Jordan's '72 2 door KA project

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JordanTr
Posts: 916
Joined: 20 Feb 2013 22:27
Location: Langley, BC, Canada

Re: Jordan's '72 2 door KA project

Post by JordanTr » 09 Jul 2019 20:13

I had a week of "vacation" to work on the ole Datsun. Nothing like a shop week to make 8 hour days back at work go by fast!

In the instalment:
Exhaust rev 4+
Camber plates
CV driveline

The plan for the week was to get the car drive-able enough (back to stock NA) that I could get it home (600 miles from pa's shop) to finish off the nagging little things (like ghetto brake lines!). I was very close to making it happen but at least I have a car that is semi-functional again for a while.

I needed an exhaust since I sold the old rusty conglomerate and I now don't have a hole in the crossmember to fit it through anyways! I toyed with the idea of running the NA KA header to a 3" exhaust since that's what I'd need for booost anyways but I opted to go with a proper sized 2.25" system. To keep things simple, I used an S14 manifold since it goes straight to a single pipe vs. the S13 4/2/1 system. Thanks to Jeff and his rack setup for providing the necessary space!

Started at this flange (ID of the cast parts is almost identical to ID of 16ga 2.5" tubing so I used that for the downpipe.

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Thankfully I have a fantastic water-jet guy in Port Kells who makes quick work of little projects. I had the header flange cut from 3/8" 304SS. Thankfully I noticed the offset center hole when I was dimensioning the flange!

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

I was able to repurpose some exhaust hangers from the Q45 I wrecked to get the BBS wheels I had for this once upon a time.

Image510 7.2019 by TRZ Fab, on Flickr

The body of the exhaust is 2.25" with a Vibrant 1790 bottle resonator and a Magnaflow 11255 muffler. I was able to tuck a V band under the trans output shaft and one after the rear crossmember. Unsurprisingly, the reworked rear xmember makes for nice exhaust routing.

Image510 7.2019 by TRZ Fab, on Flickr

I went with 2.25" into the muffler and a 2.5" pipe cut turn down tip. I'm hoping its functionality makes up for its looks.

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr


Camber Plates
________________
I first designed a set in 2012 and have periodically refined them to make them easier to build, less custom parts etc. and I finally settled on a somewhat goofy design that combines camber and caster changes by have the adjustment at an angle. There are 3 positions that the slotted plate can be installed: primarily camber, primarily caster, or a happy medium. The way my car is set up, the happy medium zone is able to push the strut tops rearward 1" without changing the camber. The ground control lower plate is re-used so only some minor machining is required on the new plates. The best part? CAPTIVE METRIC FASTENERS!

I opted to space the camber plates down to prevent and strut tower hacking.

Image510 7.2019 by TRZ Fab, on Flickr

Was able to get the proper countersink bit which was very satisfying to use.
Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Spacers are a bit of a goofy shape
Image510 7.2019 by TRZ Fab, on Flickr

If anyone has GC camber plates and wants some more caster... hit me up. I could make a few sets of these.

CV Driveline
______________
Well, I've talked about it for a while but I made it happen now. I worked with Pat's to shrink a disk onto the S13 yoke and then machine for a pilot on a scavenged flange from a BNR32 companion flange. After that, I took it from the shop and TIG welded the disc to the flange part at home since they didn't have capabilities for that. I love welding big mild steel parts. It's very satisfying. I used pre and post heat and welded in 2 passes. The shop was able to get it together and then balance the whole shebang so it must not have warped too badly. Before welding I had tapped both the intermediate disc and the BNR32 flange chunk to M12x1.25 and secured to the 3 bolt pattern on the yoke with some class 12.9 SHCS.

Image510 7.2019 by TRZ Fab, on Flickr

Scavenged BNR32 chunk.
Image510 7.2019 by TRZ Fab, on Flickr

Dummy assembly so I could mock up a driveshaft and get the proper length.
Image510 7.2019 by TRZ Fab, on Flickr

Old and dummy shafts.
Image510 7.2019 by TRZ Fab, on Flickr

As received before welding
Image510 7.2019 by TRZ Fab, on Flickr

Tacked
Image510 7.2019 by TRZ Fab, on Flickr

Root pass (note that it's now bolted too!)
Image510 7.2019 by TRZ Fab, on Flickr

All done and match marked.
Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

I welded up a nice 2.75" intake with leftovers from pa, plumbed in the new rad, cannibalized some new S13 rad hoses and coupled them with little stainless pie cut pieces. etc etc.

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

Image510 7.2019 by TRZ Fab, on Flickr

So after all that, I take it for a couple driveway rips and it's good to go. I swapped the plates over and did my classic 4 mile loop. When I came home, I noticed a ruthless drip from the pinion seal on the diff (this is the 3.9 I built last year with a 1.5 way). After pulling the drain plug and finding it full of fresh, sharp filings, I pulled the plug on the Datsun for this trip since I had to leave in ~10 hours.

I had great fun driving the Crowsnest in the Silvia. I left at Keith timing (on the road at 5) so there were great roads all the way to Osoyoos. I love how well sorted that car is. Met up with Matt who just got out of the 510 game and forced him to take Silvia for a rip... He definitely got his turbo fix for the day!

