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Old 10-11-2020, 09:52 PM   #1
zombiewolf513
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Naomi

It's been a while since I've posted any sort of updates on my cars, so here we go. First I'm going to post up what I've done since buying this car for $2500 in 2013 from the original owner in Arizona.










In 2015 the engine gave out, so I rebuilt it. Here's a copy pasta from my other forum:

'93 KA24DE in for a full restoration!

New Parts:
-Nissan Master Gasket Set 10101-53F25
-Nismo Motor and Transmission Mounts
-Energy Suspension Master Set
-FRSport Tsubaki Timing Set 13028-53F02
-OE PCV
-Gates Belts (x3) K040305, K030395, K040355
-Gates Water Pump 41162
-Nissan Oil Pump Gear Set 15020-53F25
-Nissan Oil Pickup/Strainer 15050-53F03
-Nissan Oil Regulator 15132-77A25
-Nissan Oil Filter 15208-55Y0A
-Nissan Thermostat 21200-0C811
-Nissan 40mm Freeze Plugs (x6) 00933-1401A
-Nissan Piston Ring Set 12033-70F00
-Nissan Temperature Sensors
-ACL Duraglide Main Bearings
-ACL Duraglide Rod Bearings
-ARP Head Stud Set 202-4304
-ARP Main Stud Set 102-5401
-Injector-Rehab.com Replacement Pintle Caps (x14 MAKE SURE YOU HAVE PLENTY!!!!, use a C-Clamp and a Table with something the size of the lip of the pintle cap to SLOWLY press the cap onto the injector)
-NGK Spark Plug Wires
-The Real HPS Silicone Hoses in Various Sizes to Replace All Original Lines
-Used Front Cover to Replace Cracked Original
-Spare Valve Spring Seat to Replace Broken Original
-Greddy Multi D/A Boost Gauge with Oil Pressure Sensor
-OE Knock Sensor

Machine Work Required:
-Valve Job
-Exhaust Valve Guides Replaced
-Block/Head Hot Tanked
-Head and Front Covers Resurfaced
-Head Straightened

Materials Used:
-Factory Service Manual: 91-94 FACTORY SERVICE MANUAL
-Painters Tape
-VHT Engine Enamel Primer, Flat Black, Cast Aluminum Paint
-Brake Cleaner (x8)
-Eye Protection
-Blue Paper Towels
-Loads of Shop Towels
-Simple Green
-Alternator Aerosol Cleaner (x2)
-Sta-Lube Assembly Lube
-Chem-Dip (in a Paint Can from 'the zone' [$28, but magic that cleans pistons and hardware])
-Harbor Freight Dental Picks (Rock!)
-Small 3/8inch 12point 12mm Socket for ARP Head Studs
-Hammering Impact Screw Driver (You hit it with a hammer and it does the turning for you so you dont strip phillips screws [Oil Pump Gears, Injector Caps, FPR])
-Large Tube of Black RTV (Lower Front Cover, Oil Pan, Rear Main Seal Bracket, PCV Block on Lower Front Cover)
-Small Tube of Grey Thermostat RTV
-Tube of Red RTV to collect them all
-Tube of Liquid Thread Sealer
-Tube of Blue RTV
-Castrol GTX 10W30 5Qts
-Probably some other AutoZone runs...
-Taking Time To Think Twice Before Doing Anything, Especially with a Gasket



Before:













Compression looked good taking it out:











some of the damage and other pre-rebuild pictures:















Cracked Oil Pump Gear Cover:





Broken top tab on the Original Lower Front Cover:





Wow, Cylinder #4 Head Gasket, yikes!:





Valve Spring Seat was only partially installed and was crushed over the years:





VHT Aerosol Engine Enamel Light Grey Primer:







VHT Engine Enamel Flat Black:







Chem-Dip Magic:





Cleaned up the engine bay:











Long Block Build Up:































Last edited by zombiewolf513; 10-13-2020 at 12:59 PM..
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Old 10-13-2020, 12:44 PM   #2
Fuglychuki91
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Sorta reminds me of my ka refresh but way more meticulous haha. Very clean looking build sir
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Old 10-13-2020, 12:58 PM   #3
zombiewolf513
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Replaced all those nasty hoses with that sweet silicone! About 5 feet of 3mm for the smallest. Only needed a foot or two of the other sizes, measure the outer diameter size of the hard-lines each hose goes to and use that when ordering as the I.D. (inner diameter) of the hoses. They'll fit snug, clamps just need to apply a little pressure, don't wrench them down too hard on silicone. Taking one off at a time and cutting the pieces to size after test fitting the ID is the key.

