PlusONETEN build - Zilvia.net Forums | Nissan 240SX (Silvia) and Z (Fairlady) Car Forum

donandal · 05-10-2011, 04:43 PM

This is the build thread for a project dreamed up by my oldest son, Allen
I had spent the previous four years building from scratch, a custom two seat aluminum body roadster with a Subaru 2.5 five speed all wheel drive. He got the build bug. He wanted to do an engine swap into a 240SX. We decided to try to find one. After about a year, he located this rust-free original paint coupe in Miami, Fla. We made a road trip all-nighter from Miami about two years ago in February, 2009. While he was searching for the car, he decided on the vq35 engine swap. We went to work locating a donor car for the swap. I found this 2008 350Z on an insurance auction website about 3 months later, in Salem, Mass. My wife and I made the round trip in a day, hauling it back on a rented car hauler trailer, to my shop in Lakewood, N.Y.
After we got it home and looked at it, we decided it had so many things that would work in the 240SX coupe, that we would do a lot more swapping. It has been about two years now and the swapping is done. We ended up using the 350Z engine, tranny (six speed), clutch master cylinder, steering column, entire dash, rear diff and entire wiring harness and emissions system.
We started by stripping the S13 down to the sheet metal, cataloging all the parts as they came off. Then we started rough fitting components just by eye, to see how things lined up. First was the engine fitting; it was pretty tight, but it fit, we decide early on to remove the top cross-member above the radiator and fabricate bolt flanges to make it easy to get it in and out. The engine mount cross-member needed to be modified by cutting, lowering and re-welding to use the original Z engine mounts. We also fabricated a new tranny mount, and reworked the rear diff sub frame to use the Z limited slip with 95-98 five bolt hubs and custom axles from the Drive Shaft shop. They also supplied a custom driveshaft. We looked at the dash and gauges and, thought about the options, and decided to use the entire dash and wiring harness. We used the 240 gas tank and modified it with a second riser and flange to accept the two sending unit harness. We also used all emissions systems. The dash was just a little too wide to fit but we just cut it short and fabricated. The exhaust didn’t fit but with a little chopping and welding it just clears the firewall. We also kept all of the heat/air controls and slipped them into the dash.
Allen wanted to get 265’s under all four corners, and we soon determined we would need to fab our own strut cartridges and coilovers, and rear coilovers as well. Some research on the web, and my son had the info on what struts, springs, shocks, and wheels and tires would work. We made our own camber plates and strut braces as well. There have been a lot of other little things along the way. One thing that we did come to realize was just how many things were compatible from these two cars built 16 years apart. The wiring harness chassis ground points lined up, the bolt pattern and screws on the sending unit were exactly the same, the steering column splines, the axle splines, just a lot of things worked out nice.
We are finishing up the interior now and will probably drive it for a year or so then get it painted. We already painted the engine compartment Millennium Jade, the color he chose. He has plans for a body kit and some other mods later, but we’ll see.
Now I’ll try and post some pics with explanations

this is the day we brought it home

we worked over the winter and pulled everything off

not much left of the Z

the donor car , a 2008 350Z

the cross mount was modified, slots are where engine mounts go, here it is primed with brush on enamel

we also fabricated a new tranny mount using original chassis points

the headers were shortened to clear the firewall

I fabricated this coupler so we could use stock cat converters

here it is installed on engine, I added extra heat shields on firewall because it's pretty tight

this shows the stock shifter support, and our shortened steel one

the shifter sits a little farther back

this is the rework of rear subframe to house Z limited slip diff

we reused the z rubber mount and added a brace that will also carry exhaust hanger, as shown above. These two
show the bottom side as we worked on it

since we are using all of the Z wiring we decided to keep both sending units in the tank

one is also the fuel pump unit, here fitting it to spare tire area, it will be soldered and then sealed

closing off the spare tire area, this top will be bolted together in case of service access, no room for spare,
but we can use it for tools and storage

we bought a radiator from Griffen, and built our own shroud from .060 aluminum, used 350Z fans

we also built a radiator overflow tank

making our cold air intakes

this will be capped off on top, air draws from front, we used dry type cone filters, the box is sealed around
the tube with foam rubber to allow engine shake, air can only enter tube thru filter end,even if foam wears out

Allen wanted to get 265/40/17s on all four corners, to get enough clearance we fabricated our own strut
housings with about 1 inch more offset at the lower ears

we also made our own threaded coilover converions

we ended up with about 3/8 " tire clearance

we used koni shocks and struts, the rears are an eclipse model,with adjustment at the top, same as the front

our camber plates, stainless steel with 5/8 spherical bearing and a 1 and 15/16" thrust bearing. with our custom
spring top hat , we tucked the spring in above the tire

no room for the battery

here you can see the strut tower braces.....

