Sock's 240sx Rusto Project (56k, tons of pictures)

just the fronts are plug and play

The rear rotors are the same, haven’t checked caliper or pad numbers though.

the rears are the same size as a stock 240

you sure about that? I could of swore a 180sx setup was only an altima rotor but a maxima pad + caliper. not all altima parts ?

and as for the Z32 setup, those can clear some 15’’ Rims (even the stockers) the other 15’’ Rims that they wont clear just require a 5mm spacer usually “nothing big”

The part numbers are the same. I kinda mentioned that. :stuck_out_tongue:

It’s more the price than anything. I think I might try the Q45 caliper on an Altima rotor. Some say it won’t work, but I can find any records of people actually trying it. The Q45 rotor is 28mm while the Altima rotor is 23mm. 5mm isn’t a lot of difference that a floating caliper can’t account for.

I wonder how many low spots actually exist?
http://img.photobucket.com/albums/v374/sockington/240sx/july7/01.jpg

Tons.
http://img.photobucket.com/albums/v374/sockington/240sx/july7/02.jpg

Smoothing out driver’s rocker panel.
http://img.photobucket.com/albums/v374/sockington/240sx/july7/03.jpg

Close yet? Getting there.
http://img.photobucket.com/albums/v374/sockington/240sx/july7/04.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july7/05.jpg

Driver’s side again.
http://img.photobucket.com/albums/v374/sockington/240sx/july7/06.jpg

Closed up.
http://img.photobucket.com/albums/v374/sockington/240sx/july7/07.jpg

I had to close up early today because I ran out of lightweight filler (Bondo) to smooth out the rest of the little spots. Oh well, it can wait for another day.

More work on the rocker.
http://img.photobucket.com/albums/v374/sockington/240sx/july12/01.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july12/02.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july12/03.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july12/04.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july12/05.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july12/06.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july12/13.jpg

I got a tiny bit more to do, but it’s almost all done. Jesus, rocker panels suck.

Update involving a motor? Hot Damn!

First off, boring rocker panel work.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/01.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july14/03.jpg

Wheel well work.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/02.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july14/17.jpg

Sealing in patch on passenger side.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/04.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july14/16.jpg

Whoa? What is the forklift doing? Dare I work on the engine? I dare.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/05.jpg

Building the stand.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/06.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july14/07.jpg

Went to the local Fastenal (awesome nut and bolt store. I know where I’m getting my motor mount bolt.) and picked up some Grade 8 bolts and nuts to hold the engine on the stand.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/08.jpg

All tied up and ready to lift.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/09.jpg

The god damn starter died in the forklift. I could hear how it wasn’t extending and grabbing the flywheel, but rather just spinning. Shit.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/10.jpg

So, I decided to do some more body work. Whilst sanding, I accidently dropped the can of primer and punctured a hole in it. Dammit.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/11.jpg

Moved outside. Still spraying.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/12.jpg

I decided to antagonize Mr. Miller some more.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/13.jpg

And one for you guys.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/14.jpg

After closing the hatch, I really started to see things come together (hatch is being replaced, too rotted to work with). I’m getting all excited about the project again. Tis’ a chore no more.
http://img.photobucket.com/albums/v374/sockington/240sx/july14/15.jpg

I wanted to put the engine on the stand because I noticed that it seemed really clean once the dirt was removed. It looks as if the head and block were re-painted a high-temp black, which I hope means that they were apart and new interals and porting were done. Odds are they just painted it inside the car.

what did you pay for the engine stand? I just picked up a couple used ones…

$40.

I tore into the motor today. I guess my hopes of having a slightly modified motor is gone.

Hanging out.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/01.jpg

On the stand.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/02.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july17/03.jpg

Grabbed some baggies to label and store bolts and platic wrap to wrap up the head when it’s apart.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/04.jpg

I choose you to come off first, Mr. Throttle Body.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/05.jpg

God damn. That’s an awkward as hell nut to get off.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/06.jpg

Be gone foul 40mm throttle body.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/07.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july17/08.jpg

Goodbye upper intake manifold! (Was hoping the lower would be ported. It was not.)
http://img.photobucket.com/albums/v374/sockington/240sx/july17/09.jpg

And farewell to you lower intake.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/10.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july17/11.jpg

You’re next, crappy turbo.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/12.jpg

The coolant line that did the turbo in. See the little crack? That caused coolant to no longer enter the turbo and to spew everywhere.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/13.jpg

And the exhaust manifold is off.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/14.jpg

Fucked turbo? Check. I can probably take off the impeller and housing and sell it to MX-6 GT Turbo guys for upgrade.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/15.jpg

Exhaust ports.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/16.jpg

Pulled the plugs - they all look good. Nothing too serious to worry about.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/17.jpg

Closed up for the day.
http://img.photobucket.com/albums/v374/sockington/240sx/july17/18.jpg

Tommorow I’m going to pull the head and see how things look from there. If the block is all right, then I’m going to start sourcing out some good performance parts for it.

Rebuild, eh? I wasn’t even thinking about doing that.

I owned a Merkur. I know all about them forums - they rock.

Time for the teardown. This is an update for yesterday (I was too tired to post).

