New guy here with an ITA 240SX (project)...

[orion]

Hey guys...new here, but my project isn't. It was sold off these forums back in 2007, but I bought it from the guy who owned it for the last ~3 years.

My background: I've owned a 1996 240SX for 13 years, and it's been my primary "fun car" - HPDE's and some autocross. I do all my own work...and this car has gone through several iterations...but it's currently powered by a stock motor with a T3/T4 turbo setup (325rwhp at ~12psi). Upgraded suspension, wheels/tires, 4-point roll cage, Z32 brakes, etc...round it out.

In the last 10 years or so, I've bought/fixed up/sold another eight 240SX's to fund my hobby.

Most recent project car is the ITA 240SX I alluded to above. It was built and raced by "BB Racing" for a couple years...sold in 2007 to a local Porsche race shop...and finally wound up in my garage earlier this year.

I bought it to resurrect it, and possibly get into IT racing.

I've documented my progress so far on another forum, but here's the condensed version - - - - - - >

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Here's a pic of the car as it sat when I bought it:



It's currently got a stock SOHC under the hood.

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The good: Koni Yellows with Ground Control sleeves, 225/45-15 Hoosier R6's on 15x7 Team Dynamic wheels (2 sets), Nismo 2-way diff with 4.6 gears, Momo seat, window net, arm net, JWT ECU, Injen intake, no muffler (first thing I'll fix!). Has a fuel cell that they added. Griffin radiator.

Has a spare .40-over motor (in pieces), spare trans, and a tons of other misc. bits (wiring harness, stock ECU, engine accessories, etc...).

The bad: It's a used racecar, with a little evidence of rust (rear rockers, under the hood, stuff like that)...BUT it's old rust, it's been prepped/painted since...so it's more like "sheetmetal with pinholes" in the questionable spots.

Needs a ton of little TLC to make it nice...but that part I'm looking forward to.

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UPDATE #1: Dragging it home...

Right now...it's not up to par. The headgasket is DONE.

I thought it was a little 'off' when I looked at it the first time, but the team manager said the compression/leakdown was good. Not the case today.

No huge deal, I still bought it...

I'll fix the motor that's in it...its just a HG. Bang around in it for a short while, sort it out...then drop in the "built" motor when I get it assembled.

Anyway, pics:

Leaving the shop:


It's new home:


Spares (some of it):

[orion]

UPDATE #2: Fixing the motor...

Head is off and straightened, but I'm going to do a couple things before it goes back on:

- Add the IACV back to the intake manifold (still bolted to head, no reason to remove it)

- Tap the intake manifold for the Autometer coolant temp sensor

It was clear where the headgasket was bad...it must have been going for some time:



I hope to have it back together and running on Sunday...then I can focus on fixing all the other little shit.

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UPDATE #3: Got it running, took it to the track for testing...

...and the car did "OK". (Track is Gainesville Raceway's roadcourse...it's roughl a mile, and quick cars run under 60-second lap times)

It ran well, but the drivers side front wheel bearing took a sh!t around lap #5 in the FIRST session of the day. Must have been bad already, but I haven't had it up to speed/temp like that. Luckily, a local guy had one in his garage (thanks Tom!)...so within an hour, I had a usable one on there, and was back on track.

Motor felt OK, but makes no top-end power. I have to wonder if the tiny piping after the header collector is choking it out. Max speed on the longest straight was only 72mph...that's a good 20mph slower than my S14. So that's something to address.

A couple pics:





Coolant and oil temps stayed below 200F, and this track doesn't allow much time for cooling off, so that was good.

Anyway...with the car making proper power, 59's should be achievable.

[orion]

UPDATE #4: Fixing the wheel bearings...upgrading the header:

For repacking the wheel bearings, I went with the Redline CV-2 (from Summit)...reasons being 1) cost, and 2) proven with racers. Mainly cost.

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I also ordered a new flex section for the exhaust...I think the header is WAY too restrictive.

See here:

1.5" primaries, shitty collector, and necks down to 1-7/8" ID at the flex...bumps up to 2.5" OD after, same as the rest of the exhaust.




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So I think it needs to be 2.25" or so at the collector exit, with a better transition to 2.5".

I cut off the shitty flex, trimmed the current collector a little, and opened it up:



I'll add the new 2.5" flex section after that...but it will merge smoothly this time around.

Maybe it will make power above 5500...I hope it will. KA motors typically like to really breathe on the exhaust side of things, and this should eliminate the last restriction.

[orion]

Here's what I did: Marked the new flex tubing around it's circumference in 6 evenly spaced places, 3/16" wide each.

It worked out great...I had to remove 1-1/8" of material..or 18/16". 6 cuts of 3/16" each...perfect.



Bent the pieces inward, to make a cone...

Inside view:


And finally...a nice venturi, just over 2" ID at the smallest point:


(Yeah, the welds look like shit...I had to set the heat too low to not burn through...stupid flux-core!)

[orion]

UPDATE #5: Fixing the cam timing...

Found the timing chain off one tooth - No wonder it didn't make power above ~5500.

Next track day is soon, I hope to have it perform better this time around...

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UPDATE #6: Rod knock.

I led the "parade laps" at GIR today, and that let the car warm up.

As soon as I could after pulling everyone back in the pits, I donned my helmet and headed out, eager to run faster than 59's...

Car ran a couple 1:04's IIRC, and just didn't seem quick. Slower than before, even...and that was when the cam timing was off. Laps times were dropping off, and the oil and coolant temps were headed UP. Soon it developed a tick, then a full blown KNOCK.

So the "freshened up junkyard motor" that came in the car...is now dead.

Yee Haw.

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For the questions that might arise: I was running M1 10w40 "high mileage", and it was fresh as of the night before. Overfilled by a half quart. Never over-revved.

I think it was a dying motor from day one, and the time spent making it run OK was wasted...I should have started fresh. I have the overbored (90mm) block ready to go, with a fresh head...but I need piston rings.

[orion]

UPDATE #7: Fixing the ole' SOHC KA...

So I pulled the motor this afternoon...#2 rod bearing is the dead one, and the oil pan was full of crap (???).

Silicone / gasket material, bearing 'shavings', and what looks to be rocks...????!?!?!??? Dunno exactly what it is - But it's small, round-ish, and hard...like a pebble. Most likely timing chain guide material.

Pics:

Work area - My S14 is living elsewhere for the time being, so that my wife can still park on one side of the garage -->


This is the debris...some is obvious as to what it is, the round things...are the "mystery rocks". For reference, the largest piece shown is probably just under 1/4" diameter.


After I hosed the pan down with carb cleaner, to wash it out a little...the bearing material showed itself:


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Next step: Rebuild.