620 KC project

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DADZSUN
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Re: 620 KC project

Post by DADZSUN »

Edm620 wrote: 30 Mar 2020 10:42 The blessing of the pandemic - I have even more time on my hands to work on my truck!
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Daily progress continues, achieved a milestone yesterday.
Such a clean build!

I see the 720 19 gallon fuel cell - any issues with 620 bed clearance?

How low does the fuel tank go below the frame rails? I'll be trying to squeeze the same tank on my 620 frame but won't be able to go as far back due to the IRS modification.
'72 Datsun 510 - MS KA24e, Watanabes, STI R180 w/CV axles, R&P assisted steering
'76 Datsun 620 - VQ35DE, CD009, G35 suspension & brakes.
'76 Datsun 280z - 2021 Datsun Restomods R&D project
Creativity outlet: www.datsunrestomods.com
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Edm620
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Re: 620 KC project

Post by Edm620 »

I haven't fitted the body up yet but don't expect any issues as that tank is for the KC, and is lower at the box front allowing for how the front box panel is below the box floor.

This tank is actually the 4x4 tank and is a couple of inches deeper than the 2wd one, but there is plenty of space below. The original 620 tank on mine was attached to the underside of the box (apparently that changed on later production ones) so the mounts are original 720.

As you can see from this pic, the original 720 tank ran right up to the front box mount so I think you could position whatever tank you use within that area.

Thanks for the comment!
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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Edm620
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Re: 620 KC project

Post by Edm620 »

pic was dropped
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"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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Edm620
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Re: 620 KC project - overdue update

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I haven't been on the site for awhile but work has been progressing. Chassis is complete and ready to fit up the body but the tin worms had a full meal deal where the cab mounts are, not just a snack, so much more work is required before I can mount the cab up.
Flintstone floor
Flintstone floor
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Bodywork is not my forte so please forgive the workmanship, the floor will be covered up and undercoated so as long as it's solid I don't mind.
passenger floor
passenger floor
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While lifting the cab I was lucky enough to find the sweet spot in the balance - I could raise or lower with one hand on the chain hoist and the other on the cab to simply steady it. Important when working by yourself! I'm expecting to have to lift the cab off a few times while I determine inner fender cut-outs for power steering clearance etc.
in the air
in the air
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"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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DADZSUN
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Re: 620 KC project

Post by DADZSUN »

I like that! I've removed the cab close to a dozen times now by hand (with help) and it's a PITA.
'72 Datsun 510 - MS KA24e, Watanabes, STI R180 w/CV axles, R&P assisted steering
'76 Datsun 620 - VQ35DE, CD009, G35 suspension & brakes.
'76 Datsun 280z - 2021 Datsun Restomods R&D project
Creativity outlet: www.datsunrestomods.com
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Edm620
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Re: 620 KC project

Post by Edm620 »

It's been a long while since I updated my posts here, and work has been commencing. The rust in the floor of the cab was worse than initial inspection showed and my first go at replacing the floor was not up to what I was willing to accept, so I ended up stripping out what I'd completed and set about redoing the work. Thankfully I was granted access to some HD metal equipment as I made up a complete new floor pan from 16ga and also made up a pair of rockers.
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After that it was time to fit up the new floor - I got ahead of myself and didn't bend in some stiffening ribs to prevent oil-canning/booming, so as an afterthought I welded on some strengthening angle iron which has made the floor super stiff, and I'm happier with the results. The new rocker is also mounted up on the R side, so with that part done I'm moving to the L side. I need to get the cab fit up so I can get more of the mechanical work completed.
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The L floor isn't as bad as the R was, though not exactly "better" as is rusted through in different areas. At present I think there's enough good metal that I won't have to completely remake the R floor but time will tell if I'm satisfied with what I produce. I don't like doing bodywork, and as long as the floor & cab mounts are structurally sound I'll be OK with it - bed coating + carpet and undercoating will be enough to hide the somewhat scabby work. I have someone who will be doing the actual exterior bodywork thankfully.

