Project 635 - 300HP RWD 620

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RONSLYCHUK
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Re: Project 635 - 300HP RWD 620

Post by RONSLYCHUK »

I think that you have reached all of your objectives- —-very nice work!
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DADZSUN
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Location: Ottawa, ON

635's VQ35DE fires up for the first time.

Post by DADZSUN »

I'm starting to get excited. The end of this project is looking more and more certain now - mid September she'll have her first test drive? I'm almost convinced that I'll have this running before the PITA KA24e within my 510 - wouldn't that be ironic!

Since the last update I've slowly but steadily threw some hours into the project whenever I had a bit of time. Progress has been demonstrated with a shorter and shorter To-Do list, and more and more time needed to consider new items before each 'phase' is completed (ie: motor mounted for the final time).

Here's a rough summary of the workflow:

New ARP exhaust manifold bolts arrived. ARP (673-1002) is the part number. These are a nice 1 piece bolt rather than a threaded stud and nut. Naturally, new gaskets were used. Stock heat shields were remounted.

ARP6731002.jpg
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I double checked all vacuum and coolant lines on the VQ. Clamped down as required.

Double checked the wiring harness. Ensured everything was properly clipped in and fastened.

Motor was mounted into the frame, slotted into the engine mounts perfectly, again. I really nailed that part of the build.

I focused on testing as much as I could with the body off. Fuel lines were purged with air (to clear and debris) then tightened. In doing so my first surprise was to see the return line fitting had snapped off and Tanks Inc will be out of stock until late July. I managed to find a temporary replacement, but re-doing 'done stuff' really sucks.

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Fuel was added to the tank and the pump fired up.

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No leaks except for the O ring on the rear passenger side.

ReturnFuelLines.jpg
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That was a PITA to remove the upper manifold but in the end the source of the leak was quite obvious. A quick swap with a spare part and she was leak-free.

Torn_O_Ring.jpg
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Next I pressurized the front & rear brake lines. I leveraged an S30 Master Brake Cylinder to pressurize. After a few nuts were tightened the system stayed leak-free and was bled. All the fluid will be purged again once the cab is mounted and the proper master cylinders are fastened.

TestingBrakeLines.jpg
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Next I focused on the heater lines. The electronic valve had to be positioned within the engine bay as there was no room on the inner firewall.

HeaterValve.jpg
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Here's a pic of the lines poking out. I'm a little nervous they poke out too far but we'll see and modify as required once the cab is lowered.

HeaterPlumbing.jpg
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Here's a pic of the heater mounted on the inner firewall.

HeaterMounted.jpg
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After that it was simply a matter of testing the starter and then the ECU. After some clarification on mis-labeled wire from Z Fever, my VQ35DE fired right up!!! Honestly, the thing sounded so civil, like it was running just yesterday.

https://youtu.be/JEu58_QDLgA

Even more pleasing was that the custom exhaust I built had a pretty decent tone.

https://youtube.com/shorts/IZmnfFJ91YY?feature=share

So with this done, I'll clean up the wiring and make sure everything's fastened and away from the exhaust. Next I'll be added some aluminum heat shielding between the exhaust and cab floor. Once complete, I'll be ready to lower the cab for the final time. This will take some effort to make sure the steering connect properly and heater lines work well. After that I'll connect the brake lines and then start on the elctrical.
'72 Datsun 510 - MS KA24e, Watanabe, STI R180 & CV axles, R&P assisted steering
'76 Datsun 620 - VQ35DE, CD009, G35 suspension & brakes.
'76 Datsun 280z - 2022 build
Creativity outlet: www.datsunrestomods.com
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Edm620
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Location: Edmonton

Re: Project 635 - 300HP RWD 620

Post by Edm620 »

Good to see your progress!
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
ace028
Posts: 131
Joined: 15 Aug 2010 08:29

Re: Project 635 - 300HP RWD 620

Post by ace028 »

I am not sure how I missed this super awesome build, looks amazing man!!! Looking forward to more progress!
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DADZSUN
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Location: Ottawa, ON

Project 635 - cab mounting

Post by DADZSUN »

I mounted 635's cab for hopefully the last time this weekend. It took a bit of persuasion (I did it on my own) but I managed to get all 8 bolts to line up. For those wondering where I placed them there are 4 in the cab, 2 by the front rad support, 2 on the firewall reaching the Infiniti G35 towers.

