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nissan
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Discussion Starter #21
Have never built a tray before, so was a lot of trial and error to get it done, had no plans or measurements for the tray was all in my head making it up as I went,
Started out with the rear section used a hole saw to cut the lights out and grinded out the number plate, cut up some 5” exhaust pipe had to make wider so lights would slip in,
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cut the ends to shape and welded them shut
 

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Discussion Starter #22
Went to the metal shop and got what I need to start the frame, laid it all out squared it up got it level and tacked it all together, put the lights in wired em up to a drill battery, looking good 👍
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Discussion Starter #23
Time for the main rails, cut them to length and made some caps for the ends to seal it off, was surprisingly light, could move it around myself,
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Wanted the guards to be separate from tray if they ever get damaged or I want to change them in the future, also wanted them to be adjustable to suit what ever off set I end up running, bought some cast steam pipe bends, cut it all up and tacked it together, absolute pain to do yourself haha
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Discussion Starter #24
Head board. Drew a design on the concrete to exact measurements and went about making all the pipe fit, wanted a twin hoop so had to make 2, ended up buying more cast steam pipe bends as I wanted a tight radius and didn’t own a pipe bender.

Got the tray all welded up, tacked to headboard on and started cleaning it up decided to chuck a brake light into the head board so cut a hole and taped some holes.
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Discussion Starter #25
Next was the side rails, wanted to be able to crank down on a ratchet strap with out it bending so added a few extra tubes to strengthen it, finished the ends off with another cast bend, got some sheet metal to finish of the head board, welded in some brackets so I could bolt a spare wheel to it,

Got the guards sorted out and skinned up in sheet metal.. Only took me 3 attempts to get it right .
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Discussion Starter #26
Gave the whole thing a good clean up, smoothed out all the edges, good dose of wax and grease remover, gave the whole lot a light sand the make the paint stick, bit of primer gave it a few coats of 2 pack black same as chassis, came up ok for my first tray 🤙🤙
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Discussion Starter #27
Still had to weld mounts to the tray to bolt to the chassis, so backed up the Ute, lined it all up square and level to the minimum height I wanted the tray, can always add spacers to lift tray up higher. Got it all fabed up, welded, wired in the lights and went for a spin, drove a lot better with a Solid tray on the back could feel the chassis was stiffer then before, also got rid of the sound of aluminium rubbing together on the old tray.

Took it for a flex test, tyres rubbed really bad on the guards, bump stops will have to be sorted out later, and lift the tray an inch or 2

Took the snorkel off and gave it a polish as well to get rid of the welds.
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Discussion Starter #28
Went round to the sheet metal place and got the floor cut up to fit, 5mm alloy checker plate, wanted alloy so I could drag anything across it and not worry about rust, also got a few things in the mail..... very keen

Also found another timing cover for a factory TD42T and thermostat housing not eaten out, gave it a bit of paint.
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Discussion Starter #29
Start removing the old stuff!
Old turbo off, had to cut a spanner to get it, had seen better days and was pretty worn out, new turbo on,
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Stripped the front of the engine and replaced with new cover and housing, also got the 12mm injector pump In, injectors fitted also.
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Discussion Starter #30
The sump was covered in surface rust so sent it off to be sandblasted and primed, gave it a coat of paint,
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next was sorting out the intake and intercooler pipes wanted to go front mount, bought a 600x300x76 cooler and 2.5 inch alloy pipes, 4” stainless for intake to airbox made it fit by cutting up straight pipe to get around the manifold and ac lines
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Got the intercooler mounted with some angle,
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started making the intercooler pipes up, removed the washer bottle to make life easier, got an aftermarket intake manifold as well
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Discussion Starter #31
Got a new damper to hopefully help the crank hold up and not snap,
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got the passenger side intercooler pipes all fabed up, never welded alloy so got someone to come round and weld it up for me, added some beads on the end to stop the joiners blowing off. Had to grind a heap out of the grill to fit over the intercooler, if I done it again I would of lent to top of intercooler towards the body more, grill would of almost fitted straight on.
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Had to sort out a washer bottle, pulled one out the subaru I was daily driving, fitted perfectly up the back passenger side, also had twin pumps! couple rivnuts all sweet. Good upgrade
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First drive, needed a tune badly! Bulk soot egts would get to 550 in the dump, in a second or 2, turned boost up to 25psi, a lot better, still needed someone who knew what they were doing to look at it.
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Discussion Starter #32
Time for a tune, drove it 5 hours up to Caboolture, fingers crossed the clutch would at least hold long enough to get a good tune on it, couple of pulls, clutch just held. 230hp and 700nm !! was told the airbox I had was holding it back, something else for me to build 🛠👍
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What a difference! drove unreal, could hold 5th up any hill on the highway and still have more if I needed to give it some jandel! Giving it a boot full off the lights could now keep up with a Toyota Yaris!! haha night and day difference. Was a quick drive back.

