Zedback Posted March 16, 2009 Share Posted March 16, 2009 I'll get on the bandwagon and share as much of this renovation as I can. I call it a renovation because I'm more keen on getting it back on the road than doing a "proper" restoration for which there isn't the budget anyway. So if I take short cuts that offend, that's my excuse and too bad. It arrived Xmas before last after sitting under a house since 1988... Where it was tucked away in the shed while I was distracted by the 280zx. Before tucking it away I thought it wise to first remove the engine. Though it had been sitting this way for 20 years, it had just traveled across Brisbane on the back of a truck. (There is a few bits missing: gearbox, front guard, seats, radiator) So finally after 20 years under a house and 12 months in my shed, it's out and work has begun! Stripping is a tedious process, you can do it financially, chemically or mechanically. Haven't go the $$s and can't stand the smell of paint stripper, so I choose mechanical. These stripper discs are very effective If I could get the photos off my mobile phone I'd have more detail here, but basically the bottom and rear edge of this guard were rust damaged. Replacement panels were cut from useful sections of a 280zx guard and welded in with a cheap 2nd hand gas-less mig. Por15 has been painted into the weld area and then stripped off the surface The entire inner surface of the guard has been stripped and painted with por15. Expensive stuff but I've had good results with it in the past so I'll stick with it. More to come... Quote Link to comment Share on other sites More sharing options...
RB26DETT Posted March 16, 2009 Share Posted March 16, 2009 thanks for sharing , its good to see others getting hands on with repairing these wonderful cars keep the photos coming i like looking at blogs of rebuilds i must say that the body work part is by far the worst and least enjoyable part of building a car!!! Quote Link to comment Share on other sites More sharing options...
Administrators gav240z Posted March 16, 2009 Administrators Share Posted March 16, 2009 I call it a renovation because I'm more keen on getting it back on the road than doing a "proper" restoration for which there isn't the budget anyway. So if I take short cuts that offend, that's my excuse and too bad. No need to apologise or make excuses, she is a basket case so putting her back on the road is good for everyone. I think we all know what the cost of resurrecting such a car would be, if you are happy with it that will be the main thing. Quote Link to comment Share on other sites More sharing options...
Zedback Posted March 16, 2009 Author Share Posted March 16, 2009 ...she is a basket case... LOL, THAT's not a basket case, THIS is a basket case (my 1971 240z) :'( If it's brown, it's rust. It's the next project Quote Link to comment Share on other sites More sharing options...
Administrators gav240z Posted March 16, 2009 Administrators Share Posted March 16, 2009 Well my hat goes off to you, good to see you saving these cars otherwise they would meet the crusher . Quote Link to comment Share on other sites More sharing options...
Zedback Posted March 16, 2009 Author Share Posted March 16, 2009 So the other reason to post all this up is to embarass myself into keeping the work up and not letting it slide into the "too hard, too many other things to do' basket. At this point time I'm taking the most useable bits off the 2 cars. From the '71 z I'm pinching the RH door and the fibreglass bonnet. You would think a fibreglass bonnet would be rust free, but no, the hinge attachements are steel, at least it is only some surface rust! Haven't decided yet whether to use the steel or fibreglass headlight scoops. Unless I find a front spoiler I'll also be using the lower front valence panels. So to bring you up to date: Left door has been stripped and other than dents isn't too bad. There is a rust hole which I haven't yet decided whether to weld up or fill over for now? The right door has had previous repairs to the front lower corner and rear lower edge. These had rusted over again and the filler had cracked and fallen out. They've been cleaned up as well as possible and por15'd. The area where the mirror bolts to had rusted badly. This area was cut out and a new piece of metal inserted. I'm using lap welds on all of these, but welding proved impossible. After cutting out the piece I recess the area as best and minimally as possible. Some areas are easier to do than others, this area of the door is very difficult. There will be a good layer of filler required over the top. And this is why I'm using the door off the '71, this one will get reskinned at a later date. Tailgate shut panel was removed earlier and a new one has been ordered. At the moment this is likely to be the only new panel. Area has been cleaned up and por15'd. When the new one arrives I'll look at where I need to strip it back to weld the new panel in. Advice welcome from anyone who's replaced this panel before? Yet to be done are the right and left doglegs / sills. Both need some work and I'm yet to decide how best to approach them... Quote Link to comment Share on other sites More sharing options...
