Squeaky clutch…

…meet your greasy doom. That is, if i can get to you.

For over a year now, my clutch pedal has been squeaking and squawking every now and again, just asking to be oiled, greased, lubed. And oh i have before, trust me.. I’d get on a latex glove, blindly find my way up the pedal arm till I hit something mechanical…there…some lithium grease here, some lithium grease there, a few pumps of the clutch pedal and the sound is gone… but it always comes back. Imagine what that’s like with the Z being a manual transmission. For me, I’m used to it. For anyone else, annoying!

I thought maybe the grease was just wearing away – lithium grease doesn’t seem to have the staying power as traditional automotive grease. Until I finally decided to take the plunge, seat all the way back, lay under the dash with my head on the floor and see what the heck is going on down there.

It’s hard to see, but the 280z has this nice metal wall between the clutch and brake pedal arms. Ah! so that’s why I could only get so far up…And now i need smaller hands, because the space to get to the actual mechanism that’s squeaking is for child-like hands only. You can also see from the pic where all that lithium grease went – haha!

 

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How to get up there without training my nearly 2 & 3 year old nephew and niece to be grease monkeys? WD-40. This probably should have been my first go-to solution for reasons beyond it’s extended spray nozzle: dad would’ve used this first.

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The extended straw allowed me to shoot up high into the hard to reach places. And I kinda just blindly shot stuff up there too for good measure. Viola! No more embarrassing squeaking every time I use the clutch.

Shift knob repair

Pretty much since day 1 (Oct of 2011), the shift knob of the 280z has been loose…and eventually flat out threaded.

On a occasion, I’d be in the zone (or maybe secretly racing the car next to me), and in a shifting fury find the shift knob flung off, bouncing around the cabin. sigh!

There are plenty of OEM retro looking Z shift knobs from Motorsport Auto, and a more after market junk you can fill it’s trunk with – so the choice is yours. However, in true Daily Datsun mentality, ‘why replace when you can refurbish’. And of course i wouldn’t mind using the same since it came with the car – call it owner’s nostalgia. :]

With help from my brother Kris, we were able to do just that.

Since the threads of the shift knob were all threaded and gone, it made cleaning out easy. He used a spare stock rod of some hard plastic, hammer-press fit it into the existing hole, and threaded it with a M8x1.25 tap. Add washer with nut, and we’re good to go!

Check it out – brand new again. Shift on!

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Handle the Door Handle

Sigh – the door handle…

A few weeks ago, I noticed the door handle of the 280z just kinda hanging loose… Still able to open the door, but a loose handle could mean eventual non-working doors, and cross our fingers, maybe prone to brake-ins. If anything else, the tolerances of the Datsun 280z are surprisingly tight in some places, and a loose door handle can actually mean chipped paint! ouch! (you can spot the chip in the lower right).

I took an hour this morning to fix it all up and correct a few things along the way – let’s go!

Daily-Datsun-Door-handle (8)

Oh, here’s what you’ll need to tighten up a 280z door handle:
– 8mm wrench
– philips screw driver
– flat head screw driver
– paperclip or allen wrench (to get the window crank cotter pin out)

Per the S30 service manual, take off the arm rest, window crank, door escutcheon plate, and don’t forget the door lock post (just twist to take that off). Using something flat, gently pry off the door panel.

Daily-Datsun-Door-handle (7)     

Once you have that door panel off, window all the way up, you’ll be able to see the two nuts holding the door handle in. Use that 8mm wrench.

Daily-Datsun-Door-handle (5)Daily-Datsun-Door-handle (3)

In the meantime, I also able to finally glue the vinyl covering and lube up the door lock mechanisms.

Daily-Datsun-Door-handle (6)Daily-Datsun-Door-handle (2)

When put back together – that door couldn’t close sweeter, and the door handle is perfect.

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Eh.. now for the reason why I noticed this in the first place was the paint chip caused by the loose door handle…eventually have to get to all these stupid paint chips.

240z Steering wheel on a 280z… while keeping the horn pad

A while back I picked up a 240z steering – I just love that wood-grained look (though it is composite). I did a nice refurbish on the 240z steering wheel shortly there after, but never got around to installing it… till this past weekend!

There isn’t much around the forums in the way of doing a 240z steering wheel on a 280z. Actually, it’s probably because  in terms of the steering wheel itself, there’s no conversion needed – the 240z steering wheel fits the 280z steering gear exactly. The issue I had was really mating a 280z horn button to the 240z steering wheel!

Check out the visual difference between the 240z (left) and 280z (right) horn pads…

Datsun-240Z-OEM-Horn-Pad 74-76 Horn Pad

I wish it were that easy of a swap, but upon removing the 280z steering wheel and comparing it to the 240z’s, the difference was apparent. The contact plate has 3 screws in the 280z, and only 2 screws in the 240z’s.  This different proved to be all the work, thus having to make an adapter to mate the two.

YES, I could have bought a 240z horn pad (avg $40 – $75), but I have a horn pad…and some metal…and a brain. And i like the challenge! :] Let’s go make a 240z-to-280z horn mating plate!

The 240z steering wheel has two screw holes for the horn assembly, while the 280z has three.

DailyDatsun-240z-steering-wheel Daily-Datsun-240z-280z-steering-wheel (9)

Upon disassembling the 280z horn (three screws), you’ll notice the contact plate has rubber washers and plastic guides (so that the contact plate doesn’t connect the horn pad and steering wheel). On the steering wheel, you’ll see that the 280z has a connection spring (12 o’clock). In the 240z steering wheel picture above, it uses a wire instead.

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The horn contact is located here in this pic at 4 o’clock.

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Datsun 240z to 280z steering wheel horn mating plate – design plan:
2 3/4″ diameter
3/4″ dia center hole
1 1/32″ distance between centers for 240z mounting holes
1 25/32″ lengthed iso triangle for 280z mounting holes (you can just trace these from the contact plate)

I didn’t have a compass, but I found a Mother’s polish can did the job.

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I had some time, so here’s PDF of the mating plate design in case anyone else wants to use it. It should be to scale – let me know how it goes!

DailyDatsun-240z-to-280z-hornMatingPlate copy

The NIBBLER! Since i don’t have a band saw (nor the room for one), the Nibbler gets all the attention.

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Drilled the holes and test mounted the mating plate. Not too shabby. Use drill bits smaller than the screws used in their respective places so they can bite into the metal, make contact, and maintain electrical continuity.

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Here it is assembled on the car. Important to note that the 240z wire SHOULD NOT be hanging outside of the 280z contact plate… yeah, your horn will be ringing all day if you do. It SHOULD be connected to the 280z contact plate on the back side. Don’t add anything to the face of the contact plate because you want to have an even surface to make contact anywhere you press the horn button.

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Since soldering didn’t work on the contact plate, I simply just protected the mating plate (from further contact), bent the contact wire head, and press fit it under the contact plate.

Tada! installed. love it. and it still goes beep-beep.

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Review: Motorsport Auto (MSA) Floor Mats

Swiftly got a package in from Motorsport Auto (MSA) – my new floor mats!

With summer ending and rain just around the corner, it’s always been on my mind to get some floor mats since putting in the carpet kit. Question was, which one?

Could go with a logo’d version, a $50 – $70 ebay one-size-fits-most specials, or even one those Weathertech versions you always see ads for in car magazines. Since the MSA floor mats weren’t that much more, I decided to go with simple. And coming from them, it’ll probably have the best fit. Check them out:

Pros:
1) Great solid looped carpet top
2) Very well stitched binding all the way around
3) Excellent fit, perfectly sized

While the above images show otherwise, the actual color matches quite well with their molded carpet kit. It’s nice when things match. The carpets feel solid and we’ll see how well they last through the rain.

Cons:
1) No heel pad on the driver’s side. So that heel pad that’s on the carpet kit.. covered…and i’m going to wear a hole in these.
2) No clear markings on which side was which. Yeah yeah, they’re only floor mats, but actually it took me a few trys to figure out which one was which. It’s odd there’s an undulating side that runs along the transmission tunnel which is straight… sorry, maybe i’m nit-picking.
3) Foam backing…can’t wait to see how these hold up after a year as it’s been my experience that this type of foam doesn’t last too long. Especially in such a high traffic, elements exposed area. It seems to work for non-slip against the carpet floor, but let’s see how long the foam backings last before making any more comments. I would have thought they used rubber backings.

Other than that, I’m currently satisfied with the floor mats, but the upcoming rain should prove it’s real worth.

PART III – WE MADE IT! – DailyDatsun’s Wedding 280z Complete

WE MADE IT – we did it! What started as a daily driver project, transformed into a serious restoration and finished as our wedding chariot. My fiancee and i tied the knot on Sunday, May 27th with a wedding nothing short of amazing. And getting this car completed on time was definitely a part of that weekend. 4 days and 10 people later, the 280z barreled it’s way over to our hotel and drove us to our wedding.

DailyDatsun 280z - Just Married

Truly starting the week before, I had already ordered the parts i had needed for the final assembly – window seals, weatherstripping, carpet, seat covers, and a front windshield (more on that later). I needed to those parts ordered quick to be ready as soon as the car came back. Once the car rolled out of the painters garage it was already Tuesday evening – literally only 4 days and 5 nights remaining. That night i got straight to it, sorting out the pieces getting it ready for a full attack the next day.  We quickly got into full swing with my brother Kris and a groomsman Erik helping hammer it’s way back to road-worthiness.

DailyDatsun 280z - instagram

We were able to complete the rear tail lights, some trim repaint, side marker lights, headlights, hood louvers, hood rubbers, floorboard prepping, and the front feet area of the carpet.

Thursday rolls around for another big day. During the afternoon I had the neighbors install the front and rear windows – truly a blessing to have a family who owns an auto glass repair company live next door to you! Late afternoon, brother brought over another groomsman Jerry and his girl Kennie (who had just both come over from Hong Kong) to lend a hand, helping clean windows and tackle the carpet. Carpet continued to dominate our time because of the measuring / cutting required for all the interior fittings: both sides of the seat belts, shifter, e-brake, and seat rail holes among other things. Carpet needs to go in first because it instantly transforms the visual impact of the car. Additionally, once that’s in, seats, center console, door trim, all that can go back in.

Later that evening, I had three more sets of hands arrive: my future sister-in-law Dana, my sister Kathryn and her boyfriend Jake! It was great, we all had our hands on this thing! Jake and Jerry tackled doors, Kennie and Dana helped clean parts, Kathryn helped me assemble the last seat, while Kris had the dreadful task of installing the rear driver-side interior quarter panel trim. Imagine having so many people who, for the majority, have never worked on cars (let alone re-assemble one) all help out at the same time – yes, it was a circus. Yes, you’ve gotta make sure all the correct bolts were used. But truly it was such a fun experience. I love working on projects with friends, more so with my brother and sister!

DailyDatsun 280z - Seat and sister

To top off the night, even LATER that evening, my parents flew into town, and they too dropped by to check out how things were going. I wish i got it on video / photo, but both my mom and dad would later return the next day to help out to complete the re-assemble.

Friday, My dad and i put in the seats, dash and door trims; while my mom cleaned parts, and even tackled the biggest task: clean / organized the storm of parts and trash that my garage was left in the previous night. Yes, I definitely should have gotten photos of my mom and dad helping out but we were just so focused on getting this done. Wipers went on, the last three pieces of chrome front windshield trim were found and installed. I got to say the whole project has been amazing, but there’s nothing like working on a car with your dad. More over, he’ll be driving it while we’re away on our honeymoon. It’ll be 40 years since he last drove a Z, and I can’t wait to hear what he’s got to say!

