipers with relocation brackets to accommodate 350z/G35 12.75” rotors)
- prepped/painted brake booster
- installed 300zx master cylinder and custom braided lines to replace stock hard lines in engine bay
- moved radiator overflow tank from passenger to driver side
- started assembling engine accessories – C5 alternator and power steering

300zx twin turbo calipers with 350z/G35 rotors


DIY Power Brace





300zx master cylinder with custom braided lines


Engine bay slowing coming together


I hoping to make some more progress over the weekend with more pics to come.

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91 240sx
03 Pathfinder

240boi115

holy hell this build is the shizzz!!!

2muchboost

Absolutely nuts my friend....I love it

pigeon

Paint looks great. Your running just the one 044 or do you also have one in tank?

moco

Did you have to do modified the transmission tunnel in any way?

OrangeVirus1

Can I ask why? I'd bet it's undrive-able in boost

Slideways74

You should get GTO accessory brackets to mount that ugly alternator down low where it can't be seen.

Looks good by the way.

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95' S14, Kouki front, KW V3, RPF1's, caged, built LS6, rebuilt t56... drives pretty good.

ForeignMuscle

I think the gto alt bracket interferes on the s13 doesn't it?

91 240

i dont think it interferes, but i'm not 100% sure though

i went with the C5 accessories for the extra 3/4" of pulley to radiator clearance. not to mention, putting the alternator down lower would interfere with my header collectors. Thanks!

no particular reason, other than i wanted to. it should still be driveable at around 600whp, maybe not until top of 3rd gear though

i did have to do a little bit of banging to clear the bell housing. not too much.

just that 1 external for now. should be plenty for my goals.....if not, i can add a 2nd one easily

Thanks!

Thanks!

Where in Austin are you? i'm down south over by ABIA. I definitely want to check yours out too. i've been following you build on ls1tech. Has Russell been doing a lot of you work? I haven't talked to him in years....he's come a long damn way.

Thanks man! just had to get a little creative

Thanks

Thanks!

Thanks

Thanks. i've been in love with these wheels ever since the FR500 concept came out. I was originally going to go with the Black Chrome version, but when i found out about these, i decided to wait 8 months for the backorder to be filled.

Thanks

No shroud. i've changed the intake from what's pictured and tucks more into the bumper. plus, i dont plan to drive it all that much in the rain.

Thanks! first time painter here. i think it came out pretty good. there are a couple of runs, but hey, it's just the bay! i'll pay a little more attention to the exterior when that time comes.

i appreciate it!

my wife has said that to me before.

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91 240sx
03 Pathfinder