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Project Theseus

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  • Got the fender on, and the gaps are all as they should be. It's not hugging the rocker as tightly as it should be at the botttom, but I believe that's from the rockers' weight being on that section for a while, bending it a bit. Should be an easy bit of tweaking to do when I get to the fenders.

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    • Got the rocker fully welded on.



      All seamsealer'd and primered:



      Probably going to redo this patch at some point, as it was done before my new welder:



      To finish this section up and get the floor in I'm going to need the seatbelt mount/swaybar mount section from a parts-car. If anyone knows of a car being parted out with this bit (both sides) let me know! If need-be I'll repair it all with homemade patches, but just replacing the entire section would be nice.


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      • Didn't have a massive amount of time to work on the car this evening, but still got some stuff done.

        Cut out the bad section of cargo-area floor on the driver's side:



        This is what the frame rail under that looked like. I'll definitely need to source a new rear bumper mount. Going to try to get the whole section from a parts-car if possible, but cam fabricate it all no problem if not. Surprisingly the frame from the cut forwards looks to be in perfectly fine shape.



        Cut the inner arch to match my replacement section, and mocked it up. Will need to do some patches on the "new" section, but nothing major. Can't really weld it on yet until I fix the floor behind, and need to do some other stuff before I can do that either.



        All cleaned up for now. bracing and then more cutting to come.

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        • Insane.
          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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          • As I divide the work into sections it becomes more and more manageable, but still a lot of work. getting there though!

            Found someone on FB with a parts-car 240 that they're cutting up for scrap, and they will be cutting out the seatbelt mount/swaybar bracket areas and rear floor/rail/bumper mount sections for me. They're in Buffalo NY, so those should arrive relatively quickly once they get shipped (probably will pick up from ogdensburg to save $ on shipping).

            Ebay find came in today; I managed to snag some NOS Bosch H4 e-codes at a great price. Better light, and I have the ability to change/upgrade bulbs. They look brand new!





            I also ordered a headlight relay harness. Was going to make my own as it's pretty simple, but it was literally cheaper to buy a complete harness then to just purchase the relays separately. It's on the slow boat from china, so will probably take a month or two to arrive.


            Going to do a 4 hour round trip tomorrow to get new floorpans and rails.

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            • new floorpans and rails acquired! Man I love having a wagon.



              and mocked-up the driver's side. Little tweaking to do, but initial fitment is otherwise great.



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              • Decided to sort the a-pillar rust. Still need to grind down the welds etc, but pretty happy with how it turned out. Cut the bit off my 280z shell parts and welded it in. Kept the inside part of the pillar intact to not have the roof sag; removed the spot welds and clamped it on and welded back on from the inside.









                Next up will be to finish up the join from the doorjamb to the rocker, then get the firewall sorted so I can start getting the floor welded in.

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                • Now's the time to check the fit of the windshield in that corner. I've seen Z's that fit so poorly the dash got painted when spraying the body. Mine had water leaks until the last go around where the shop modified the curve to fit the glass.
                  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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                  • Originally posted by zedfoot View Post
                    Now's the time to check the fit of the windshield in that corner. I've seen Z's that fit so poorly the dash got painted when spraying the body. Mine had water leaks until the last go around where the shop modified the curve to fit the glass.
                    Excellent point! Once I grind down the welds I'll testfit and see what may need tweaking.

                    How did the body shop end up sorting yours? Little bit of filler, or cutting and welding to move the whole section a little?

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                    • Got the a-pillar patch ground down. Pretty happy with it; little work obviously required for the window channel to be perfect. That'll happen after the whole car is primered.





                      I also found a picture of another Z in the same colour I'm planning on going with:

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                      • Started work on the firewall area today, as that needs to be solid before the floor can go in.

                        Starting point:



                        Cleaned up and initial cuts made. I saved the section of steering-column brace plate, and will be welding it back in when repairs are done.



                        Next up, this mess.



                        Initial cleanup done. More cleaning to do (especially inside the frame rail), then patches can begin.

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                        • More patchwork done today.

                          Remade the flange on the left by the rocker, as I had just eyeballed the distance before I welded the rocker back in, and it was about 1" off from actually touching the rocker. It's now spotwelded to the rocker for good.



                          Made up and welded in a bottom section too, to tie it into the floor. You can see here the crushed/rusty bottom triangular-frame-thingy; I'll be cutting out the afftected sections and remaking it at a later date.



                          And floor mocked up. Once I get the rear seatbelt mount section that someone's cut off a parts-car for me welded in, I can get the floor tacked in where it touches existing metal, then start working my way down the trans tunnel making patches. Obviously the patch I made will need to be trimmed for where the floor bends, but I'll deal witrh that when installing the floor.



                          I also 3d-printed and tapped a shifter knob; you can see it on the right of the above pic. A little more finishing work to do, but I'm pretty happy with it.


                          next up is to finish up the firewall patches, then see what I can do next while waiting for the seatbelt mount areas to be shipped.

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                          • The person sending me some floor/rear frame bits sent me some pics of the floor sections. Will need some cleanup, but look solid and should work well for what I need them for.







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                            • Ok, parts have arrived! They look a little crusty, but are actually really solid where I need them. Lots of undercoating removal to do, and wire-wheeling paint off. Then can start to fit to the car.







                              (I have both asides of all, and all the rear seat mounts too).

                              I's going to be really nice to finally get rid of this mess:

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                              • You're making fast progress, looking good. On the later Z's Nissan added some gussets and reinforcing plates in that triangular area you have opened up, now's the time you'll need all the stiffness you can get.
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