Zedback Posted March 25, 2009 Author Share Posted March 25, 2009 I had to revert back to paint stripper for the cowl panel, those vents just cannot be done any other way! The wire cup brush was still useful though. Nearly there, but I still have more work to do cleaning out the vents... You can see the pitting where foam pads were glued on. What have people replaced these with? Along with the door the RH sill panel has taken a hit. I've cut two vertical slits with hacksaw And now I'm slicing the crease across the top The sheet parts easily along the crease and then fold it down I've decided this is the most useful tool in the workshop! It's being used to straighten out the outer sill Ta-da! It worked a treat A bit if work with hammer and dolly and it's folded back in place ready to be welded in Very exciting, the only new steel in the Z. Got it off ebay but I think it's the Rare Spares item Stripping headlight scoops is particularly tedious! The right one is pretty good But the left one has the telltale sign of bodyfiller appearing Two scoops stripped, damn! Sure enough, the front of the left one is a little crumpled. Got it off ebay but the seller is unlikely to have known, I couldn't tell until I started stripping it. Started in on the left dogleg. It's just a little worse than hoped for, but isn't that always the way with rust... Now this is the danger point where a renovation can verge into a restoration. Do I close my eyes and weld a bit of sheet over the top? Or do I start tearing the dogleg apart? It's too much to ignore, dive in! Spot welds Horizontal cut More spot welds and it'll pop off Fold it down and... this is why everywhere you read or hear about rust, they say it's always worse than looks on the outside. My '71 240z stands testament to that too. Yuck, rust, dirt, bog, wax sealer, holes, it's a mess. Time to toilet train the Z, it's just left a pile of crap on the floor Take out the remaining spot welds along the bottom and tear the junk off Wire cup brush helps clean it out and shows up where the holes are And a bit more cleaning up with a grinding disc Patch made up for the easy hole where the dogleg meets the sill. It's held in place by a small Neodynium magnet. I picked up a bunch of these off ebay. Very strong and very useful. Great for holding sheet while you tack weld. Don't let them get too hot or they lose all magnetism and become useless ceramic pellets. Tacked in place Shape a bit with hammer and weld in Clean it up and "hey presto" There was a small hole on top of the sill, this one I just bridged More on the nasty dogleg when I figure out what to do next, but I did a bit more on the LH door. Bridged one small hole Made up some small patches for the others and again using the little magnets, tacked, Welded, and cleaned them up! Progress is good at the moment but I'm back to work next week. I'll see how far I can get before the weekend is over and it grinds to a halt. Quote Link to comment Share on other sites More sharing options...
sexual_sushi Posted March 25, 2009 Share Posted March 25, 2009 yay rust good to see another zed being saved Quote Link to comment Share on other sites More sharing options...
Administrators gav240z Posted March 25, 2009 Administrators Share Posted March 25, 2009 Great work mate, really good to see it documented like this too. I know how you felt about the rust in the lower sill, but I'm sure your glad you got in there and cleaned it up. Eager to see this progress along, makes me anxious to dive into my own Zed too bad its half the world away though . Quote Link to comment Share on other sites More sharing options...
chinaelephants Posted March 25, 2009 Share Posted March 25, 2009 come back away from the light nice work mate Quote Link to comment Share on other sites More sharing options...
Zedback Posted March 26, 2009 Author Share Posted March 26, 2009 Thanks all for the encouraging comments. I love bringing a wreck back to life. Having a good day today building a new dogleg panel from scrap, posts with lots more photos to come. Quote Link to comment Share on other sites More sharing options...
xa1973 Posted March 26, 2009 Share Posted March 26, 2009 LOL, THAT's not a basket case, THIS is a basket case (my 1971 240z) :'( If it's brown, it's rust. It's the next project Chop the top and make a convertible Quote Link to comment Share on other sites More sharing options...
Aaron Neubauer Posted March 26, 2009 Share Posted March 26, 2009 I'm paying keen attention to this project log! I've had rust in almost all the same spots you have! I haven't fixed all mine yet as I wasn't sure how to approach some spots....this will do as a guide though Quote Link to comment Share on other sites More sharing options...