A tip worth sharing that was passed to me by some old-school hot rodders, is to use construction adhesive as seam sealer - it works like a charm.
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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Edm620
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Re: 620 KC project

Post by Edm620 »

Milestone achieved today, first fit-up of cab to frame, everything went according to plan even found the perfect balance point from the gantry.
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Cab will sit about 4" lower than this.
Still need to do about a dozen smaller repairs, but no more major repair work ahead :D
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
muck
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Re: 620 KC project

Post by muck »

Looking forward to seeing this on the street one day soon. Great little build thread you have here.

Ryan
'67 1600 Roadster
'68 4-door 510
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Edm620
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Re: 620 KC project

Post by Edm620 »

Thanks Ryan.
Well "no more major work ahead" was overly optimistic, as while modifying the L inner fender for PS clearance, the rusty rad support frame mount decided to shit the bed, so I have now built and installed new mounts for both. All 6 cab mounts are now new.

After completing those mounts, I did a triangulation check on all the mounts and as best I can tell my largest error is 15mm, so I can live with that. Should bolt right up nicely onto the frame.

All I need now is more time, have been working 12+ hours daily...
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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Edm620
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Re: 620 KC project

Post by Edm620 »

Work has been very busy these past months, and combined with the heat wave I haven't been getting many hours in the garage. Progress does continue however at a slower pace.

I have moved on to the repairs to the cowl ends and ATM have only finish welding to do on the L side, then it's time to do the R side.
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I have pre-fit the doors and after completing both of these inner fender/cowl repairs I can repair the bottom edges of the doors. Driver's door is a bit worse than the passenger, but is really only the bottom edge that needs work.
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After that, there is really only some small repairs to do on the rad support. I am looking forward to being DONE with the body repairs (I hate doing bodywork) and getting back to completing the mechanical.
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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Edm620
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Re: 620 KC project

Post by Edm620 »

About time for an update here, I've been plugging away during what little free time I've had and presently have the cab fitted to the frame for another test fit. Found a few spots where I have some contact issues which will be addressed shortly. All the structural repairs are completed, the cab has been undercoated, cab floor coated with bed liner, and the engine bay primed. The wiper motor from the 720 required some work to fit properly as it was designed to mount in the engine bay vs the 620 which mounted behind the dash.
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My next big task is to adapt the 720 steering column to mount to the 620 firewall and make supports to support it below the dash.This is my opportunity to ensure the column fits exactly where I want it to be relative to the dash, the seat, and me. Comfort for long haul cruising!
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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Edm620
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Re: 620 KC project

Post by Edm620 »

Not posting much of my build on this forum, mostly on Ratsun if you're interested.
Have sorted the steering column install and fabbed up mounts to secure it though the firewall, noting the 720 column used a very different mounting plate at firewall and at dash.
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Brake master also very different between the 2 models, the 720 master is substantially bigger in every respect and is now in it's final position, with just enough clearance for the clutch master as well.
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Most of the hard lines are run now, still to finish the final line to the clutch slave then can cross that off the to-do list.

Fitting up the rad and deciding what to do for a fan, have modified an electric from puller to pusher as the fan blades are scooped to maximize airflow, as there just isn't enough room to stick with it as a puller.
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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Edm620
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Re: 620 KC project

Post by Edm620 »

Radiator is now installed after converting a regular "puller" fan assembly into a "pusher" noting the fan blades are scalloped to maximize efficiency and conversion is more complex than simply reversing motor rotation.
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The radiator I'm using is wider and shorter than the original one, thus necessary to make custom mounts - these were made using detailed CAD process, then finished with stainless steel. The shrouding is rubber isolated to prevent unwanted vibration or noise. I'm in process of fabricating some lower pieces to further duct the airflow through the radiator and complete the install.
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Winter arrived with a BLAM forcing me to reconfigure my garage workspace and "gasp" share the garage with my wife's car. Some tasks will be bumped to spring due to a sudden shortage of space to work in.
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
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