so it went in the trunk in this sealed and vented stainless battery box we made. the vent goes out the cabin vent
panel in the rear wheel well area of the trunk

the other side of the trunk, this protects the stereo amp and radio/phone/antennae components

we needed to protect that low sitting aluminum oil pan

so we built this skid plate, the mesh is painted stainless steel

some work on the interior, I am building the center console

fitting it to the Z dash

after I covered it in black vinyl

here is the headliner, I recovered it with headliner material that had a foam backing, that is the Z mirror

This just about brings it up to date...the carpet is in and I am installing the seat belts...two side panels of the
dash need to be fabricated and covered in vinyl...package tray needs to be covered...I'll post more pics shortly
I have hundreds of photos so if something strikes your interest and you want more details on something,
let me know
Thanks

dued · 05-10-2011, 04:56 PM

Bravo young chap. Bravo.

Wheelchair · 05-10-2011, 04:57 PM

this is insane! there have been cool build threads on zilvia... but i really like this one.

Good work!

[email protected] · 05-10-2011, 04:58 PM

Good shit!!!!

bejota180sx · 05-10-2011, 05:00 PM

great build! it's good to see more real builds going on zilvia!

*Wake* · 05-10-2011, 05:04 PM

Um may I be the first to say............

HOLY SHIT BATMAN!!!!
Welcome to zilvia, we need more like this.

R33E8 · 05-10-2011, 05:07 PM

My friend who bought some stuff from you (I think a ka and some other stuff) was telling me about this..

wow..

slomar91 · 05-10-2011, 05:09 PM

This is amazing.

donandal · 05-10-2011, 05:16 PM

Quote:

Originally Posted by R33E8

My friend who bought some stuff from you (I think a ka and some other stuff) was telling me about this..

wow..

Hey
how is he doing on that project?
Those three kids who came to get the engine
were great kids....funny to see them stuff it into the back
of that mini van....there wasn't any room left to sit and they had
a long drive home, I think the day before father's day a year ago

deolio · 05-10-2011, 05:18 PM

wow this is an awesome build.

looks like it won't be able to go very low though due to how low the engine/tranny sit

Backintoans13 · 05-10-2011, 05:31 PM

Sick build!! Crazy workmanship

donandal · 05-10-2011, 05:33 PM

I've got a few pics here of the car on wheels

we rolled the fenders and lowered it to allow the tires to just miss the inner fenders by about an 1/8 " at full bump coil bind and this is how it looks
there is about 3.5 inches from the skid plate to the ground
the rears aren't rolled yet in this picture

Phate · 05-10-2011, 05:33 PM

Wow looks awesome. A lot of good fab going on here.

sickstatus · 05-10-2011, 05:52 PM

Very sick build thread.

str84dapokie · 05-10-2011, 05:52 PM

only on zilvia would someone be sad a car cant go low when it was built like this smh....

i saw this car in person and this swap is scary clean...
it just looks great... cant wait to hear what it sounds like...
but that f**king garage is... AMAZING!!!! if only it wasnt a 6 hour drive

Heh Don we had to lay that KA to rest but the trans lives on. lol

str84dapokie · 05-10-2011, 05:58 PM

..... and that roadster of yours is sick!!!!!

drftwerks · 05-10-2011, 06:01 PM

pics of roadster.

please.

donandal · 05-10-2011, 06:02 PM

Quote:

Originally Posted by str84dapokie

only on zilvia would someone be sad a car cant go low when it was built like this smh....

i saw this car in person and this swap is scary clean...
it just looks great... cant wait to hear what it sounds like...
but that f**king garage is... AMAZING!!!! if only it wasnt a 6 hour drive

Heh Don we had to lay that KA to rest but the trans lives on. lol

I hope it wasn't a bad engine we sold you... I'd be happy to send your money back... let me know

herbieS13 · 05-10-2011, 06:04 PM

this build looks like such an epic win it disgusts me...subscribed

donandal · 05-10-2011, 06:06 PM

Quote:

Originally Posted by drftwerks

pics of roadster.

please.

ok I'll post the build here

Drft_S14 · 05-10-2011, 06:11 PM

Wow .. the Fabrications are awesome!!!! the Fan shroud and the suspension are my fave ! good job sir!

str84dapokie · 05-10-2011, 06:19 PM

Quote:

Originally Posted by donandal

I hope it wasn't a bad engine we sold you... I'd be happy to send your money back... let me know

def wasnt a bad engine my lil cus who came with me out there had some fun with it before he sold his s13 shell... car sold engine gone...
the trans is what i wanted but the price was to good to not get both from you...

his build is going good i'll send you the pics of that..

my build is just a pile of parts now but soon to come together

donandal · 05-10-2011, 06:19 PM

the subie is posted in chat now

**Phlip** · 05-10-2011, 06:23 PM

Quote:

Originally Posted by donandal

the subie is posted in chat now

I had to move it to off-topic.

