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Project Tosbo: almost there

Even though the progress was slower during summer and holiday season, I’m super happy to report that I’ve driven the first 5km to test everything. The carbs need a bit of tweaking, the brakes need a proper bleeding and some other minor stuff. But I’m super happy of where it’s at. Exactly 1 year and 23 days after I started disassembling the car. 1 year and 23 days to do a complete nut&bolt resto myself (except body work). Every part, nut and bolt on this car was either cleaned, painted, coated, renewed, changed, modified,…
So here are a few pics of the last months in chronological order:


Custom heatshield for the Fujitsubo header. New gaskets everywhere,…
Didn’t go with the usual blue engine paint, as it doesn’t go very well with the safari gold
Lonely driver spark plug wire separators and Datsun Spirit MSD spark plug wires
Long block ready to be put back in
Long block ready to be put back in
Engine in
Added the Garage Theory strut bar
In good company. My 70 240Z, my 73 240Z and my ex KE25
Engine and gearbox all mounted
Rear diff, suspension and fuel tank mounted
Just missing the airbox now
Interior completed. Datsun competition steering wheel, Tomei shift knob for the KA14 gearbox, Speedhut tach, Cobra RSR seats
The underbelly in all it’s glory! I could look at this all day long
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Project TOSBO: starting to reassemble my dream Datsun

So as the shell is back home, the reassembly can finally begin. This whole process will take loads of time, as I’m stillgoing by the motto: No part will be mounted back up without touching it to make it better, newer, cleaner,…
Just out of tradition I started with the most random part possible. The first thing I saw on the shelve was the fuel filler neck, so back in it went.

Next thing were brake hard lines and some elements in the engine bay

Gave the car it’s identity back with some of it’s badges

Mounted the aftermarket JDM/EU taillights to see how they turn out

they turned out awesome

Started fiddling with the interior sound deadening

paper templates
I do like the result

Mounted the fuel tank

More interior work

Dash back in

Started the reassembly of the doors

Head loghts back in. Need to finalize the wiring
Even though the fenders need to come off again, I saw the rubber flaps on the shelve and screwed them on.

I still don’t have a “plan” on how I’m going to proceed the reassembly until it’s all back together. Right now it’s a matter on what parts catches my eye, what is half way logical to mount first, and what is pleasing me that day to see mounted back on the car.
Wiring looms are 90% back in, horns are back in, pedals and master cylinders are back in…

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mid march update: it’s back home :-D

Well with all these pandemic things going on, it wasn’t that easy to get the shell back home to the shed. I wasn’t allowed to go to belgium to pick it up myself, so I had it delivered by a transport company.
So I could finally see it with my own eyes, the color I never saw in person before. I decided to go with safari gold just by looking at pictures of it! But I have to say, I really don’t regret it. The color is awesome, looks so different with different lighting conditions. And it has to be one of the most 70’s colors from the 240Z color chart!

Back home in good company

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february 2021 big updates from the bodyshop

At a future date I will make a post abouth all the metal work that was needed. All I can say is that the guys (or should I say wizards) at SLG classiccars absolutely killed it. Their skills are beyond belief.
Here is the car after 1 month of metal work and panel beating

And here it is in it’s actual state 😀

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january 2021: project TOSBO update

The list of parts and assemblies to freshen up seems endless!
Front suspension back together

Fuel tank looks good now too:

And I decided to have some wiring fun! Over 30 hours went into my adapted and modified harness. Or shoud I say harnesses, as there are 4. I used the original harness and modified it to have relays for lights, starter,… I rewired everything related to ignition. Adpated for the use of JDM/Euro spec tail lights, got rid of the way to complicated stock hazards wiring,… In the end I drew a new wiring diagram for future diagnose,…

In the beginning there was chaos:

But in the End I’m really satisfied with my job. Crossing fingers everything will work as intended 😉

As the dash is out, I disassembled all the gauges, cleaned the up, polished the glas. Mediablasted an painted the housings, reassembled everything except for the tach. A Speedhut electronic tach with gps speedo will take the OEM units space.

