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86 Flatty Euro Spec RHD


Lunacy
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Well last weekend i finally put the car up on axle stands and made a start on this build.

Car is to be mainly a track car but will keep it road legal for as long as possible.

Plans at the moment are as follows:

 

1) Remove all rear suspension, fuel tank, subframes, diff, torque tube and sway bar. DONE

2) Have all above sand blasted and powder coated DONE

3) Replace all bushes in rear end with poly ones DONE

4) Rebuild axles and rear callipers DONE

5) Replace all fuel filters and lines, install walbro pump DONE

6) Install new KYB GR2 shocks with coilovers (yet to be decided what kind)

 

Will update progress pics as i go.

 

Heres the car before she went up on the stands:

http://i73.photobucket.com/albums/i203/Lunacy55/100_1063.jpg

 

Few pics of dropping the tank:

 

After a bit of dust cleaned off, was a layer about half an inch thick on the top:

http://i73.photobucket.com/albums/i203/Lunacy55/100_1156.jpg

 

Undercar with tank removed:

http://i73.photobucket.com/albums/i203/Lunacy55/100_1158.jpg

 

Not a bad state for a 22 year old fuel filter:

http://i73.photobucket.com/albums/i203/Lunacy55/100_1164.jpg

 

More to come soon

Edited by Lunacy
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Few more pics:

 

Drivers side rear hub off, gotta love those LCA bolts that are rusted in <img src="http://www.starquestclub.com/forum/public/style_emoticons/<#EMO_DIR#>/sad.gif" style="vertical-align:middle" emoid=":(" border="0" alt="sad.gif" /> think i mite need new ones as mine may be a bit stuffed now <img src="http://www.starquestclub.com/forum/style_emoticons/<#EMO_DIR#>/sad.gif" style="vertical-align:middle" emoid=":(" border="0" alt="sad.gif" />

 

<img src="http://i73.photobucket.com/albums/i203/Lunacy55/100_1170.jpg" border="0" class="linked-image" />

 

These shocks are well shot, they just sank down into the strut housing when i undid the top nut <img src="http://www.starquestclub.com/forum/style_emoticons/<#EMO_DIR#>/ohmy.gif" style="vertical-align:middle" emoid=":o" border="0" alt="ohmy.gif" />

 

<img src="http://i73.photobucket.com/albums/i203/Lunacy55/100_1169.jpg" border="0" class="linked-image" />

 

Hub shot. These seem to be fine <img src="http://www.starquestclub.com/forum/style_emoticons/<#EMO_DIR#>/smile.gif" style="vertical-align:middle" emoid=":)" border="0" alt="smile.gif" />

 

<img src="http://i73.photobucket.com/albums/i203/Lunacy55/100_1167.jpg" border="0" class="linked-image" />

 

Also managed to drop all the subframes, diff, torque tube and swaybar today, but pics will have to wait camera batteries died.

 

On a random note my diff was only attached to the drivers side mount; the bolt on the passenger side one was nowhere to be found and hadnt been there for awhile from the amount of filth on it. Cant have been good <img src="http://www.starquestclub.com/forum/style_emoticons/<#EMO_DIR#>/sad.gif" style="vertical-align:middle" emoid=":(" border="0" alt="sad.gif" />

Edited by Lunacy
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Well the subframes out now, just gotta burn the bushings out :)

http://i73.photobucket.com/albums/i203/Lunacy55/100_1171.jpg

 

And gotta do something with the diff and torque tube, talk about rusty on the outside!!!!

Very rare to find a LSD here too :)

http://i73.photobucket.com/albums/i203/Lunacy55/100_1174.jpg

 

Will hopefully get the bushes burned out tomorrow and get all the bits off to the powder coaters.

 

On another note saw a bit of paint peeling in the passenger wheel well, so gave it a tap with a screwdriver and lo and behold a heap of filler and rust fell out so looks like il have to cut that out and weld in a new piece. :( Really need to buy a welder

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  • 2 weeks later...
  • 1 month later...
  • 3 weeks later...

Well progress has been hellishly slow lately as college has been sucking up all my time but now exams are done theres more $$ and time for the car.

Have been buying bits for my new 4g63 twincam engine, Mahle pistons and arp fasteners, and a few other goodies so can get onto doing the engine too.

More pics soon :)

PS Removing the old suspension bushes is a PITA without a press!!!!

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You need to get the large nozzle attachments for the propane bottles, the flame gets hotter, which is what you need for those bushings.

 

Also, don't be surprised when you put it back together and the rear wheels steer the car. That huge bolt in the LCA you took a pic of have a bad tendancy to take the hole through the hub out of round. Happened to my car and a friend's car. I have fixed mine, his has been sitting for years so it doesn't matter too much, but it was a b*tch trying to drive that thing.

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You need to get the large nozzle attachments for the propane bottles, the flame gets hotter, which is what you need for those bushings.

 

Also, don't be surprised when you put it back together and the rear wheels steer the car. That huge bolt in the LCA you took a pic of have a bad tendancy to take the hole through the hub out of round. Happened to my car and a friend's car. I have fixed mine, his has been sitting for years so it doesn't matter too much, but it was a b*tch trying to drive that thing.

 

Yeah ive only got a small butane torch which doesnt quite cut the mustard really.

And as for THOSE lca bolts, well im in the market for new ones as those may or may not be unusable now, threads are a little bit stuffed thanks mainly to my effort getting the rusted up things out. :( :( :(

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  • 1 month later...

Well finally got all the bushes out today and all the bits off to the powdercoaters so couple of weeks and they should be back all nice and shiny.

Professor quests guide to bush replacement is gold and definitely a good read for anyone attempting this.

