Project 635 - 300HP RWD 620

View and post your Nissan/Datsun project(s)
RONSLYCHUK
Supporter
Posts: 656
Joined: 12 Sep 2004 19:42
Location: Abbotsford B.C.

Re: Project 635 - 300HP RWD 620

Post by RONSLYCHUK »

I think that you have reached all of your objectives- —-very nice work!
User avatar
DADZSUN
Supporter
Posts: 542
Joined: 08 Aug 2011 18:35
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
ARP6731002.jpg (60.56 KiB) Viewed 2438 times

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.

BustedReturnFitting.jpg
BustedReturnFitting.jpg (153.58 KiB) Viewed 2438 times

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

TestingFuelLines.jpg
TestingFuelLines.jpg (168.55 KiB) Viewed 2438 times

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

ReturnFuelLines.jpg
ReturnFuelLines.jpg (189.88 KiB) Viewed 2438 times

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
Torn_O_Ring.jpg (51.4 KiB) Viewed 2438 times

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
TestingBrakeLines.jpg (148.91 KiB) Viewed 2438 times

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
HeaterValve.jpg (148.92 KiB) Viewed 2438 times

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
HeaterPlumbing.jpg (154.81 KiB) Viewed 2438 times

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

HeaterMounted.jpg
HeaterMounted.jpg (129.5 KiB) Viewed 2438 times

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 - Future track toy
Creativity outlet: www.datsunrestomods.com
User avatar
Edm620
Posts: 123
Joined: 06 Dec 2017 20:44
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!
User avatar
DADZSUN
Supporter
Posts: 542
Joined: 08 Aug 2011 18:35
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.

20220715_085034.jpg
20220715_085034.jpg (152.47 KiB) Viewed 2339 times
20220715_085052.jpg
20220715_085052.jpg (131.66 KiB) Viewed 2339 times

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

20220715_115728.jpg
20220715_115728.jpg (134.73 KiB) Viewed 2339 times

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)

20220715_141809.jpg
20220715_141809.jpg (195.52 KiB) Viewed 2339 times
20220715_141820.jpg
20220715_141820.jpg (195.12 KiB) Viewed 2339 times
20220715_141829.jpg
20220715_141829.jpg (183.8 KiB) Viewed 2339 times

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

20220715_132528.jpg
20220715_132528.jpg (281.83 KiB) Viewed 2339 times

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 - Future track toy
Creativity outlet: www.datsunrestomods.com
User avatar
Edm620
Posts: 123
Joined: 06 Dec 2017 20:44
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
User avatar
DADZSUN
Supporter
Posts: 542
Joined: 08 Aug 2011 18:35
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
Koyo_1.jpg (126.77 KiB) Viewed 469 times
Koyo_2.jpg
Koyo_2.jpg (116.14 KiB) Viewed 469 times

Awhile ago I posted my rear suspension bump stop solution.

ReworkedTowersBumpstop.jpg
ReworkedTowersBumpstop.jpg (108.84 KiB) Viewed 469 times

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
Shortened Bumpstops.jpg (140.95 KiB) Viewed 469 times

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
AutosportsEngTopMount.jpg (172.26 KiB) Viewed 469 times

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
DententLimiters.jpg (137.29 KiB) Viewed 469 times

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

ClutchMaster.jpg
ClutchMaster.jpg (139.56 KiB) Viewed 469 times

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
OverlyAmbitiousUp-sizing.jpg (130.56 KiB) Viewed 469 times

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 - Future track toy
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.
User avatar
DADZSUN
Supporter
Posts: 542
Joined: 08 Aug 2011 18:35
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 - Future track toy
Creativity outlet: www.datsunrestomods.com
User avatar
DADZSUN
Supporter
Posts: 542
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
PassengerDetentRodAccess.jpg (151.31 KiB) Viewed 420 times

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
DriverDetentRodShortening.jpg (104.22 KiB) Viewed 420 times
DriverDetentRodSpringBolt.jpg
DriverDetentRodSpringBolt.jpg (132.44 KiB) Viewed 420 times
DriverDetentRodInCD009.jpg
DriverDetentRodInCD009.jpg (140.1 KiB) Viewed 420 times

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
DriverPassengerDetentRodSpring.jpg (134.91 KiB) Viewed 420 times

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
OnTheRoad.jpg (144.7 KiB) Viewed 420 times

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 - Future track toy
Creativity outlet: www.datsunrestomods.com
User avatar
Edm620
Posts: 123
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!
User avatar
DADZSUN
Supporter
Posts: 542
Joined: 08 Aug 2011 18:35
Location: Ottawa, ON

October update - slashing some unsprung weight

Post by DADZSUN »

Despite the lack of updates, progress on 635 has been steady over the last couple of months. For the first time in over two years, I'm free of any other Datsun commitments for the next few months. The plan is to get this build wrapped up and registered, likely by end of year. I even plan to sneak it out occasionally this winter for shake-down runs on my local gravel road. When spring comes I want this truck ready for DD duties.

