duffymahoney

Osgiken clutch is in. Big thanks to Zgarage for the kit. Install was a breeze.

She is in. Gosh I hope it works nicely and I didn’t screw up! I really like how the half shafts hades turned out.

Well shimming the r-180, backlash, pre load and wipe pattern took most of a couple days after work and most of a Saturday morning. I think I took it apart 20+ times. Finally happy with the wipe pattern. Luckily I didn’t have to change the pinion shim. Edit: I think in a perfect world I would have had a special tool to set the pinion nut at the factory 125-150ftlb. Then used different shims to get the bearing pre load perfect. But I had no way, so a couple of hits with the impact is what I used to set pre load, I found that info on here and a few youtube videos. It's not precise at all, just hopeful the factory had it correct enough. A bunch of site posts and a few guru told me to just reuse the pinion shim and move on. Everyone basically told me backlash is the most important. Ended up with 5 thousandths for backlash give or take and then ring side backlash shim if .05 and other side of .07. Total inch pounds is around 8-10 on the pinion. No carrier I had around 3 inch pounds for the pinion. This is worth paying someone to do. Just FYI. I had fun. But super frustrating.

I wanted to send it back, since it was so blue/ purple, I decided to just live with it.

Nos 240z starter solenoid score. eBay 9$ shipped! Time to rebuild the starter.

it's probably a 10mm:)

I screwed something up in the trans rebuild, it becomes tight with the front cover on, plus I guess I love spending money, so I decided on the KA swap for my 240z. This is a longer tail shaft on the trans, so it should fit in my series 1 better (no cutting), plus the 1st is better gear ratio and 2nd is slightly better. I found a 1989 240sx trans, with 576 miles on it. It's been in storage inside since 12/01/89! Zinc is still in tact. Paid too much for it, but hopefully it's good. The shop tested all the gears and syncros. Troy Emerish Racing will do the bell housing mod. He is just about as cheap as my local machine shop, plus has done a ton of them. Using this info for reference http://zhome.com/ZCMnL/tech/240SX5spd/Transmission2.htm http://zhome.com/ZCMnL/tech/240SX5spd/Transmission2.htm

Stainless lines and steel fittings is very nice. I wouldn't do stainless with stainless, I had to tear a brake line kit in my bronco for that reason. Plating is super super cheap, find a local shop, you will be surprised. I would guess all the brakes and fuel lines would be 50$-75 for me to have plated. Can you get all yours off? Proper brake line wrenchs, heat and time and I got all to break free but 1.

Hopefully shimming the r180 and getting it installed this weekend. Looks pretty amazing. I ended up getting new side bearing holders. They were 18$ from Subaru with seals. Which seemed too cheap not to replace.

Nice. TFC has been great. I am making my starter pretty (vapor) Plus my r180 cover. Starter will get a nos solenoid, then some zinc and some black paint. I can’t get the side screws out so they will get painted. Should look nice.

Osgiken single disk clutch is in from japan. I took a stab in the dark with it. Zgarage had me be a guinea pig. Flywheel and overall weight is pretty great! Very very well made. Comes with everything needed.

I would use local, try and stop by the shop. I bet you can figure it out. If zinc is intact and oxidized or whatever, then i don't do anything. Rust has to be removed, paint has to be removed, some places can acid bath before, so not much prep is needed at all.

TFC in Oregon, they do Z theraphy's stuff, and I was impressed, so I switched, this is the 3rd zinc shop I have used, they are my favorite. But prep is key. This batch is a little more blue/ purple then I would like.

More stuff back from zinc. Time to install some stuff.

4.11 it’s going to be a rocket ship

Well I don’t know if the effort was worth it. But the 5 speed trans is rebuilt. Shifts great. Looks killer! I would guess next time I will just buy one rebuilt.

I ended up buying a small torque wrench, which helped dial in the bearing pre load on the R180. Worked great.

Bolts torqued and bearings pressed. I also got the pinion seated. I had to buy a smaller Torque wrench for the bearing pre load. Seating the bearings for the pinion was a giant pain but I got it. I love owning s press.

No that was a non issue. I just forgot a C clip one time, then forgot a shim/ washer:)

Got the trans parts back from zinc and got most of the trans rebuilt this weekend. This is my first time doing this. I used the FSM, friends and this youtube video. Super helpful. Also a shop press jumped for sale locally, I picked it up for 80$. Youtube video. Below. Here is mine spinning. I had to take mine apart a few times. So I am a little worried I put some wear on the bearings. I got a brass hammer which seams to help a lot.

More parts off to zinc. Also got the longer 74 drive shaft back from powder. What a pain to prep these parts. Last time I powder coated some of the half shaft parts. Which was a mistake. So i will zinc them and the drive shaft parts. I also decided to zinc the rear engine dust plate.

Wow, what a cool build.

All better. Holes drilled to 11mm

I got some zinc parts back. Sadly the aluminum is more pitted then I would like. But nobody will know but me. Also I got my osgiken LSD. Sadly the K R180 I got was from a 87-88 200sx. So it has the beefier 11mm bolts instead of the truck 10mm which the osgiken is setup for. I have the silly expensive LSD at a machine shop having the holes inlarged now. Fingers crossed they don’t mess it up. He is a very good machinist.

Shop charged $75 to coat the rear end. I built my own vapor blaster (I like that name) system. It's pretty simple, my cabinet is a giant piece of junk, but other then that is awesome, it's not a fast process, but makes things look amazing.