I had a two hour window to install the final touches late Saturday afternoon – front grill, front parking lights and their trim, horn, side-view mirrors, and of course, the c-pillar ‘Z’ markers. I took it off the battery tender attached the night before, and started him up. Perfect – solid and strong. Looks – amazing and fast. I’m proud and thankful that my friends and family helped get car back on the road, and ready in time for the wedding.

Sunday night we drove it back from the reception only to be stopped by a police officer 1/4 mile from our hotel. Doh. Were parts falling off? Lack of rear bumper? Nope. No tail lights. Brake lights were working but the car was “invisible out there” with no running tail lights. Luckily the officer was more concerned about our safety, and with the ‘Just Married’ sign and us still being in our wedding get-up we were let go with a congrats rather than a ticket. :] Sigh! now this rebuild story is complete!

Pictures of the re-assemble will come soon – for now here are some pics straight from the painter that Tuesday afternoon.

DailyDatsun 280z - fresh paint

DailyDatsun 280z - fresh paint 2

DailyDatsun 280z - fresh paint hood

DailyDatsun 280z - fresh paint 3

 

 

 

Getting Wedding Ready – Part I

OH yeah. It’s on.

Time is ticking, and the Z is on it’s way to being our wedding car! Yes, I convinced my beautiful, sensible minded fiancee to use the 280Z as our chariot. The only catch: it has be 100% ready. For my wedding, is there anything else it would be? :]

Since that day (about a month ago) i’ve been planning, scoping, and wrenching on the 280z to get it ready for game day. With little over three weeks away, it seems like it’s got a great distance before it gets to 100%.

This morning, it was back to the seats.

Last time, I had just recovered the seat backs leaving the seat bottoms to be finished.

Datsun 280z seat

There are three small screws that hold in the cover plate to the adjustment mechanism. Behold! the underside uses that same straw-like padding as seen in the seat backing.

Datsun 280z seat - cover plate screw Datsun 280z seat - underside

Seat adjustment mechanism

Datsun 280z seat -adjustment mechanism

I was blocked by these stubborn screws holding down the chair adjustment spring fixture. Even with WD-40, corded drill with PH-3 (big) bit, and some taps from a hammer – those tough screws were NOT coming out.

Datsun 280z seat - spring mechanism

So I got a little clever and cut the old vinyl to slide it out from the seat spring fixture. This method will prove VERY useful when putting the new cover on.

Datsun 280z seat - working around frozen screws

Undoing the chair slider…

Datsun 280z seat - seat slider

The original seat foams are from Toyo. A quick part search on google for ‘PM690M9’ reveals nothing – surprise.

Datsun 280z seat - seat foam

Minor surface rust in the seat spring; only a little clean up required.

Datsun 280z seat - spring seat frame

Tada! No one’s going to see this part anyways…

Datsun 280z seat - resprayed

After a quick test fit of the new seat cover, I thought there was a bit too much play in the cover and the seat foam. So i decided to use some extra foam i’d been saving just for this purpose. Though pink open celled foam like this isn’t ideal (as it WILL eventually disintegrate), it should last several years before collapsing out, by that time, i’ll just get new foams entirely. Here, i cut a pattern for the seat bolster because the seat cover is a touch wider than the tapering original seat shape.

Datsun 280z seat - extra foam pattern

Datsun 280z seat - extra foam applied

I also decided to replace the straw-like padding on the bottom between the seat foam and the seat spring. My first thought was it was just a protective layer between metal and foam.. but the other day when working on the driver seat (which had this material and burlap…), i realized it’s other responsibility… absorb any excess moisture. oh well.

Datsun 280z seat - spring pad cut Datsun 280z seat - spring pad replaced

The new seat covers use a string to cinch the cover to the frame. I decided to re-use  the hog tie re-bars (as well as the string) to make sure the covers sit firmly in place.