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These pics give bit more clarity as to how the Infiniti G35 'floating' towers are designed to clear the cab's inner arch.

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With the VQ mounted, I finally got a good idea on the ride height. Spring rate seems like a decent first-guess, camber looks good too (OEM upper A-arms still, no adjustment)

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Finally a pic with my 510 (which has received a TON of attention lately too).

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I'll install & bleed the clutch this week, finish the heater coolant plumbing, finalize the steering column connections, and finish the cab brakes (including the handbrake). I'm thinking I'll be able to do an initial test drive by August.
'72 Datsun 510 - MS KA24e, Watanabe, STI R180 & CV axles, R&P assisted steering
'76 Datsun 620 - VQ35DE, CD009, G35 suspension & brakes.
'76 Datsun 280z - 2022 build
Creativity outlet: www.datsunrestomods.com
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Edm620
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Location: Edmonton

Re: Project 635 - 300HP RWD 620

Post by Edm620 »

Looks great! That truck should be a monster of fun
"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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Location: Ottawa, ON

Late August update

Post by DADZSUN »

It's been a month since the last update but 635 has received a steady amount of attention.

The truck fires up easy and has a hell of a bark when I hit the loud pedal - I don't think those 225 Michelin AS4 have a chance, but I do have a neat traction control solution planned which I'll work on over the winter.

First I'll start with what's done.

Koyo G35 rad is installed and after screwing around with a cut throttle body coolant nipple (source of a coolant leak), the system now holds coolant.

Koyo_1.jpg
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Koyo_2.jpg
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Awhile ago I posted my rear suspension bump stop solution.

ReworkedTowersBumpstop.jpg
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Since then I realised I could leverage some older BC Racing rear dampers to increase compression. This extra travel meant the bump stop boss had to be shortened. I now have 8cm of compression and 7cm of droop in the rear - not bad!

Shortened Bumpstops.jpg
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The major delay in getting to drive the truck is twofold:

1) Autosports Engineering top-mount CD009 shifter won't let me select the left or right gates (1, 2, 5, 6, rev). I've reached out to the owner and he's been very helpful in solving this known issue (see vids in the attached: https://autosportsengineering.com/produ ... ont-mount/).

AutosportsEngTopMount.jpg
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Essentially the detents (circle below) on the CD009 have to be pulled out and the rods shortened 1/8-3/16" to allow enough side-to-side travel. Unfortunately, access to the detents is only available with the cab removed... No worries as there's a bunch of things I've discovered that need to be done once its off ... :-/

DententLimiters.jpg
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2) Second issue is the sizing of the clutch master cylinder. I'm just not getting enough travel.

ClutchMaster.jpg
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The original 5/8" Master Cylinder (MC) might be a touch too small for the 3/4" bore slave cylinder. I went two sizes up to 13/16" and it was ridiculously hard to press.

OverlyAmbitiousUp-sizing.jpg
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Typically, the MC and slave are the same (pedal ratio/leverage can have a large influence) so maybe I should have tired the Tilton 6/8". However, I also suspect my bleeding is an issue as there's lots of useless play in the initial pedal stroke.

My next step will be to work on the ECU mounting location (front of tranny tunnel) and the fuse box/wiring. I'll then remove the cab to perform the necessary changes (and repair that HUGE hole in the driver side tunnel - excessive tranny contact so it had to be redone). So, I won't hit my August 'driving' goal, but I am taking 3 weeks off this September and expect major progress.

