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Another PF Kent Buys a GTR

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    It must feel great to have all that rust sorted out. Your man is clearly very skilled at his craft.

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      Yep, the car is in good hands. You can see his work here: https://performanceforums.com/forums...rera-cabriolet

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        In other news, I picked up all the zinc plated parts today. Totally blown away by how awesome they look. Will post pics soon. Lots of shiney stuff coming

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          Just finished the last of the panel work on Simon's GTR. He has new photos of the panels and even nicer photos of the subframes rebuilt, hassle him for an update.
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            OK, so it's time to play catch-up for the PF world. For the past month or so I've spent most evenings in the garage and haven't had time to post pics. So now it's time to bring you guys up to date. So lets rewind to a few months back after the subframe left Brad's place..

            This is how it all looked in my garage. Pretty average!
















            After a quick pressure wash, it looks slightly better and should make disassembly a bit cleaner..









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              Next the disassembly began...
              I've taken a lot of photos along the way to help with re-assembly. I still found when I was re-assembling that I didn't have enough pics. Thankfully the service manual is pretty helpful.

              Knuckles off...

              Everything was put in bags, measured and labelled.






              More pics to help for later.



              And more bolts labelled.


              A quick test fit of the R34 Brembos and discs. Happy days



              ..and a bloody huge pile of dirty parts.

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                So at this point, I realised that I'm going to need a hydraulic press. I bought this cheap 12t one off ebay.



                I then attacked the diff. It's looking terrible. Rust. Lots of rust.






                I only have to look at an M6 nut and it snaps (left of this pic).





                Internally, it looks fine.






                These wheel speed sensor dust covers are in very bad shape. Fortunately, Robbie Goddard had new ones in stock



                And at this point, my mate Alex convinced me I should replace the LSD discs with some Nismo replacement discs to tighten up the diff. They come in 8kgf/m or 12kgf/m. I went with 8.
                Last edited by Willy; 02-03-20, 09:24 PM.

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                  Next cab off the ranks was the ATTESA pump. This is supposedly a "non serviceable" part according to the manual. It looks simple enough and mine looks terrible, so I thought I'd strip it down anyway.

                  Here's how it looked..

                  The rubber hoses were available through the Nismo heritage program

                  A closer view: Bottom left is the motor. It connects though the pump above it (top left). Bottom right is the nitrogen accumulator and above that (top right) is the solenoid. The little sensor next to the accumulator is a pressure sensor.


                  The nitrogen accumulator has a diaphragm inside with nitrogen on the top side and hydraulic fluid on the bottom side. It's a pretty simple system. When the pump runs, it pushes fluid into the accumulator so that it's charged for when required. To engage the front wheels, the solenoid is opened which drains from the accumulator. A pressure sensor is installed in the manifold to turn the motor on when the pressure needs to be increased.

                  So the sticker on the accumulator says you should drill at the point where the X is to release the nitrogen. I did this (it's damn thick) and all that came out was a dribble of oil. I'm guessing my accumulator was dead. I remember I used to hear the pump turn on about every 60s when the ignition was on.



                  Pressure sensor removed


                  Getting the accumulator off was not easy. I needed to use a of Stilson


                  Manifold accumulator port


                  Next I removed the valve solenoid body


                  I tried to open up the end of it, but couldn't get the internals out. I chose to put it back together and leave it be.

                  Manifold beneath solenoid body




                  Next I removed the pump housing


                  It all looked mint inside


                  Motor off



                  I removed the case of the motor. This is how the armature looked


                  Brushes


                  At this point, I realised that I couldn't easily get it back together, so I opted to get it reconditioned. I took it to Bashi's Auto Electrical in Caboolture. They turned it around in 1 day!

                  Pump disassembly




                  So from here, I got the pump casing and steel lines zinc coated, the motor reconditioned and the manifold wet bead blasted. I also tried to get new o-rings from a bearing shop, but they struggled to find the right sizes, because they stock imperial sizes.

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                    Next was the subframe bushes. Oh man, what a pain in the arse these things are. So initially, I tried to press them out. I really don't have the right size drifts. This ended up breaking my press...



                    Time to break out the welder..



