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  • Originally posted by zedfoot View Post

    Yes, please.
    Sure thing! May take a couple days to find time, but I'll try to get it done relatively soon. What's the best way to send it to you when complete?

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    • zedfoot at Rogers dot com
      Eric Zondervan
      72 240Z
      54 Chevy 3100 pickup
      91 Nissan Figaro
      11 Sierra 4X4
      17 Nissan Juke Nismo
      18 Audi SQ5
      18 Polaris Switchback XCR 800
      17 Yamaha FZ-10
      65 Honda Moped

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      • Made some good progress on the rear today.

        needed to fix this:



        so I made this:





        Welded in, seam sealer'd and painted:



        Next up, bumper mount. Decided that transferring the one off the other cutoff would be a pain, so I welded up the holes after I ground out all the rust.



        Patch was a bit of a pain due to not being able to cut the area out square (the overhang of the panel meant it was hard to get the cutoff wheel in there), but I managed.





        Made the overlap brace thingy for the frame rail:



        And started to weld it in. It was getting later at this point, and I make mistakes when I'm tired, so I decided to wrap things up here and get back to it on saturday. WIll weld up the rest of this inside and out, then seam seal everything both sides before the floor section is welded on top.





        Looking good! Rear is just tacked, and I need to trim off the excess from the bottom of the 1st patch I put in.





        I did mess up and weld the rail on about 1-2mm too far to the rear, unfortunately. Trying to decide if I want to drill out the welds and move it back, cut it around the middle somewhere, narrow 1mm and re-weld, or just leave it as-is as that entire rear panel is a bit bent from an old accident anyway. Thoughts?

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        • Turned my attention to the rear doorjamb corner, which I've been neglecting for a while. This turned out easier than I'd expected, which is always nice.

          I started by cutting off the relevant section from my replacement quarter, and spent a good amount of time hammering it back into shape, as it was rather bent. Cleaned up and made a replacement section.





          welded in:





          Mocked up to make sure I got the curve right:




          The section on the car to replace:




          Ready to weld:





          and in:




          And ground down. Pretty happy with the result. I then seam-sealed/primered/painted the backside.





          I then turned my efforts to getting the rear frame rail in for good, after I got the fitment at the rear nice. Welded up the overlap brace. A little ugly, but will be hidden so whatever. Welded around the outside too, but no pics.





          Welded in at the rear:




          Sealed and painted:





          The overlap brace is a little ugly, but It'll never be seen, and a bit of undercoating should smooth things out nicely.



          Next up, the floor panel and patch of the inner wheel arch, then I can move on to welding in the taillight surround and will be nrealy ready to mock up the new quarter panel!

          Comment


          • That's awesome, you're an inspiration to get my second series one from what was supposed to be a parts car to a restoration

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            • Originally posted by FieroLuke View Post
              That's awesome, you're an inspiration to get my second series one from what was supposed to be a parts car to a restoration
              Thanks! Glad to hear more Z's are being saved, I wish I'd come across a basket-case series-1 car to do all this work to haha. Be sure to make a thread on here as you go!

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              • Here is an inside look
                You do not have permission to view this gallery.
                This gallery has 1 photos.

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                • We did the same thing with a less rusty specimen
                  Bought a quarter and removed the skin and welded it in place.

                  Comment


                  • Originally posted by Casey_z View Post
                    We did the same thing with a less rusty specimen
                    Bought a quarter and removed the skin and welded it in place.
                    Thanks for the pic! Should be rather useful for reconstructing some missing stuff when I get to that side. My plans for both sides are roughly in line with that, just will be cutting at the C-pillar join (like you did) and removing the spot welds from the bottom of the C-pillar window area to replace in its entirety. Also keeping the stowage pockets on my replacement quarters as the ones on the car are long gone.

                    Actually, now that I think about it, I should do the fitment work needed to mock up the replacement quarter first, so I can make sure the floor section I'm fabricating actually mates up to the side pocket properly; a gap would be a pain to fix once the quarter is on.

                    ------------------------------------------

                    Mocked up the rear valence cutoff I have to ensure that the work I did was actually the correct angle etc. I'm happy to report that everything lines up properly, including the top/bottom flanges that are hidden behind the piece.

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                    • Just snagged a set of mint-condition quarter windows pretty inexpensively. Should be here early next week, and then they get to sit in the basement for a few months before finally going on the car lol.

                      Saves me a ton of work trying to strip/clean out all of the paint and scratches from my window trim, which is nice. Should be able to just bolt them on and go.

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                      • Got the new quarter on today! Still many things to do before It can be welded for good, but this is still an awesome milestone.







                        Mocked up with my subaru's winter wheels as they're closer to the final tire diameter. Some lowering will still be needed





                        Made up the patch for the inner quarter, and welded in.