Valve cover off. Damn, it looks brand new.

The head. Nice and clean.


Goodbye alternator.

Timing cover off.

SOOO clean. Damn, I thought things were doing to be worse. Head bolts all loose.

Head bolts vs. 1/2 Drive Socket wrench. Big bolts.

OH SNAP! Timing belt is gone. Good old non-interference.

Oh, the first three look good.

Oh shit. Cylinder #4 was crap.

The head.

Cyl #4.

Cyl #3

Cyl #2

Cyl #1

Well there’s your problem right there. A bee in Cyl #2.

I guess there was still a bit of oil left in the engine.

Coolant and oil in the pan. I’m guessing the headgasket failed in #4 as there was a slight crack in the gasket.

The end for today.

Packed up. Good old cling wrap will keep crap out of the cylinders for the night.

Today’s work.

The start.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/01.jpg

Oil pump and pickup removed.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/02.jpg

Rod cap #1 removed.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/03.jpg

The rest removed.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/04.jpg

Crank caps removed.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/05.jpg

Everything bagged and tagged.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/06.jpg

Crank out.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/07.jpg

Hello pistons.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/08.jpg

Crank all wrapped up. I don’t want any damaged too it as it’s going back in.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/09.jpg

Pistons out.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/10.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/11.jpg

The bad piston (#4).
http://img.photobucket.com/albums/v374/sockington/240sx/july19/12.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/13.jpg

The block.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/14.jpg

The bad cylinder.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/15.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/16.jpg

Water pump removed.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/17.jpg

Now you see the dizzy.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/18.jpg

Now you don’t.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/19.jpg

Pulling the dizzy crank gear.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/20.jpg

Dizzy gear and shaft out.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/21.jpg

The almost clean block.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/22.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/23.jpg

Weird ass thing. It has to do with the PCV system. I suspect it will be hard to find a replacement/replace.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/24.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/25.jpg

Engine stripped.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/26.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/27.jpg

Body work!
http://img.photobucket.com/albums/v374/sockington/240sx/july19/28.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/29.jpg

Bagged, tagged, and removed parts.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/30.jpg

Closed up for the day.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/31.jpg

The block is going to be bored over 30 over to clear out that bad spot on cylinder #4. Then I’ll be picking up some Crower Sportsman rods, ARP bolts, Pistons (probably Weisco or Diamond depending on reviews on TurboFord), A237 Cam (a little more performance) or just a Ranger Roller cam (better than stock), some home head porting, and a few other things.

if that 240 ever runs with this engine, than i’ll be impressed, i cant wait to see the wiring setup 8)

The wiring is pretty straight forward. The gauges will have to be custom made (VDO or something along those lines) since the T5 (tranny) uses a mechanical drive rather than an electronic setup (ala the 240).

Also, you’re not impressed that I stuck with it so far? :stuck_out_tongue:

^ I know I am :slight_smile:

http://img.photobucket.com/albums/v374/sockington/240sx/july19/32.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/34.jpg

Most the bits out.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/33.jpg

Bottom of head.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/35.jpg

Intake Port #1
http://img.photobucket.com/albums/v374/sockington/240sx/july19/36.jpg

Intake Port #2 and #3
http://img.photobucket.com/albums/v374/sockington/240sx/july19/37.jpg

Intake Port #3 and #4
http://img.photobucket.com/albums/v374/sockington/240sx/july19/38.jpg

#1
http://img.photobucket.com/albums/v374/sockington/240sx/july19/39.jpg

#2
http://img.photobucket.com/albums/v374/sockington/240sx/july19/40.jpg

#3
http://img.photobucket.com/albums/v374/sockington/240sx/july19/41.jpg

#4
http://img.photobucket.com/albums/v374/sockington/240sx/july19/42.jpg

More bits coming out.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/43.jpg

So god damn clean.
http://img.photobucket.com/albums/v374/sockington/240sx/july19/44.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/45.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/46.jpg
http://img.photobucket.com/albums/v374/sockington/240sx/july19/47.jpg

The wiring is pretty straight forward. The gauges will have to be custom made (VDO or something along those lines) since the T5 (tranny) uses a mechanical drive rather than an electronic setup (ala the 240).

Also, you’re not impressed that I stuck with it so far? :P[/quote]

what about the z31 300zx. they have a t5 in the early turbo cars with a speedo pinion and cable but it can be exchanged with the electronic one from the later cars I think…

on a similar topic if you could figure out how to run/translate the cas signal off the ford engine you could use pretty much any 4cyl engine management, possibly even a stock nissan one, maybe an sr, maybe a ka, doesn’t matter much what you end up with, because matching functioning guages will be available for it for that factoy look

why would cylinder 4 be more rusted than the others?

The head gasket was blown on that cylinder and sat for a while (water in the cylinder).

As for the engine management, I’ll be using just a stardard Ford 16-bit ECU system (LA3, for those who care).

The gauges are going to be the pain in the ass part. I’m using the OEM sending unit in the fuel cell, so I can retain a proper fuel gauge.

I’m not sure how everything is going together. I’ll fly from the seat of my pants and deal with the problem when I get there.

EDIT: Worse case senario, I just bring a GPS along and record what RPM in which gear = what speed.