This truck will be driving before Christmas!
'72 Datsun 510 - MS KA24e, Watanabe, STI R180 & CV axles, R&P assisted steering
'76 Datsun 620 - VQ35DE, CD009, G35 suspension & brakes.
'76 Datsun 280z - 2022 build
Creativity outlet: www.datsunrestomods.com
ace028
Posts: 131
Joined: 15 Aug 2010 08:29

Re: Project 635 - 300HP RWD 620

Post by ace028 »

This is awesomeness, keep up the great work. Looking forward to the next update.
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DADZSUN
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Location: Ottawa, ON

Re: Project 635 - 300HP RWD 620

Post by DADZSUN »

ace028 wrote: 26 Aug 2022 17:36 This is awesomeness, keep up the great work. Looking forward to the next update.
Thanks! You won't have to wait long for an update. :lol:
'72 Datsun 510 - MS KA24e, Watanabe, STI R180 & CV axles, R&P assisted steering
'76 Datsun 620 - VQ35DE, CD009, G35 suspension & brakes.
'76 Datsun 280z - 2022 build
Creativity outlet: www.datsunrestomods.com
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DADZSUN
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Posts: 528
Joined: 08 Aug 2011 18:35
Location: Ottawa, ON

Project 635 - FIRST DRIVE!!!

Post by DADZSUN »

So after Friday's update I figured out a way to 'hack' the shifter issue to hopefully sneak in a quick test drive.

On Saturday my son and I worked the clutch line to get a better bleed. With the truck running and the rear wheels in the air, I was able to confirm the clutch was working in 3rd gear. That was issue #1 resolved.

For #2, I had to somehow make the shifter work. First I dropped the tranny a bit to get better access to the detent mechanism. For those who don't know, the detent mechanism provides that spring pressure for the shifter to return to neutral.

PassengerDetentRodAccess.jpg
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Removal wasn't too hard and I proceeded with shortening the driver's side rode approx 3.5mm. The problem was getting the rod to slide back in fully.

DriverDetentRodShortening.jpg
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DriverDetentRodSpringBolt.jpg
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DriverDetentRodInCD009.jpg
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I decided to abort reinstallation and simply put the bolt caps back on. This gave me all the gears, albeit with quite a bit of flop and difficulty knowing the exact gate I was in.

DriverPassengerDetentRodSpring.jpg
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I'll reinstall these once the cab is off the frame and the tranny is fully exposed. Interestingly, the passenger rod/spring is significantly longer than the driver's side.

OnTheRoad.jpg
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With the clutch working and 1st gear access now in place, this happened. :D 8) The truck drove surprisingly well on my short 2km out & back. Besides the doors flapping around (duct tape is NOT a good temporary replacement to proper latches), traction was quite good, steering behaved normally, and throttle modulation was perfect.

https://youtu.be/Pu3lfjvCkRA

So now I'll take a few steps back on the build and remove the cab to address a list of small modification/fixes. As before, I'm confident she'll be back on the road for late fall.
'72 Datsun 510 - MS KA24e, Watanabe, STI R180 & CV axles, R&P assisted steering
'76 Datsun 620 - VQ35DE, CD009, G35 suspension & brakes.
'76 Datsun 280z - 2022 build
Creativity outlet: www.datsunrestomods.com
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Edm620
Posts: 118
Joined: 06 Dec 2017 20:44
Location: Edmonton

Re: Project 635 - 300HP RWD 620

Post by Edm620 »

Great to see it mobie under it's own power, helps get the jiuces flowing!
"If you don't know where you're going, any road will take you there"
Ugandan Proverb
greenthumb
Posts: 261
Joined: 19 May 2013 20:57
Location: Langley, BC

Re: Project 635 - 300HP RWD 620

Post by greenthumb »

That’s awesome to have it mobile at last. Your pulse must have been racing!
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