                        And mostly ground down. A little more to do before it's perfect.




                        Made the new floor section, and mocked up. Still some tweaking to do, that gap at the back won't be there obviously. Going to do final cuts/drilling then weld this all in on Saturday.




                        Pretty happy with how the corner turned out:




                        Once the floor is in, I need to put the section of rear upper rail in (that the quarter sits on), and the other half of the inner arch. Once that's done it's on to a little repair work on the quarter, then it can get welded on!

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                        • Had time today, so did the final cuts, and tacked the new floor section in. Plug welded the whole way along the length of the frame rails as well.



                          All welded in. This only took about an hour, which surprised me. Not too much warping, and the car was already hit in this corner at some point, so I'm fine with it.



                          Seam sealed, primed, and painted both sides. Really happy with how it all turned out, and it's awesome to have a complete trunk floor again.



                          With quarter on:



                          Also found some paint at a local Walmart that I didn't think existed in Canada. Rustoleum Metallic blue. I'm definitely leaning towards this as a colour now; the blue of the jdm legends 240z has always been awesome, and this should be pretty similar in shade if I use black primer underneath. My plan is for a budget paintjob that still looks good - epoxy primer, spraycan paint, and then 2k clear in a can to ensure longevity. Should look decent while ensuring I don't have to mind when I get rock chips etc.

                          Just sprayed on an unfinished fender to see the colour:

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                          • One of the last big things before the quarter goes on was to get the inner wheel arch reconstructed, so I did that today.

                            Cut/tacked section from my stash of replacement bits:



                            And welded in fully:







                            Sealed and painted:



                            Same thing for the quarter itself:





                            It's so nice to finally not see massive amounts of daylight through here. Still deciding on side marker/antenna hole deletes.




                            Happily, the flange on the lip is perfectly lined up. I still need to remake a section of the flange at the front (it rusted out), but I'm using a repair panel for the dogleg there too, so will do those both at the same time, after the quarter is welded on for good.




                            The flange at the top by the door was pretty ragged, so I used some copper bar to weld it up. No point making a tiny patch.



                            Not perfect, but it can be welded to properly now (for quarter install), and will not really be visible after that.



                            Cut a section from my selection of bits remaining from the 280z shell, and replaced the rusted-out section of my replacement quarter.




                            Not as seamless as I would have liked, but nothing a tiny bit of filler won't sort after epoxy primer is down:





                            This will be the last piece of the puzzle so I can finally weld the quarter on for good. It needs a couple patches, but nothing that major.





                            Also cleaned and painted (with bedliner for a slightly textured look) the rocker cover. Kind of lipstick on a pig at this point, but I'll get the rest of the engine cleaned up down the line. New valve cover gasket while I had it off, no sense in doing it twice.





                            and zedfoot I'll get that write-up to you in the next couple days. The past little while has been pretty crazy busy, and my little brother just had heart surgery.

                            Comment


                            • No hurry. We've gone to press on this issue, but need lots of material for the Fall issue.
                              Eric Zondervan
                              72 240Z
                              54 Chevy 3100 pickup
                              91 Nissan Figaro
                              11 Sierra 4X4
                              17 Nissan Juke Nismo
                              18 Audi SQ5
                              18 Polaris Switchback XCR 800
                              17 Yamaha FZ-10
                              65 Honda Moped

                              Comment


                              • Ok! I'll still aim to get it done shortly though.

                                --------------------------


                                Welded up the antenna hole and the side marker hole:






                                Tacked the quarter on; it is on for good now! Window mocked up to make sure fitment was right, and it is spot on. it's really starting to look like a car again!









                                Especially compared to before (although even this pic is after a ton of welding):





                                I must have welded in the rear quarter patch slightly off, so I had to pie-cut it a little to make the cap with the hatch correct. The gap was fine all the way to that point, so it was no an overall alignment issue.



                                Much better:





                                Mocked up the taillight. WIll still need to drill the holes for it in the proper locations, unless I decide to go with 240z taillights and rear valence. Still undecided which route I want to go, but if someone has a 240z rear valence they want to sell, let me know!




                                And overall. pretty decent:




                                However there are some small bits I need to sort out before finishing welding. The right hand side overlap is like this:




                                While the left is this. Need to figure which bit is out of whack (quarter or underneath brace), and decide what to do. If it's the brace I may just drill the light holes slightly crooked to compensate, as they will then sit in the correct place, and shouldn't affect anything else.




                                Flange is still a little bent from when it was pried off the old frame, but the gap is overall good. Some hammering and welding and it'll be good. Plus, the outer hatch seal goes over top there anyway.



                                Next time I have time to work on it, get the door on to check that gap, tweak the other fitment issues, and weld the rest in for good.Then seam sealer it all, and I can move onto the dogleg outer skin repair.



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