Zedback Posted March 26, 2009 Author Share Posted March 26, 2009 Chop the top and make a convertible The thought has crossed my mind once or twice I must admit... :-\ ...this will do as a guide though Hope it gives you some ideas. I've been staring at it for more than 12 months wondering how and where to start. Finally decide to just jump in! Quote Link to comment Share on other sites More sharing options...
Zedback Posted March 26, 2009 Author Share Posted March 26, 2009 The driverside dogleg as I found out is swiss cheese. Does anyone know if there are repair sections available? I didn't menton earlier, this is where I am sourcing my patch panels, a bent 280zx guard. It's been more useful than I first though because I have beem able to reuse profiles and folds that suit. Here is the donor section for the dogleg The fold on the rear edge is modified from the guard. The lower profile is shaped by gently bending with pliers. The trick is to use the nose of the pliers to carefully form the crease. Don't bend more than 30 degrees at a time. Work along and back a few times until you get the right angle. The wider fold was formed the same way but using the deeper grip of my favourite tool using exactly the same technique Tidy up both folds with a hammer and dolly. Trial fit Lower profile not right, have another go Had a brainwave! Reuse the top profile of the old dogleg Double check it still fits Put new section on as well and mark out where they meet Add about an 8mm overlap, cut to shape and form a lip. Same technique as above but take even more time and care. You want to form the lip fold first and then bend the overlap back to parallel Should end up looking like this Clamp the two parts together Start tacking them together Not too bad I think Can't weld the new dogleg in yet, more holes to patch Judicious use of a hammer to shape... Easy Until next time... Quote Link to comment Share on other sites More sharing options...
dazzed Posted March 26, 2009 Share Posted March 26, 2009 kameri have stock of new engine mounts, as i think you may need them Quote Link to comment Share on other sites More sharing options...
zzzzed Posted March 26, 2009 Share Posted March 26, 2009 good job mate. I tackled my dog legs a few months back i also fabricated the inner seals. It was a big job Quote Link to comment Share on other sites More sharing options...
Zedback Posted March 28, 2009 Author Share Posted March 28, 2009 kameri have stock of new engine mounts... Where do you get them from? Is there any advantage over stock Nissan mounts? It was a big job That I can believe! Did you fabricate your own patches/panels or source them from somewhere? Quote Link to comment Share on other sites More sharing options...
Zeddophile Posted March 28, 2009 Share Posted March 28, 2009 Awesome work! Good to see I'm not the only one who was crazy enough to say to themselves its just a bent piece of metal, how hard can it be to make from scratch! Quote Link to comment Share on other sites More sharing options...
zzzzed Posted March 29, 2009 Share Posted March 29, 2009 Where do you get them from? Is there any advantage over stock Nissan mounts? That I can believe! Did you fabricate your own patches/panels or source them from somewhere? yeh i fabricated the dog legs and inner seals here is a youtube vis of how i did it Quote Link to comment Share on other sites More sharing options...
nuclear_z Posted March 29, 2009 Share Posted March 29, 2009 you sir have a pretty camera face Great work there. Cant wait to see more... Quote Link to comment Share on other sites More sharing options...
zzzzed Posted March 30, 2009 Share Posted March 30, 2009 thanx man i try hard ;D Quote Link to comment Share on other sites More sharing options...
Zedback Posted March 30, 2009 Author Share Posted March 30, 2009 Hey that looked familiar, especially the 'woops'! Very nice work, I'm going to have to do a rottisserie for the '71. I think I can get away without for this one. Quote Link to comment Share on other sites More sharing options...
zzzzed Posted March 30, 2009 Share Posted March 30, 2009 Thanks guys the rotisserie makes life so much easier and it only took half a day to build. I'll do some more vids soon, I am finding it hard to find time at the moment other peoples projects have to come first unfortunately. especially when they are paying me Quote Link to comment Share on other sites More sharing options...
zedevan Posted April 11, 2009 Share Posted April 11, 2009 These stripper discs are very effective where abouts did you get them from? what brand? and how much? I just went and got the only similar looking thing from the local hardware store, and for the price it was and amount of a panel that i managed to strip it seems like an expensive method!?! Quote Link to comment Share on other sites More sharing options...
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