Also, you could make a killing selling those consoles

donandal · 05-10-2011, 06:27 PM

Quote:

Originally Posted by str84dapokie

def wasnt a bad engine my lil cus who came with me out there had some fun with it before he sold his s13 shell... car sold engine gone...
the trans is what i wanted but the price was to good to not get both from you...

his build is going good i'll send you the pics of that..

my build is just a pile of parts now but soon to come together

good to here it wasn't a bad engine...
hope all is well with you and your cousin and friends
you are allways welcome to stop in if you are up this way
I'll be looking for the pics

treken2t87 · 05-10-2011, 06:29 PM

Top notch build. Very great attention to detail here.

Also kudos for offering a refund on a transaction over a year ago

donandal · 05-10-2011, 06:37 PM

Quote:

Originally Posted by PHLIP

I had to move it to off-topic.

Also, you could make a killing selling those consoles

sorry ...and thanks for moving it
that console has probably a weeks work in it
I couldn't build it and sell it for a profit...oh well

**Phlip** · 05-10-2011, 06:40 PM

Quote:

Originally Posted by donandal

sorry ...and thanks for moving it
that console has probably a weeks work in it
I couldn't build it and sell it for a profit...oh well

No problem, I would have sent a lesser thread to the graveyard, so thank YOU.

If you don't mind me asking, what do you do professionally, like for a living?

tricky_ab · 05-10-2011, 06:56 PM

This is great work so far!

Okinawandrifter87 · 05-10-2011, 07:04 PM

I am thoroughly impressed which I dont say too often here on Zilvia with alot of build threads.

05-10-2011, 04:43 PM	#1
donandal Leaky Injector Join Date: May 2011 Location: Lakewood N.Y. Age: 61 Posts: 56 Trader Rating: (0) Feedback Score: 0 reviews	PlusONETEN build This is the build thread for a project dreamed up by my oldest son, Allen I had spent the previous four years building from scratch, a custom two seat aluminum body roadster with a Subaru 2.5 five speed all wheel drive. He got the build bug. He wanted to do an engine swap into a 240SX. We decided to try to find one. After about a year, he located this rust-free original paint coupe in Miami, Fla. We made a road trip all-nighter from Miami about two years ago in February, 2009. While he was searching for the car, he decided on the vq35 engine swap. We went to work locating a donor car for the swap. I found this 2008 350Z on an insurance auction website about 3 months later, in Salem, Mass. My wife and I made the round trip in a day, hauling it back on a rented car hauler trailer, to my shop in Lakewood, N.Y. After we got it home and looked at it, we decided it had so many things that would work in the 240SX coupe, that we would do a lot more swapping. It has been about two years now and the swapping is done. We ended up using the 350Z engine, tranny (six speed), clutch master cylinder, steering column, entire dash, rear diff and entire wiring harness and emissions system. We started by stripping the S13 down to the sheet metal, cataloging all the parts as they came off. Then we started rough fitting components just by eye, to see how things lined up. First was the engine fitting; it was pretty tight, but it fit, we decide early on to remove the top cross-member above the radiator and fabricate bolt flanges to make it easy to get it in and out. The engine mount cross-member needed to be modified by cutting, lowering and re-welding to use the original Z engine mounts. We also fabricated a new tranny mount, and reworked the rear diff sub frame to use the Z limited slip with 95-98 five bolt hubs and custom axles from the Drive Shaft shop. They also supplied a custom driveshaft. We looked at the dash and gauges and, thought about the options, and decided to use the entire dash and wiring harness. We used the 240 gas tank and modified it with a second riser and flange to accept the two sending unit harness. We also used all emissions systems. The dash was just a little too wide to fit but we just cut it short and fabricated. The exhaust didn’t fit but with a little chopping and welding it just clears the firewall. We also kept all of the heat/air controls and slipped them into the dash. Allen wanted to get 265’s under all four corners, and we soon determined we would need to fab our own strut cartridges and coilovers, and rear coilovers as well. Some research on the web, and my son had the info on what struts, springs, shocks, and wheels and tires would work. We made our own camber plates and strut braces as well. There have been a lot of other little things along the way. One thing that we did come to realize was just how many things were compatible from these two cars built 16 years apart. The wiring harness chassis ground points lined up, the bolt pattern and screws on the sending unit were exactly the same, the steering column splines, the axle splines, just a lot of things worked out nice. We are finishing up the interior now and will probably drive it for a year or so then get it painted. We already painted the engine compartment Millennium Jade, the color he chose. He has plans for a body kit and some other mods later, but we’ll see. Now I’ll try and post some pics with explanations this is the day we brought it home we worked over the winter and pulled everything off not much left of the Z the donor car , a 2008 350Z the cross mount was modified, slots are where engine mounts go, here it is primed with brush on enamel we also fabricated a new tranny mount using original chassis points the headers were shortened to clear the firewall I fabricated this coupler so we could use stock cat converters here it is installed on engine, I added extra heat shields on firewall because it's pretty tight this shows the stock shifter support, and our shortened steel one the shifter sits a little farther back this is the rework of rear subframe to house Z limited slip diff we reused the z rubber mount and added a brace that will also carry exhaust hanger, as shown above. These two show the bottom side as we worked on it since we are using all of the Z wiring we decided to keep both sending units in the tank one is also the fuel pump unit, here fitting it to spare tire area, it will be soldered and then sealed closing off the spare tire area, this top will be bolted together in case of service access, no room for spare, but we can use it for tools and storage we bought a radiator from Griffen, and built our own shroud from .060 aluminum, used 350Z fans we also built a radiator overflow tank making our cold air intakes this will be capped off on top, air draws from front, we used dry type cone filters, the box is sealed around the tube with foam rubber to allow engine shake, air can only enter tube thru filter end,even if foam wears out Allen wanted to get 265/40/17s on all four corners, to get enough clearance we fabricated our own strut housings with about 1 inch more offset at the lower ears we also made our own threaded coilover converions we ended up with about 3/8 " tire clearance we used koni shocks and struts, the rears are an eclipse model,with adjustment at the top, same as the front our camber plates, stainless steel with 5/8 spherical bearing and a 1 and 15/16" thrust bearing. with our custom spring top hat , we tucked the spring in above the tire no room for the battery here you can see the strut tower braces..... so it went in the trunk in this sealed and vented stainless battery box we made. the vent goes out the cabin vent panel in the rear wheel well area of the trunk the other side of the trunk, this protects the stereo amp and radio/phone/antennae components we needed to protect that low sitting aluminum oil pan so we built this skid plate, the mesh is painted stainless steel some work on the interior, I am building the center console fitting it to the Z dash after I covered it in black vinyl here is the headliner, I recovered it with headliner material that had a foam backing, that is the Z mirror This just about brings it up to date...the carpet is in and I am installing the seat belts...two side panels of the dash need to be fabricated and covered in vinyl...package tray needs to be covered...I'll post more pics shortly I have hundreds of photos so if something strikes your interest and you want more details on something, let me know Thanks

05-10-2011, 05:04 PM	#6
Wake Premium Member Join Date: Dec 2003 Location: Santa Cruz, ca Age: 38 Posts: 6,699 Trader Rating: (8) Feedback Score: 8 reviews	Um may I be the first to say............ HOLY SHIT BATMAN!!!! Welcome to zilvia, we need more like this. __________________ S.P.P.S. Member #00 CoUpe LOve Member #00

05-10-2011, 05:18 PM	#10
deolio Post Whore! Join Date: Mar 2007 Location: Sacramento, CA Age: 32 Posts: 4,572 Trader Rating: (13) Rides Gallery: deolio Feedback Score: 13 reviews	wow this is an awesome build. looks like it won't be able to go very low though due to how low the engine/tranny sit __________________

05-10-2011, 05:52 PM	#14
sickstatus Zilvia FREAK! Join Date: Sep 2009 Location: SoCal Age: 30 Posts: 1,539 Trader Rating: (15) Feedback Score: 15 reviews	Very sick build thread. __________________ straights are for fast cars, corners are for fast drivers.

05-10-2011, 05:52 PM	#15
str84dapokie Leaky Injector Join Date: Dec 2009 Location: right here Age: 37 Posts: 119 Trader Rating: (2) Feedback Score: 2 reviews	only on zilvia would someone be sad a car cant go low when it was built like this smh.... i saw this car in person and this swap is scary clean... it just looks great... cant wait to hear what it sounds like... but that f**king garage is... AMAZING!!!! if only it wasnt a 6 hour drive Heh Don we had to lay that KA to rest but the trans lives on. lol __________________ www.iDigsThat.com ....Check it out....