I haven't bothered posting pics of the many mundane pieces that are being re-installed (door handles/locks, wiper assembly, headlights/grill). I'm getting to the point of focusing on electrical which for me is the home stretch. I still have to remove the cab one final time which is a drag, so I'm trying to get as much possible done inside the cab so there's no last-minute surprises once the cab is back on.

While the re-assembly continues, I have been focusing on upgrades. Namely in the area of front unsprung weight and some new wheels. The wheels will have to wait until the grand reveal, but let's just say they take this build to a new level - worthy of the effort and potential this truck. :D

In other areas I've decided to address what was a VERY porty front end. Anytime I removed the front suspension/brake assembly as a single unit off the frame, I was shocked at the weight.

First up are the front hubs. The AWD hubs use a typical ball/grease setup along with an axle spline & nut to hold it together. Due to the age and crustiness, I decided to replace and upgrade to RWD units. Thankfully the AWD uprights accepted the RWD hubs.

AWD_vs_RWD_FrontHubs.jpg
AWD_vs_RWD_FrontHubs.jpg (197.21 KiB) Viewed 188 times
CrustyUpright.jpg
CrustyUpright.jpg (136.92 KiB) Viewed 188 times

These uprights received attention in the past, per the chisel hack marks trying to get the hub/bearing out.

NewHubMounted.jpg
NewHubMounted.jpg (129.71 KiB) Viewed 188 times
AWDHubWeight.jpg
AWDHubWeight.jpg (94.96 KiB) Viewed 188 times
RWDHubWeight.jpg
RWDHubWeight.jpg (68.03 KiB) Viewed 188 times

Weight saved with the hub swap is 2.46 lbs per wheel.


Next, I scored a set of new replacement lower TC arms ($100 CAD for the set LOL). Thankfully they too fit, after some shaving of the front hub bolt... 8)

AWD_TC_Weight.jpg
AWD_TC_Weight.jpg (73.06 KiB) Viewed 188 times
RWD_TC_Weight.jpg
RWD_TC_Weight.jpg (91.13 KiB) Viewed 188 times

The difference between the cast iron vs aluminum was quite noticeable, 5.08 lbs/per wheel. AWD TC arms used cast iron for occasional front axle/propulsion duties which are N/A for me at this point.

R33Caliper.jpg
R33Caliper.jpg (95.15 KiB) Viewed 188 times

Next up, I snagged these R33 aluminum calipers, more details will be in the next post but they managed to shave 7lbs/wheel vs the 2005 G35/350z dual piston calipers. Accompanying these calipers will be will be some 2-piece rotors. These are slightly smaller at 11.75" but if it's enough to stop an R33 GTST and 2004-2005 AWD G35, then it's good enough for my 2400-2500lbs pickup. The anticipated weight savings on these will be significant vs the 2006 G35/350z 22lbs rotor...

When it's all said an done, I'm expecting an unsprung weight savings of 22-24lbs PER wheel vs the previous setup.
'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 - Future track toy
Creativity outlet: www.datsunrestomods.com
User avatar
DADZSUN
Supporter
Posts: 542
Joined: 08 Aug 2011 18:35
Location: Ottawa, ON

GTST R33 front caliper details

Post by DADZSUN »

A quick post to update my front caliper change from OEM Nissan/Infiniti G35/350z 2005 cast iron slide calipers (twin piston) to Skyline R33 GTST fixed 4-piston caliper. This is a key part of my goal to reduce unsprung weight.

SlideCaliperWeight.jpg
SlideCaliperWeight.jpg (147.9 KiB) Viewed 138 times

With pads, the fixed Sumitomo caliper is 7.26 pounds lighter.

FixedCaliperWeight.jpg
FixedCaliperWeight.jpg (157.92 KiB) Viewed 138 times

Both calipers use the standard Nissan bolt hole distance (4") so the only major work was tapping out the mounting threads from M12 x 1.25 to M14 x 1.5

Tapped.jpg
Tapped.jpg (148.82 KiB) Viewed 138 times
CaliperBolts.jpg
CaliperBolts.jpg (235.16 KiB) Viewed 138 times

Everything worked great and the calipers mounted up like OEM.

Mounted.jpg
Mounted.jpg (137.64 KiB) Viewed 138 times

Next I'll need new front brake lines (Z32/S14) and some Wilwood 2-piece rotors.
'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 - Future track toy
Creativity outlet: www.datsunrestomods.com
User avatar
gooned
Posts: 939
Joined: 07 Jul 2003 23:19
Location: Langley

Re: Project 635 - 300HP RWD 620

Post by gooned »

When it's all said an done, I'm expecting an unsprung weight savings of 22-24lbs PER wheel vs the previous setup.

That is impressive savings, great work sourcing all the complimentary bits.
Post Reply