Datsun 280z seat - seat re-bar inserted

Here, you can see where i cut the new seat cover to fit in between the bolts that hold the spring assembly. I pulled the string out from that portion of the seat cover, cut, slid the cover through the opening between the bolts, and then fished the string back through. First thing i thought of was that this solution would be something my dad or grandfather would think up of. Worked like a charm, and best of all I can move forward.

Datsun 280z seat - seat cover fix

Looking pretty full in there – now just to pull down that mid-section to give it contour…

Datsun 280z seat - seat complete topside

Seat completed, hog tied tight.

Datsun 280z seat - seat complete underside

Perfect. The seat bottom is extra cushy, and it’s got great shape. I lightly sanded down the bolts, sprayed the seat back bracket with bed liner for a nice rough texture, and cleaned / sprayed the slider lever.

Datsun 280z seat - seat complete side

Datsun 280z seat - seat completed

Datsun 280z: Gutted

Yesterday I started to tear down the 280z.
In about 2.5 hrs, I had the car just about 80% done before it can go to the painter.

Carpet: out.
Seats: gone.
Passenger door: stripped.
Center console: removed.
Passenger side door trim / seal: off.

Just need to remove the driver side door / trim, all the lights, and most importantly the windows…
And I need to make more room in the garage to store all this.

We’ll let the pics do the talking.
280z interior - gutted

280z interior - door

with the door paneling off, i was able to grease up the sticky door locks. NO MORE CRAWLING THROUGH THE BACK HATCH TO UNLOCK THE DOORS! :]

280z door lock mechanism

Like a well worn couch, it’s amazing what you’ll find after 35yrs…

280z interior - found pen

… a nasty 400W amp under the driver seat (that’s probably 400W PMP (max rating) haha, so more like 100W).

280z interior - amp

And i’m now $0.39 richer. Oldest coin here though is 1983 (the quarter).

280z interior - coins

280z Carpet!

Pulled the trigger on some new carpet!

Motorsport Auto (MSA) has 280z molded carpet on sale right now for $240!
They’re manufactured by AAC, and right off the bat they look and feel great.
This kit includes the passenger area, area under the seat, and the rear trunk area (no shock towers or wheel wells). This is fine because i don’t like having carpeted towers / wells.
The carpet is a short, cut-pile carpet with sewn edges (where needed), and a very nice thickness. It even includes some carpet padding in most areas (again, where needed).

Since carpet pics on their site / internet are seriously lacking, here’s some for viewing pleasure, and a look at things to come.

MSA 280z carpet

Check out the sewn edges and ~1/4″ thick carpet pad.

MSA 280z carpet - carpet pad close up

Note the padding goes around most of the areas of carpet, even up over the center console / transmission housing area.

MSA 280z carpet - carpet pad close up 2

Passenger carpet piece

MSA 280z carpet - passenger area

Close up of the foot pad

MSA 280z carpet - foot pad close up

Carpet piece for under the seats

MSA 280z carpet - area under the seat

Carpet piece for the behind the seats, up over the luggage bar, and throughout the trunk deck. The 280z is going to look great with the new carpet!

MSA 280z carpet - back and trunk area

Both Seat Backs Covered: 50% done

Finally got around to covering the other seat back on the 280z this past weekend – Kris was down to help me out.

After taking off the old ’77 280z basketweave seat covers we found something interesting…

77 280z original drivers seat - open

the driver side is padded! an additional layer of foam covers the hairy jute-like seat cushion.

Here’s Kris setting the hog rings, getting them in place. Again, honestly, you don’t to worry about getting hog ring pliers – we used them for a whole two seconds for a job that could’ve been done using regular pliers.

280z drivers seat - re-cover

Stretching a seat cover can be difficult work. It was a fairly warm day, so we were working with optimal conditions. Really, it’s the seat pattern that was just a touch too short for the liking.

280z drivers seat - stretching 1  280z drivers seat - stretching 2

But pulling, stretching and team work prevailed. Tucked and pierced the n0n-barred flap under the barred flap, just like last time.

And installed!

280z seat backs - installed

Now to get those seat bottoms done and the 280z will start to look good.