Here are some shots of the intake manifold cleanup:
























Painted this piece after leaving it in chem-dip over night:









This is why we double check our work (pickup gasket):





Broken exhaust manifold stud. Luckily I had extras







Nasty steering rack and sway bar bushings were swapped with fresh Energy Suspension bushings:





Picked up this sweet hat at the local Nissan dealership:





Engine is ready to go in:




Engine in and ready to roll!







Passed Emissions with flying colors!






In neutral, steady idle at 700 RPM, operating temp, timing at 20 degrees BTDC (spec 20 degrees +/- 2), idle oil pressure at 160 kpa (spec is 80 kpa minimum), 3000 RPM no load oil pressure at 460 kpa (spec is 410-480kpa).
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Old 10-13-2020, 01:12 PM   #4
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In late 2016, I swapped in a POS SR20. Then I switched to building the 65 Mustang. This 240 has really taken a back seat for a while, but now (in late 2020) she's back on the operating table.



Painted the valve cover (and helicoiled the stripped intake threads):

















Aluminum brazed a fitting on the intake for a vacuum source for the Mishimoto compact catch can:






Cleaned up this intercooler hot pipe with progressive sanding up to 1000 wet, then hit it with some aluminum polish:










Cleaned up the headlight surrounds and gas tank surrounds with some plastic restorer:














Broken Turbo Lines, Replaced with DIF Insulated Lines. I also didn't notice the impeller on the GT2871 was damaged. I replaced with a brand new CHRA:






Painted the exhaust manifold with VHT Manifold paint:




I swapped out these stock cams with JWT S3HL, and removed the RAS:




Swapped out the thermostat for a Mishimoto unit:







My first hotwheels car (Hence the moniker "zombiewolf"):





Basically how the engine bay is chillin right now + the circuit sports coil pack ground cover. I'm going to be pulling the motor and redoing basically everything:



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Old 10-13-2020, 01:16 PM   #5
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I was cleaning up the garage when I found SNEK in the old KA24DE! I unwrapped the plastic wrap from the engine, and I saw a bunch of hoses on top of the TB. I didn't think there were so many hoses there so I decided to investigate by poking at them. The hoses were a snake lol.








Removed the rear suspension:

















Removed the old wing. Guess that's where all that water was coming from:







Installed a kouki wing:

Made a cardboard template:





Put masking tape on the car, aligned the template, marked the holes on the tape:











Double checked the markings:





Drilled the holes all the way through:



Perfect fit:





Drilled out the underside of the holes for tool access (don't cut the wires behind the metal), finish with some paint:








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Old 10-13-2020, 01:20 PM   #6
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In the process of fixing these crushed pinch welds:





*sigh* the current state of my gas tank:









Now I'm spending about 3 hours at a time painstakingly scraping the underside with a wire brush to remove the decades of baked on crap.
It's gonna take a few weeks to get this done and ready for new undercoating. These are before shots:











After removing the rear subframe, I had it sand blasted.









I welded GKtech rear subframe reinforcement brackets and lower control arm anti-anti-squat relocation brackets onto the subframe:









Then I had it powder coated in silver vein:


















Finished it off by pressing in the SPL solid subframe bushings:

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Old 10-13-2020, 02:22 PM   #7
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What exhaust is that? Looks sexy, all the pie cuts!!
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Old 10-13-2020, 02:50 PM   #8
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Tomei Expreme Ti. Hands down the best.
Vid from another one of the 240s:
http://www.youtube.com/watch?v=ooO_bbSqMrk
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Old 10-13-2020, 02:57 PM   #9
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Originally Posted by S14rebuild View Post
What exhaust is that? Looks sexy, all the pie cuts!!
Looks like a Tomei Expreme Ti Titanium Catback
EDIT: damn, too slow.
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Old 10-13-2020, 03:20 PM   #10
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Looks and sounds glorious...but that price tag....
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Old 10-20-2020, 07:40 AM   #11
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Subframe looks great! Every time I see somebody rebuild a KA or SR all OEM-like it makes me want to do the same, haha. That's what my build was supposed to be! Wooops. Careful with that Tomei exhaust, they're known to crack at the hangers! Make sure you don't solid mount it.
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Old 11-02-2020, 11:24 AM   #12
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I like the Attention to detail, good to see some solid work done.
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