05-10-2011, 04:56 PM	#2
dued Zilvia Junkie Join Date: Dec 2005 Location: Vista, CA Posts: 450 Trader Rating: (3) Feedback Score: 3 reviews	Bravo young chap. Bravo.

05-10-2011, 04:57 PM	#3
Wheelchair Leaky Injector Join Date: Mar 2009 Location: ATL Posts: 137 Trader Rating: (0) Feedback Score: 0 reviews	this is insane! there have been cool build threads on zilvia... but i really like this one. Good work!

05-10-2011, 04:58 PM	#4
[email protected] Join Date: Mar 2011 Location: Phoenix Age: 41 Posts: 13 Trader Rating: (1) Feedback Score: 1 reviews	Good shit!!!!

05-10-2011, 05:07 PM	#7
R33E8 Zilvia Addict Join Date: Jul 2006 Location: NJ Age: 31 Posts: 797 Trader Rating: (14) Feedback Score: 14 reviews	My friend who bought some stuff from you (I think a ka and some other stuff) was telling me about this.. wow..

05-10-2011, 05:09 PM	#8
slomar91 Leaky Injector Join Date: Jul 2010 Location: San Diego Age: 29 Posts: 69 Trader Rating: (0) Feedback Score: 0 reviews	This is amazing.

05-10-2011, 05:31 PM	#11
Backintoans13 Zilvia Addict Join Date: Apr 2009 Location: Las Cruces, NM Age: 39 Posts: 620 Trader Rating: (16) Feedback Score: 16 reviews	Sick build!! Crazy workmanship

05-10-2011, 05:33 PM	#12
donandal Leaky Injector Join Date: May 2011 Location: Lakewood N.Y. Age: 61 Posts: 56 Trader Rating: (0) Feedback Score: 0 reviews	I've got a few pics here of the car on wheels we rolled the fenders and lowered it to allow the tires to just miss the inner fenders by about an 1/8 " at full bump coil bind and this is how it looks there is about 3.5 inches from the skid plate to the ground the rears aren't rolled yet in this picture

05-10-2011, 05:58 PM	#16
str84dapokie Leaky Injector Join Date: Dec 2009 Location: right here Age: 37 Posts: 119 Trader Rating: (2) Feedback Score: 2 reviews	..... and that roadster of yours is sick!!!!! __________________ www.iDigsThat.com ....Check it out....

05-10-2011, 06:01 PM	#17
drftwerks Nissanaholic! Join Date: Mar 2004 Location: california Posts: 2,343 Trader Rating: (1) Feedback Score: 1 reviews	pics of roadster. please. __________________ giantroboteyes.wordpress.com/

05-10-2011, 06:04 PM	#19
herbieS13 Zilvia Junkie Join Date: Nov 2008 Location: FT Campbell, KY. Posts: 329 Trader Rating: (2) Feedback Score: 2 reviews	this build looks like such an epic win it disgusts me...subscribed

05-10-2011, 06:11 PM	#21
Drft_S14 Zilvia Member Join Date: Sep 2006 Location: Cathedral City Age: 34 Posts: 192 Trader Rating: (7) Feedback Score: 7 reviews	Wow .. the Fabrications are awesome!!!! the Fan shroud and the suspension are my fave ! good job sir! __________________ I never narc'd on nobody

05-10-2011, 06:19 PM	#23
donandal Leaky Injector Join Date: May 2011 Location: Lakewood N.Y. Age: 61 Posts: 56 Trader Rating: (0) Feedback Score: 0 reviews	the subie is posted in chat now

05-10-2011, 06:29 PM	#26
treken2t87 Zilvia Junkie Join Date: Apr 2008 Location: Indianapolis, IN Age: 34 Posts: 337 Trader Rating: (4) Feedback Score: 4 reviews	Top notch build. Very great attention to detail here. Also kudos for offering a refund on a transaction over a year ago __________________

05-10-2011, 06:56 PM	#29
tricky_ab Post Whore! Join Date: Sep 2008 Location: It's dark, and hell is hot! Posts: 9,413 Trader Rating: (23) Feedback Score: 23 reviews	This is great work so far!

05-10-2011, 07:04 PM	#30
Okinawandrifter87 Post Whore! Join Date: Jun 2006 Location: Sacramento, CA Posts: 3,959 Trader Rating: (22) Feedback Score: 22 reviews	I am thoroughly impressed which I dont say too often here on Zilvia with alot of build threads. __________________ Driftphreak87

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