The g35 fan wasn’t cutting it anymore with the new setup so ordered up a Qikazz fan and hub, and dt79a thermostat. had to do a bit of sanding to get it over the water pump, no biggie,first start up can hear the fan screams! (In a good way) Pulls so much air, temps were great very stable wouldn’t go over 90c 😃 happy days
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Discussion Starter #33
Straight after the tune the clutch never felt “right” under load, boost would go straight to 20psi then very slowly creep up to 25psi, 2 days later driving home from work clutch let go in 3rd, slipped 2nd, 3rd, 4th and 5th under any acceleration, lasted longer then I thought it would😂

ordered up a NPC viper clutch and a billet steel 10kg flywheel 👍
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Yanked the box out, pulled the old clutch and fitted the new, chucked a rear main in as well, had to space it out a touch to get it off the old grove.
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couldn’t give it to much as I had to bed the clutch in, but drove a lot nicer with the lighter flywheel, revs up a lot easier and accelerated a bit quicker, clutch also held the power, instead of creeping up to 25psi, would go straight to 25psi as soon as I put my foot down! Definitely gained more power to the wheels.
 

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Discussion Starter #34
Rear setup, couldn’t order a prefabricated canopy as my tray dimensions were an odd size, so I spent a few hours on google sketch up and designed my own to fit the tray, sent it off to MW tool boxes in Brissy, got the design back from them and paid the deposit.
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month later hooked the trailer up to the daily drove up to Brisbane and picked up the canopy, 3mm aluminium and braced internally, spare wheel holders on the back, few welds to clean up around it but the price was to good! Good quality over all, and was actually waterproof!
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Nice build mate. A lot of work doing a chassis swap but looks like it has been worth it.
 

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Discussion Starter #36
Took it for a quick beach run one Sunday arvo, had almost 950ks on the clutch so should be right in the sand,
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Just got back into town, was idling along in 3rd gear. Bang!!
Whole drive line shook, rear wheels locked up for a sec, put the clutch in and pulled over, loud ticking noise from the engine, shut it off and called for a tow... will have to pull it apart.
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Discussion Starter #38
Started pulling it apart took sump off, crank and all bottom end seemed fine, bores looked clean from what I could see,
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took tappet cover off, valve clearances were all in spec and nothing was loose.. mmmm

Pulled the injectors, NO.2 cylinder had oil on the injector and a couple looked like they were running hot!
Heat shield in the head was almost melted away as well, Have to pull the head! ( yes I snapped the spill rail, few beverages before I pulled it off haha 🍺 )
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Discussion Starter #39
Got into pulling the head off, found the problem! Cracked a precomp NO.1 cylinder few bits dropped into the bore, messed up the liner and the piston, all the other precomps had excessive cracks and looked as though they would of let go soon.
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Might have to chuck the EGT gauge in the manifold next time instead of the dump! Never took it over 550 for more then a second or 2... Will also add more boost! Get the afrs a bit leaner
 

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Discussion Starter #40
Bought a new engine crane, pulled the td out, had to buy a new engine stand as well to hold the weight of it,
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Just didn’t fit! Had to cut the arm and extend it 40mm to get enough adjustment, bit of scrap welded to brace it, works a treat👍.
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stripped it down ready to be sent off for new liners, cam bearings, and crack test / linish the crank, ordered up some genuine izumi pistons sent them off to be ceramic coated, also got a set of ARP head studs to keep it sealed up when I put more boost down it’s throat haha 🤙
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Ended up selling the billet steel flywheel and got NPCs new aluminium flywheel 8kg.
Interesting to see how it drives being that light, also “may” save the crank from snapping no guarantees but, wasn’t keen on spending 4K just for a billet crank, rather put a Turbo Barra into it, ( possible future plans) if this rebuild doesn’t hold up!
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