Next on the list the window scraper rubbers which were all brittle and disgusting. As I didn’t want to buy the expensive chrome trim with the attached rubber scrapers I decided to give it a try and just replace the stock scrapers on my existing trim

Another upgrade over stock is a Subaru STI LSD differential with a 3.9 final drive. So I bought the diff, bought some conversion axles from datsunrestomods and refreshed the diff. New gaskets, new hardware,…

Looks good now

Reassembled the rear suspension and brakes

Started my home made zinc plating again

Reassembled the wiper motor after cleaning everything

Fuel filler neck has a second life too

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december 2020: shell update

The shell was transported to a specialized media blasting company to remove all the layers of old paint, bondo, under sealing,… Nothing better than bare metal to start building a “new” car.

After I went to see and inspect it, the naked shell was then transported shortly after back to the resto shop where they instantly put in epoxy primer to prevent any oxidation while the works have to be done. All in all we found a few bad repair jobs, some minor rust spots,… Nothing major and nothing shocking. The guys at the resto shop are quite satisfied with what they have to work with.

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december 2020

To change a bit from blasting and painting I started to fab some cupro brake lines and fuel lines from scratch. I reused things like the T-piece, the pressure valve,…

rear brake lines, refurbished T-piece (blasted and clearcoated)
In detail, the refurbished T-piece
Fuel supply line and clutch hard line
Heater box. Media blasted, primered, painted, new seals, new foam, new hardware. And new heater valve (not shown)
Heater box. Media blasted, primered, painted, new seals, new foam, new hardware. And new heater valve (not shown)
Fuel tank straps. Media blasted and powder coated, new foam.
NEW hardware. Yellow zinc plated where available

And sometimes you need to find new motivation. To do so I just assemble some parts and enjoy myself.

Front subframe powder coated, steering rack greased, newly painted, new steering bellows, new balljoints, LCA powder coated and PU bishings, tension rods blasted and coated, outer tie rods cleaned and clear coated, new hardware.
headlights
Pedal box. Disassembled, media blasted, coated, greased and reassembled. New datsmo rubber pads on all 3 pedals

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november 2020: meanwhile at the garage

While the shell is out, there is plenty of space to start organizing and refurbishing parts. Some parts went of to powdercoating, other stuff will be sandblasted and painted/coated by myself. But where to start? It isn’t easy when you have all the elements on the shelves, floor, hanging from the roof,… So I picked the most random part I could think of. The interior blower fan.

The stock unit
Disassembled and media blasted
2 coats of primer and 2 coats of black paint, new foam, new gaskets, cleaned or renewed hardware
All back together and ready to be mounted in 2021 or 2022 😀

After the start was made I wrote a list of elements that needed to be refurbished, what parts needed to be ordered, what parts I wanted to have a makeover. So now, everytime I go to the garage I just choose a task and get work done. As there is so much different things to chose from, I can match the work to my mood 😉

The parts which I dropped of to powder coating
More parts that I media blasted
Aluminium drum brakes blasted, cleaned and painted
Calipers: Disassembled, media blasted, cleaned, painted, new seals, new hardware, new pads
Fabricated some new rubber gaskets myself
And the parts are already back with fresh black powder coat

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november 20th 2020: the shell is with the wizards

One major step. I brought the shell to the resto guys of SLG classic cars in Belgium. This will be a first for me. I never done anything quite as exciting (and expensive) to a classic 😉 But I’m really looking forward to it.
Whats’s on the menu?
– remove all paint (inside, outside, underside, engine bay)
– repair where needed (the old school way! by metal shaping, heat shrinking,…)
– some random metal work (close side marker holes, close side molding holes,…)
– prepare for paint
– paint it ……… (insert color here. I’m still not sure what color I should go with)

For now, enjoy some pics of the delivery: