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Ross' New 1600
http://www.ozdat.com.au/forum/viewtopic.php?t=17898		 Page 56 of 58
Author:  Anth510 [ Wed Jan 25, 2017 10:31 am ]
Post subject:  Re: Ross' New 1600
OEM is the way to go mate, can't wait to get rid of my adapters and generic CVs one day.
Author:  MY110 [ Wed Jan 25, 2017 8:01 pm ]
Post subject:  Re: Ross' New 1600
Coming along nicely Ross!
Author:  RJB510 [ Thu Jan 26, 2017 8:01 pm ]
Post subject:  Re: Ross' New 1600
Little bit of an Australia Day update:

After lunch i managed to get the old r180 out. Took a bit of work, one of the spacers was jammed under the diff so it wouldn't budge forward so i struggled to get the moustache bar off. Also might have put it on upside down when installing originally so it doesn't want to drop below the pins. Anyway... it's out.

Turned out that my rear crossmember wasn't the r200 ready version. Some work with the angle grinder and die grinder sorted that out.
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Then i went ''that'll do'' and packed up for the night.
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Next job will be to make the moustache bar. Just got to decide what thickness Steel i want to use. It'll be braced pretty solidly.
Author:  RJB510 [ Thu Jan 26, 2017 8:08 pm ]
Post subject:  Re: Ross' New 1600
Oh, but before all that i assembled my axles. Silastic added to the rear hat too.
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Author:  SR20Datsun [ Fri Jan 27, 2017 8:59 am ]
Post subject:  Re: Ross' New 1600
RJB510 wrote:
...Turned out that my rear crossmember wasn't the r200 ready version. ...
I feel for you on this mate. Those bloody R200's are heavy damn things and jamming one in there and then pulling it out finding it didn't fit would have been a PITA.
Did you follow the little tutorial I did about the removal of material in this area?
Author:  RJB510 [ Fri Jan 27, 2017 9:33 am ]
Post subject:  Re: Ross' New 1600
Oh mate, PITA!
I ended up setting it on a jack and got a second pair of hands to assist with lifting it while i manoeuvred it into position.

No i didn't, I'll have a sticky beak though because you have probably done something better than mine! I had an old crossmember that i previously modified to fit the diff into, so i had a good idea of what metal needed to be removed and i basically just copied that.
Author:  RJB510 [ Mon Feb 13, 2017 11:41 am ]
Post subject:  Re: Ross' New 1600
So after a really hot Friday off work.
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I finally got the big diff installed.
8" of Nissan R200 with S15 helical centre.
New bearings and set my own backlash and preload.
Built my own moustache bar with new Whiteline bushes.
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Built my own axles with shortened shafts (would have got my ones cut down but it's been 12 months since i started putting this thing together i needed to just get it done!)
All new bolt hardware.
We'll soon see if I'm any good at rebuilding diffs :shock:
Still yet to drive it though.
Author:  SR20Datsun [ Mon Feb 13, 2017 11:49 am ]
Post subject:  Re: Ross' New 1600
Nice work Ross. I will be very interested to know how it drives!
Author:  hailest [ Mon Feb 13, 2017 10:08 pm ]
Post subject:  Re: Ross' New 1600
That's fantastic Ross, great work. Hows the exhaust going?
Author:  RJB510 [ Tue Feb 28, 2017 10:52 am ]
Post subject:  Re: Ross' New 1600
Turns out something isn't right in the diff. Could be a busted bearing that i haven't replaced. Actually i think that's what it is. Has a nice whine at about 50km/hr up.

The diff was bought off a guy who i suspect used it for drag stuff. It had a welded up centre but all the preload was off the pinion gear.

I noticed that when i torqued it up again, it added way too much preload to the bearings that made it difficult to turn the pinion flange without a socket on the nut for assistance. I decided to replace some bearings at that point.

I replaced the rear pinion bearing (closest to the crownwheel) because i thought that bearing would be the one to flog out first (it was exactly the same height as the old one in the race). But it was still too tight so i only torqued the preload to about 55 ft lb. After speaking with a few guys, i think that the conical piece and the spacer between the front and rear pinion bearings is too short, allowing too much force to be applied to the bearings.

Once i added the centre i could only set the backlash using the shims i had.

It was on the high end of the tolerance and i think that would contribute to some of the noise also. Wipe pattern and mesh looked central so i was happy with that.

Without a bigger selection of shims and spacers i don't think I'll get this thing setup right, so unfortunately (and disappointingly) I'll probably have to take it to someone to look at.

Trent, no movement on the exhaust yet. I'm not sure if i mentioned but i took the car to performance exhaust centre and spoke with the owner who has a very nice black 1600, he suggested putting the std manifold back on. Basically said that not only will my stainless one crack eventually, it's also not designed for the turbo i have (t28) and the whole inlet and outlet of the engine will contribute to its overall sound.
He also said that they flow well enough standard anyway so unless I'm making over 250rwkw then it won't impact upon my final power figure.

So that's next. But when i do that, i also want to take the head off and fix the oil leak coming out of the timing cover... will replace the head gasket with a metal cosworth one (when i work out who supplies them) and probably do a bit of head work while it's off...


That's the plan :)
Author:  TD.711 [ Tue Feb 28, 2017 4:16 pm ]
Post subject:  Re: Ross' New 1600
Nice work Ross,

Shame about your diff, but that's modified cars isn't it!
Hope you can get it sorted without too many dramas
Author:  RJB510 [ Tue Feb 28, 2017 5:52 pm ]
Post subject:  Re: Ross' New 1600
Thanks mate and yes, you're right. I just like being able to do things myself. Unfortunately i don't have enough stuff to sort this one out i don't think.
Author:  SR20Datsun [ Wed Mar 01, 2017 8:54 am ]
Post subject:  Re: Ross' New 1600
It's certainly frustrating isn't it Ross. I had a similar saga with my old R200 diff, but I didn't touch it!
I hope you get it all sorted!
Author:  RJB510 [ Tue Apr 18, 2017 11:22 pm ]
Post subject:  Re: Ross' New 1600
So i've never really been happy with my seats. I bought them because i just wanted to get the car registered. But over time (and i mean i've travelled about 6000km only in my car since i've had it on the road) the cheap foam has begun to break down and you can feel the side steel bolsters. They really aren't that great.

I have only just this weekend, picked up a set of wrx seats that look to be in really great condition and I got them nice and cheap. So next on the "fix things that you don't like on your car" projects, i'll be replacing the seats with the WRX items. I'm just mulling over how i'm going to fit them. Either modify the rails similar to what alandatsomefun has done (or my own derivative), or change the brackets on the seat to allow them to bolt to the OEM Datsun slides.
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Unfortunatley, they're not as easy a fit as my last lot or the RX7 seats that I swapped into my first 1600 in... 2005! damn, 12 years, its been that long!

The front seat support sits about 440mm wide as opposed to 415mm for the original Datsun slides. The subaru seats are also offset slightly on the slides. I'm not sure if the original datsun seats are offset also, but i certainly pushed my ones in slightly to allow them to line up with the steering wheel a bit more.

I'm not sure how much work i'm going to create for myself just yet. Whilst i like the idea of using the OEM Subaru slides and making brackets. I don't want to have to drill and create new holes in my seat rails and weld up the old ones. It would be much easier though.
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Whilst these seats look better and fit nicer and more comfortable, the down side is that they're much heavier too.
Author:  RJB510 [ Tue Apr 18, 2017 11:32 pm ]
Post subject:  Re: Ross' New 1600
Oh, and I re-trimmed my boot (another tick of the list of 'fix the things you don't like about your datsun'. I boxed it in so that you can't see the rear lights and i've made two covers identical to cover my battery and fuel pumps. It looks much nicer. It also looks much smaller now, but really, the use-able space is identical, i just filled in all the little gaps. Pic:
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I need to for it a vacuum and fix up the lower boot mat, but that's about it.
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