Datsun 1600 Special

[Stu]

Looking great. The improvement to the firewall is impressive. Keep it up.

[Doraemon]

Thanks!



This 510 had originally a booster but the membrane was broken. Found a replacement booster in Australia but found it too expensive. After some more searching I managed to find a smaller booster sold for AE86's in at a shop in Ireland. Ordered the booster and new master cylinder (same size as the original 510). The new booster and master together were at the same price as just the booster from Australia. And since they are in Europe no customs fee's.. yay!

Booster has the same diameter of the original but it's a bit flatter.

Funny enough the two upper bolt from the booster do fit at the original bolt holes. Except the below ones who had a minor offset.
Had to hack away some of the pedal box frame and weld the corners together to able to bolt on the nuts.

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Mounted the booster + master. And all the brake lines and clutch line are replaced with new Nickle Copper lines.

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[Doraemon]

All engine mounts and racks etc.. have been sandblasted and have a new layer of two component industrial paint (love that stuff!).

New Exedy clutch mounted and the engine was ready to go back in the car.

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[RONSLYCHUK]

Very nice work. Keep those pics coming.

[datzenmike]

Make sure there is about 5mm play in the clutch pedal. Just push down on pad with your thumb and the pedal should have about 1/8"of movement before there is resistance.

[Heinrich]

Nice job on the booster, trying to source a new one as well.

[datzenmike]

15/16 or 7/8"?

[Doraemon]

15/16 or 7/8"?

13/16 as far as I know.

[Doraemon]

Looking through my pictures found out the master is indeed a 13/16 bore.

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After I took the alternator apart found out that somewere the winding had a shortage with the casing. Which isn't suprising after all those years and the isolation material will go bad. Friend of mine rewinded the alternator and it's like new again.

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I had a set of Advan 14 inch wheels imported from Japan laying around for a while. After the tyre company straighten the wheels for me I put the wheels in a laith the the company to kind polish them up witch a scotchbrite. Could let the tyre company fix them up with diamon surfaces cutting but that was very very expensive. And the scotchbrite trick does work for me enough.

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I will ditch the sealed beams and go for H4 headlights replacements. But had to tackle the problem of not frying the lightswitch in the dashboard.
After figuring out the schematic I came up with the idea to let the current through extra two relays. Since I don't want to tear up the whole loom I made this little plug-in relay loom that you stick between the original loom and old hi/low relay.

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And here the extra relay and loom pluged in between.

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Wanted to replace the old water coolant and fuel pipe with a stainless example. And made my own bender.

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[Doraemon]

Looks great in my opinion.

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[RONSLYCHUK]

Very nice!

[miguel sss]

Nice project...i´m from Portugal , and i see this car for sale...

[Doraemon]

Putted one headlight cluster back in to test if the small plugin loom with extra relays worked. After some testing found out the hi beam relay wasn't working. Took it out and had a good look at it. After some head scratching I found two pins were wrong in the plug. Switched it and had another go.
And yes!! It's working!

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Took the thermal camera and had a look around. The rearligts etc still go through the light switch but it remains cool so I'm very sure all the headlight current goes through the relais. Only thing I found out is that the fuse was glowing dim and getting hot. So that one needs to be a big bigger.

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[MK510]

Just check the fuse box bottom, there could be loose contact that causes fuse getting hot.

[MikeY]

Soak that fuse box in white vinegar for a few hours. Works great to clean hidden contact points. Many time this has fixed headlight problems that look like it should have been relay.