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Pb's - '77 260Z 2+2 Rebuild


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#21 Lurch ™

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Posted 31 May 2015 - 03:45 PM

Riiiiiight... Over a year since an update on this but there has been a lot happening!

Like any personal build, it's been coming second to paying customer cars. However I have found a few hours here & there over the last year to perform repairs on it.
As it happened, I had a cancellation early last week so I decided to do a final 'push' on the ''blue bus" & get it to a point ready for paint.
My spray painter has been around early last week, given me a price & told me I can drop it off late THIS week to start prep  :D

So this week has been doing all the little jobs on it & getting the front panels on & gapped.
So on with the photos!

Guard repairs were done last year:

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Spare wheel-well was rusted out & required repairing:

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And once the body deadner was lifted from the boot floor, more rust was found :(

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#22 Lurch ™

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Posted 31 May 2015 - 04:02 PM

Mid last year (2014) I had the boys at the local panel shop, bolt it to their chassis jig & pull the front out.

After it was pulled straight:

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Then the rust in the bonnet hinge mounting area could be repaired:

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Yuk... this didn't look good.

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Hrmmm... that's buggered. Stuff it - I'll just cut it off!

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New section made & welded on:

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Next I noticed that the inner guard area under the battery tray has a LOT of surface rust, so I decied the best way to treat it was to unpick the tray:

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I then wire brushed (wire death brush on the angle grinder) the area, applied some kill rust (phosphoric acid).
The old spot weld holes were welded up, but a few of the old ones were drilled out so I could install Nutserts / Rivnuts to secure the battery tray. Afterwhich the area was given a coat of etch primer:

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And finally the grill mounts were installed & the front end panels bolted back on along with a good 2nd hand bumper:

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Check out the hektic rake y0!

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Hopefully the next few photos will be of it in colour! Stay tuned ;)

#23 chris240

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Posted 31 May 2015 - 06:13 PM

Hooley dooleys....those pics give me a headache and Im not the one doing the work !  What colour ?

#24 Lurch ™

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Posted 31 May 2015 - 07:21 PM

The original 305 Light Metallic Blue, Chris.

#25 Brabham

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Posted 01 June 2015 - 08:32 PM

Nice work Locky :) When you cut out patches do you make them slightly undersize to prevent warpage when you butt weld them in? Noticed that there is a small gap around 1mm around them. What are your plans for the bus? Stock daily? Is she an auto or a manual? Good to see another light blue bus saved. Let me know what you do for the rubbers on the 2+2 as I have been looking for where to source these.

Cheers

#26 Lurch ™

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Posted 01 June 2015 - 08:50 PM

Nice work Locky :) When you cut out patches do you make them slightly undersize to prevent warpage when you butt weld them in? Noticed that there is a small gap around 1mm around them.



1mm gap for MIG welding Alex, none for TIG welding.
It depends on access to the back of the weld which process I use & weather or not it can be dollied straight after welding.

What are your plans for the bus? Stock daily? Is she an auto or a manual? Good to see another light blue bus saved.


Well since I've agreed on a sale price with Peter after it's back together, what happens to it will be up to him.
I do know it'll be converted to manual transmission though ;)

Let me know what you do for the rubbers on the 2+2 as I have been looking for where to source these.


I already have a new windscreen seal so the only one I'm replacing is the hatch glass rubber. Door seals etc are servicable.

2+2 rubber kits are available from Rare Spares
http://www.rarespare...x?product=DAT21

or Scotts Old Auto Rubber
http://www.scottsold...8 240Z-260Z.htm

And probably the US as well...


#27 PB260Z

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Posted 01 June 2015 - 09:01 PM

Well since I've agreed on a sale price with Peter after it's back together, what happens to it will be up to him.
I do know it'll be converted to manual transmission though ;)


Now is probably a good time for me to comment  :)

The car is coming to Sydney and initial plans are
New springs, fix the hectic rake  ;)

Gold Simmons V4 (16X8 and 16X8.5)

L28E, Manual & R200

Beyond that nothing major, but are they ever finished ?

