Jordan's '72 2 door KA project

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JordanTr
Posts: 906
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: 766
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: 3409
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: 906
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)

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