                    So some research on the internet suggests there are two ways to get these out. 1. you get a hole saw who's diameter is about the same as the large ID and drill out the rubber. 2. you burn them out. Since I had no hole saw of the right diameter, I went for option 2. What a mess that made of my garage. I strongly recommend option 1 next time (or take it to a suspension shop).



                    The next stage is to get a hacksaw and cut out the outer steel shell before bashing it out with a chisel. This got old really fast, so I borrowed a saber saw from my father in law. This worked, but I went a little far on this one.


                    After a bit of welding and grinding with the dremel. Fixed.


                    And after many nights and much swearing, the subframe was ready to go to the powdercoater.

                    More to come tomorrow.

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                      Epic update. Im looking forward to seeing all the shiny come back

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                        Time for the next round of updates...

                        At this point, all of these parts were degreased and sent off to the powdercoater. The knuckles, diff cover and ATTESA pump manifold went off to be wet bead blasted.

                        [url=https://flic.kr/p/2iA64Lw]

                        Many hours were spent degreasing this lot in preparation for zing plating.



                        I also knocked up a couple of brackets from the diff speed sensor wiring that were too far rusted.


                        I also dropped these lines off to by zinc coated. These run from the ATTESA tank to the pump. The parts under the car were rusted pretty badly.



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                          And finally time for some shiny stuff!



                          The powder coating on the subframe is sensational!






                          I made one major mistake.... I dropped off the diff housing, but left the pinion gear installed. I assumed they would tape it off when they sandblasted, but I was long. Dust went all up inside the housing and into the pinion bearings. They send the diff home for the pinion to be removed before powder coating. This turned out to be an easy job for the press.





                          And at this point the diff housing was returned to the powdercoater..

                          My plan is to take the diff to a diff specialist and get it all reassembled with new bearings.

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                            The next part of the process was a painful one... subframe bushes. I knew these would be a pain in the arse and that turned out to be correct. So I'd read that pressing these into a powdercoated subframe is nearly impossible and most people sand out the cups. I did this on one, but it seemed counter-intuitive. Removing all that rust prevention is not good. So I sprayed it again and left it overnight. I also chucked the bushes in the freezer overnight to shrink them as much as possible.

                            I set it up in the press and...it went in suprisingly easily.


                            The next day, I did the other side, left the powdercoat in place and used a bit of lube. The bush went in easily. You beauty.

                            The next bushes were the rear ones. These are a real prick, because of the shape of the subframe. I ended up with this concoction, but the diameter of these tubes I'm using is really too big. It needs to be close to the OD of the subframe cups (70mm from memory).


                            It got this far and just wouldn't go further... Much swearing as now this bush is no longer cold and has expanded.


                            Then I flipped over the subframe... God damn it, my oversized concoction of "receiver cups" has chewed out the cup in the subframe and damaged my nice powdercoat.


                            I didn't get much sleep that night and opted to take it to my local Pedders. They got it done with no issues. They said they had to turn the subframe upside down. If only I thought of that...

                            Anyway, I was glad to have this issue resolved and I gave the damaged powdercoat a few layers of satin black.

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                              More shiny stuff!! The knuckles and diff cover came back after being wet bead blasted and ceramic coated. Very, very impressed.





                              Also, Robbie delivered a bunch of new parts.
                              Midori Seibi HICAS eliminator


                              NISMO LSD clutch packs


                              New ATTESA nitrogen accumulator. It's slightly bigger than the old one, but should fit fine.




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                                So the diff housing is back and looks amazing. So much better than before.




                                And then I visited the Zinc plater... There was a huge bag of bolts on the table. I said "who's are those?". He says "they're yours mate". Damn nice.
                                Seriously impressed. He even managed to do the hoses. The fittings were terribly rusted before.




                                This pipe looked terrible before. I thought I'd have to get it remade. You can see it's still a bit pitted, but I don't really care. It's under the car and I'm not building a show car.


                                I then had to sort this lot back into the 20 labelled plastic bags I had made. This took a few hours.






                                Prior to assembling the knuckles, I decided to strip the powerdercoat off the front face of the hubs. I gave this some thought and realised that powdercoat is not a good idea as it compresses over time and might cause the wheel nuts to loosen. So I spent a few nights stripping them back to this. I really should have got these bead blasted instead, but it is what it is.


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