Heres a couple of pics from last day or so.

 

Getting the crossmember bushes out - these were rusted in solid!!! took alot of heat and prying.

http://i73.photobucket.com/albums/i203/Lunacy55/100_1199.jpg

 

Halfway thru the 2nd one

http://i73.photobucket.com/albums/i203/Lunacy55/100_1201.jpg

 

All the bits in the trunk ready to be powdercoated

http://i73.photobucket.com/albums/i203/Lunacy55/100_1205.jpg

 

For anyone doing this a small wire brush on a drill is a essential piece of equipment for gettin the last bits of rubber out of the bush holes and for cleaning up the metal.

 

My new bushes (stedebani), pistons (mahle) and arp bolts showed up a few days back too so might have to get onto doing the engine soon, well as soon as i find some eagle rods for a decent price. Also have mookeehs camber plates on the cards for next payday :)

 

In the meantime though, will wirebrush and clean the underside of the body, and respray it with tough underbody paint.

Will update again soon :)

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  • 3 weeks later...

Well got all the subframes back from the powder coaters today and man what a difference.

Pics tell the story:

http://i73.photobucket.com/albums/i203/Lunacy55/100_1225.jpg

http://i73.photobucket.com/albums/i203/Lunacy55/100_1227.jpg

 

And heres the sleeves that ive removed all the rubber from, and then wirebrushed, primered and painted

http://i73.photobucket.com/albums/i203/Lunacy55/100_1229.jpg

 

Next is get under the car and wirebrush and redo the underside which got on hold due to me having to do 4 days straight on my wifes car as it died :(

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  • 1 month later...

Well managed to get under the car yesterday and today and start sanding back the crap off the underside and unfrotunately this is what i found in the left rear wheel well:

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0183.jpg

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0184.jpg

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0185.jpg

 

A heap of rust, and filler :( So thats gonna add to the bill to have all that cut out and replaced :(

Edited by Lunacy
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looks like your doing an amazing job. keep it up.

Haha its kinda got out of hand, was going to be a quick tidy up initially but the deeper i go the lower my bank balance gets :)

At least when its done il know that everythings new or renewed and wont cause me any issues in the future. Il be keeping this one for a LONG time :)

 

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Well was looking on net this morn and found this for sale for $20NZD so decided that was a bargain :)

Will need to flip it upside down so turbo is topmounted on my 4g63 and add a pipe and flange for the wastegate but other than that not a bad deal i think!

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0188.jpg

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0189.jpg

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  • 2 months later...

Well its been awhile but just got decent paycheck so getting a bit done now.

Just got turbine and compressor wheels back from being bead blasted, polished and balanced.

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0276.jpg

 

Also sent my twincam head off to shop to have it hardness and vacuum tested, and providing they check out ok, will have it hot tanked, skim the face, decarbonise everything, replace valve stem seals and check guides, springs and retainers.

As for cams, im eyeing up a set of billet 264s at the moment with adjustable gears :)

 

Have also just bought ARP head studs and new RWD water pump as well so parts are all coming together.

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awsome build man. Powdercoating in unbelievable. Just curious what did that run$$ you?

Very little actually, was about $50USD for the whole lot definitely one of the best value things ive done to the car.

That included blasting all the pieces as well :)

All my front end parts will be going there too when i get them out :)

 

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Well courtesy of my trip to Australia in the weekend, and the local trademe website i now have a couple more pieces of the puzzle.

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0325.jpg

24mm front swaybar

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0324.jpg

4 Pot alloy R32 skyline brake callipers

 

Was some good and bad news on the head front, hardness test came back fine, but found a bit of pitting on nearly all the exhaust valves.

So long story short, am having the valves recut, seats ground and lapped and reassembled.

At least for peace of mind will know the valves are sealing properly now.

Roll on next pay so can get the block assembly and balance done :)

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Well these weren't exactly planned but was too good an opportunity to pass up.

As im going with 4 pot brakes was worried the 16" wheels wouldnt clear them so picked these up for $400NZD.

17 x 8.5" ROH ZS with correct offset for the starion :)

Shouldnt have trouble with brakes now :) Just gotta find some tyres that will not rub on the guard or strut :)

And give the lips a sand back and repolish as the clear coat is a little crazed.

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0326.jpg

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  • 1 month later...

Well after 6 weeks at sea am back at it again.

Have just ordered ACL race main and rod bearings, a custom underbody surge tank and a rear thermostat housing adaptor so will post pics of these soon as they arrive.

Block and crank will be having machine work done shortly, and then as soon as my rods get here long block will be assembled.

So next few days are going to be going to be working hard to get the underside done, and the rear subframes, suspension and fuel system back in so i can drop the SOHC 4g63 and pull all the front subframes and suspension out.

Pics soon :)

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Today managed to finish the back half the underside of the car - worst job ever!!!

Have removed 23 yrs of dirt/grease/tar off all surfaces, then wirebrushed and treated a little bit of surface rust, and then sprayed on new underbody paint.

Pics tell the story:

 

Nice and clean

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0345.jpg

 

This stuff is horrible

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0348.jpg

 

After coating

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0351.jpg

 

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0350.jpg

 

Will do another couple of coats in the morning all going well then start putting the rear suspension back together :)

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Haha normally hate being woken up early when im on leave, but when its the courier man with something cool - no complaints :)

This arrived this morn, thanks to JAS here in NZ who did a run of 5 of these surge tanks :)

Designed to mount between the diff and the fuel tank under the car to keep those fumes out :)

http://i73.photobucket.com/albums/i203/Lunacy55/CIMG0353.jpg

Now just gotta buy another fuel pump as il be using the Walbro as a pickup, Bosch 044 me thinking :)

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