Silvia safe at new home.
Image510 7.2019 by TRZ Fab, on Flickr

Next on the 510 list:
Working diff
Re-work trans tunnel doghouse
Re-work brake lines
etc.
Hopefully soon I can get it going with the S13 SR ECU and individual coilpacks/Nistune etc. Once that works, then I can get back on the turbo bandwagon! Too many house projects these days!
Jordan | '72 2 door KA project | '94 240sx RB26DETT | '97 Silvia RB25DET | '90 Audi 90 Quattro 20V (DD)

User avatar
gooned
Posts: 770
Joined: 07 Jul 2003 23:19
Location: Langley

Re: Jordan's '72 2 door KA project

Post by gooned » 09 Jul 2019 21:55

Big update!

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icehouse
Posts: 3431
Joined: 17 Jul 2005 17:06
Location: Everett Wa

Re: Jordan's '72 2 door KA project

Post by icehouse » 14 Jul 2019 03:46

How did the steering feel on the 5 mile drive?
"People don't like it when shit doesn't match their rule of thumb." Sam

User avatar
JordanTr
Posts: 916
Joined: 20 Feb 2013 22:27
Location: Langley, BC, Canada

Re: Rack Impressions

Post by JordanTr » 14 Jul 2019 07:16

icehouse wrote:
14 Jul 2019 03:46
How did the steering feel on the 5 mile drive?
Right... the steering rack!

It's certainly way tighter than it used to be and no more effort than I remember despite the new caster. Unfortunately, I have not had the car plated since Sep. 2017 so it's hard to remember exactly what it felt like. I didn't really push the car since I was getting used to the nuances of an old rattlebox all over again. I also lost the front sway bar in the process of repositioning the engine so that's a bit of a sad news story in the handling department right now. Sufficed to say, it's a bit of an apples to oranges comparison right now but the initial impression is great! The 2.5 turns L-L means that there is a definite reaction in the car when you turn the wheel compared to the old steering box.

The good news is that I'll be back at the shop in a couple weeks to throw another diff in the car. Let's hope it behaves after that! The driving ambiance will improve dramatically once the trans tunnel cover is all rebuilt as well.
Jordan | '72 2 door KA project | '94 240sx RB26DETT | '97 Silvia RB25DET | '90 Audi 90 Quattro 20V (DD)

User avatar
JordanTr
Posts: 916
Joined: 20 Feb 2013 22:27
Location: Langley, BC, Canada

Re: Jordan's '72 2 door KA project

Post by JordanTr » 23 Nov 2019 22:54

Today marks an exciting day... After years of planning to modify and do Nistune etc. on the engine, I have the engine running on an S13 SR20DET ECU with Nistune and Audi R8 coilpacks. So far, all that it has is a stock SR tune with resized injectors from 370 to 270cc.

I modified the harness to remove the old coil and provide outputs for the coilpacks. The power architecture is the same between the SR and KA ecus so nothing changes there.
The reference marks between the SR and KA CAS optical discs are different so the SR disc must be used in the KA distributor.
Image510 by TRZ Fab, on Flickr

The clocking on the CAS shaft is different as well so timing it is a bit of a challenge. I mocked up the relationship between the flat key of the CAS wheel and the optical pickup of the SR CAS when it was located at the timing marks (TDC power stroke).

SR timing marks
Image510 by TRZ Fab, on Flickr

SR CAS with KA wheel. Note the flat key to pickup angle
Image510 by TRZ Fab, on Flickr

KA dizzy with SR optical disc. Note the angle is very similar. First attempt!
Image510 by TRZ Fab, on Flickr

After the one tooth adjustment. It actually runs here!
Image510 by TRZ Fab, on Flickr

I oriented the KA to the same spot by rotating it by hand and peeking through the oil cap the see the #1 exhaust cam lobe pointed away from the motor. Then I inserted the franken-CAS and tried my best to mimic the clocking as shown on the SR CAS at the timing marks. This ended up being 1 tooth off but it was close enough to get it going.

The S13 SR uses a "skinny" titania heated O2 sensor (M12x1.25 threads) whereas the KA uses a fatty (M18x1.5 thread) single wire/non-heated O2 sensor. I had to adapt the threads to accept the new O2 sensor. Thankfully I had purchased new spare O2 sensors while working on Golddust so those met the bill perfectly.

Image510 by TRZ Fab, on Flickr

First run video here. Timing still needs to get set properly.
https://www.youtube.com/watch?v=irTFqbdXCdg

Rich but running! Much wiring clean-up to do still.
Image510 by TRZ Fab, on Flickr

I spent some time distracted this week since I picked up an '88 Z31T for the LSD rear end. The car is all dismantled and ready to live on in other cars!
I've basically searched for ~8 years to find one of these!!!

Image510 by TRZ Fab, on Flickr
Image510 by TRZ Fab, on Flickr

The plan now is to get the car running well with new injectors and new MAF (R35 in 3" tube).
I now have in hand brand new AC Delco 6.2L E85 Escalade injectors that are ~550cc/min. They're Bosch EV14s with a normal cone spray pattern. They are compact size so that when installed with the Radium fuel rail, they should be pretty unobtrusive. The best part is that they're new tech only $38 USD per.

More updates soon!
Jordan | '72 2 door KA project | '94 240sx RB26DETT | '97 Silvia RB25DET | '90 Audi 90 Quattro 20V (DD)

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MarkReidHRC
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Joined: 08 Jan 2018 10:32
Location: Langley BC
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Re: Jordan's '72 2 door KA project

Post by MarkReidHRC » 24 Nov 2019 08:36

Nice Work! Would love to see the car in person somtime as I live in Langley also.
If all else fails... try again

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