Cheers

PB

#28 gav240z

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Posted 01 June 2015 - 10:56 PM

Good to see updates, a little scary that it was rusted near the rear shock tower. Never seen that before, but then again it is a Datsun :). Is the battery tray permanently going to be held in place with nutserts? Any reason you didn't spot/plug weld it? Do you want to remove it in future?

When you post all those updates in 1 go it makes me think you did this all yesterday. :).

Looks like panel gaps at front are nice and straight again.

#29 Brabham

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Posted 02 June 2015 - 12:01 AM

1mm gap for MIG welding Alex, none for TIG welding.
It depends on access to the back of the weld which process I use & weather or not it can be dollied straight after welding.


Hmm looks like I might need to leave a bigger gap rather than get stuff to fit too snug! I tried the trick with cooling stuff down with the compressed air blow gun straight after I mig it and that seems to work pretty well, takes the heat out of it pretty quickly, beats standing around waiting for it to cool down after every few tacks!

#30 Lurch ™

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Posted 02 June 2015 - 07:20 AM

I believe the hatch seal was leaking & water got into the hatch area, ran to the lowest point under the deadner & rusted out the floor.

Yes, the battery is going to be held in place like that indefinitely, Gav. It makes it easier to remove any dust, dirt  & debris that gets caught under there. Also makes it easier to paint ;)
I've converted quirt a few Zeds to removable trays - none have had any issues. I've done it to mine & that thing gets used at tack days.

The battery tray & panels were all done last week - everything else has been spread out over the last 12 months!

Good to see updates, a little scary that it was rusted near the rear shock tower. Never seen that before, but then again it is a Datsun :). Is the battery tray permanently going to be held in place with nutserts? Any reason you didn't spot/plug weld it? Do you want to remove it in future?

When you post all those updates in 1 go it makes me think you did this all yesterday. :).

Looks like panel gaps at front are nice and straight again.



#31 Lurch ™

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Posted 22 July 2015 - 01:40 PM

The bus is now blue!

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The crappy phone camera doesn't do it justice!
Now to put it back together...

#32 Lightmaster240z

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Posted 22 July 2015 - 01:49 PM

Very nice mate

#33 gav240z

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Posted 22 July 2015 - 02:43 PM

Come a long way... Very nice.

#34 PB260Z

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Posted 22 July 2015 - 03:31 PM

The bus is now blue!

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The crappy phone camera doesn't do it justice!
Now to put it back together...


;D  ;D  ;D

#35 CroS13

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Posted 22 July 2015 - 05:38 PM

awesome work as usual, its all down hill once it gets in paint so im told. 

Any particular reason you decided to use Nutserts instead of welding a nut to the back of the sheet metal before paint? Id be afraid that if i had painted the body the nut insert could crack the paint around its hole after you crimp it down, and it could rust there, in saying that ive only installed them into 3mm plate and not sheet metal.  trying to think which way to go for flares if i put them on my bus

Cant wait to see this thing in the flesh once it comes north.

Rudi.






#36 Scoota G

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Posted 22 July 2015 - 06:18 PM

You must be very Proud buddy, another Zed saved and it's looking Mint!

#37 dat240z

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Posted 22 July 2015 - 09:23 PM

Looking good.. Great color choice

#38 PB260Z

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Posted 22 July 2015 - 09:23 PM


Cant wait to see this thing in the flesh once it comes north.

Rudi.


All going to plan should be in Sydney mid August, it will be a while before it is out on the road though.

Cheers

PB


#39 PB260Z

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Posted 09 August 2015 - 09:44 PM

Gidday

Quick update, The Bus is now in Sydney  :) :) :)

Lurch has done an incredible job on the paint & panel work - the body looks amazing.
Now it is time for me to get busy sorting everything else out: Mechanicals, Suspension, Electricals, Interior & a host of other little things.

I will start making a to do list next weekend, for now having a beer and relaxing after a long drive.

Cheers

PB

#40 Lurch ™

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Posted 09 August 2015 - 09:54 PM

With the body & paint it now sorted, it'll be an excellent base to build on, with the refurbishment of the 'Blue Bus'.

Was great to catch up again Pete!
This build thread is now your's, mate. I look forward to more updates as the build progress's :)
Post some decent photo's when you can - I didn't get a chance to get a photo of it all back together before you left!







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