First batch of TL70 conversion shifters are done.
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First batch of TL70 conversion shifters are done.
Machining KN20 manifolds
A lobe is born.
All the lathe work is done and now I’m machining the lobes. It’s a slow process with the equipment I have but it gets the job done....eventually:)
As a pattern maker I have machined a fairly large range of materials over the years but this is the first time I ever machined sand. I’m thinking my end mill isn’t too happy:)
This is an inner core for the intake castings, They were designed for a normal tilt motor. They worked fine on reverse tilts like RK’s Hako and Behemoth because they were injected and there was some latitude on the angle of the dangle. Now I have two customers that want to tilt their engines and run carbs and there just isn’t enough material on the manifolds I have to make it happen. I was just getting ready to send this batch of cores over to the foundry and came up with the bright idea of trying to remove enough sand to add more metal to the casting. Total kludge but it’s actually working.
Finish pass on bearings 5 and 6.
Took my Flir infrared camera to the foundry to record one of the pours. All went well. Now I have to wait patiently until they shake everything out to see what we ended up with. This is pours #18-22 so we have a pretty good idea how the mold should be taking the metal and all five were right on the money.
SN003 stopped by to (finally) pick up his head and he dropped this bad boy off for me to use. Guess I have no more excuses. Time to start the stroker build.
Gun drilled S7 tool steel cam blanks just arrived. Got a whole lot of chips to make before they are camshafts.
Machining cam towers for the next batch of KN20 heads
Crank sprockets before and after.
Bored, reamed, broached, hardened and honed. Only the center row is used. The triplex design adds strength since it’s such a large bore.
Testing the new (to me) Tomei adjustable cam sprockets on SN003. My math said they would work with my cam dowel system and considering I slept through high school geometry class I'm pretty happy. Plus I have 5 sets here and 2 in the wild so they really needed to work:)
Just completed retrofitting the new timing goodies into SN003. It was tricky because at that point I had not figured on using the sub plates for the idler and tensioners. I had to machine off all of the previous fixed mounting points and then figure out how to fit all the new bits in. Worked out really well.
So Pretty:) Pistons for SN003 have arrived. This dinosaur of a build is actually moving forward finally.
SN016 sent me the flow data. This is after a basic smoothing of the ports. Numbers are looking good.
Final test fit of the cams and towers on SN018. Pretty close to the end on this one. SN017 is following close behind then it's time to start a new batch!
And so it begins. Starting to machine a fresh batch of CD009-L6 bell housings.
Just some Saturday morning chamber volume measuring.
Ignore the whirling disc of death:)
This is what happens when Z Car Garage likes you :) Thanks Rob!
Inspired by the design of the legendary Honda K20.
Not everyone can have fancy rides like Z Car Garage. Some builds are more down to earth. Or maybe was in the earth at some point. No matter. Here is our latest build with the Datsunworks KN20. This is one sweet ride let me tell you. Plenty of weight reduction due to major portions of the frame and floor missing. No radio but the constant buzzing of the wasps makes for some beautiful music. If you suffer from post Covid lack of smell then this car will be the perfect choice for you since the putrid smell of the ever damp interior won’t bother you one bit.
Ok enough Tom Foolery. This is a 280 I bought when I was developing the 280Z speaker pods. There is (was) a clearance issue on S30’s with the engine tilted the stock way. The valve cover would hit the hood latch perch when you tried to remove or install it. I modified my latch in a not so elegant manner and back then it was no big deal. Now that these cars are bringing stupid money I figured I better come up with a solution. Since my perch was modified I had to work with this piece of crap. It looks like a minor reshaping of the back edge of the valve cover will provide enough clearance to get it on and off. Ok Duffy no more excuses :)
First head of the new batch out of the mill.
Everything is going great. The combustion chamber chills are working as expected.
This particular head is getting the RK Water Mod which removes the water outlet casing and then makes provisions to mount an external water outlet manifold. Ralph Keynon started this trend with his 3.5 Hako. On this batch of castings I modified the 3D printed sand to make it easier to implement. That’s the beauty of digitally printed sand. Making changes is not really an issue. I added individual pads for the flanges as well as bosses internally to provide easier drilling and tapping of the mounting holes. Since the datsunworks branding and the serial number pad is removed I added that to the casting as well. Not a lot of room but it did print really well.
Ralph is producing and selling the water manifolds FYI for anyone interested in that mod.
KN20 raw castings heading back to the foundry prepped for heat treatment and shot blasting.
Normally this is done at the foundry but they are slammed so we decided to do them ourselves to keep them moving forward.
Machining cam towers for the next batch of KN20 heads.
First batch of TL70/L6 bell housing castings just arrived from the foundry. One more piece of the puzzle.
New timing chain design.
I finally made a bottom pivot guide system work. This has been something I have been trying to make happen for a while and from my perspective the last check box on the head design. It uses a custom top tensioner. This should make setting up a new build much easier as far as the timing chain and cam timing. It has removed a lot of the bespoke work needed. I have more details on my build thread on HybridZ as well as my blog if you are interested in the details.
And another head leaves the mother ship. Bound for down under.
OD grinding KN20 cams. One journal down, sixty nine to go :)
Had to run home earlier and parked my car in the shade. It looked so good I had to snap a pic. I really love my car :) The DOHC is just icing on the cake.
Last test fit of the TL70-L6 bell housing before it heads to Godzilla Raceworks for in car fitting and cross member design. Also finalized the pilot bearing extension design. Instead of making it out of bearing bronze I opted to make it out of steel and design it to use off the shelf 12mm ID bronze bearings. I also drilled and tapped the back M6X1.0 for a jack screw for removal.
Pretty stoked for sure.
Making some progress on the TL70 bell housing.
So far everything is going mostly according to plan. Since the TL70 shape is much more organic than the CD009 and has no clear marker to cut with I decided to design the casting to do a decorative surround. I’m happy with the results. Tomorrow is the first test fit bolted to the test engine to see if my clutch spline engagement is correct.
Finally got the first two TL70 bell housings in. Since there is no clear line on the TL70 like the CD009 has I designed the casting to wrap around the cut transmission. Hopefully it will work out with a minimal of issues. Sometime things look great in the 3D world only to fall apart when real word manufacturing steps in.
The first one is going out to Gozilla for testing. My car no longer has the ears for the cross member and they have a 280Z ready and willing. I’ll get feedback from them then decide if the pattern needs altering and then it is full (6) speed ahead.
As requested by Duffy:)
Shifting first through fourth. Does not need a lot of aiming it just seems to know:)
Finished the working prototype shifter. Came out really well. It's mounted in rubber like the factory and shifts great.
It's shifter Saturday!
I worked on the linkage today. Took a few tries but I'm happy at this point. Being as the parts are plastic there is a bit of flex and the TL70 has slop built into the coupling on the end of the shift shaft to make up for misalignment. Some things that will improve it. First a shift k**b. After shifting about a hundred times working out the linkage geometry my hand hurts. Second. Finish it up with an aluminum pedestal and a steel linkage bar. Design wise I think I'm ready to commit to the first working prototype.
This puts the shifter pretty much where the factory shifter is. The inner tunnel boot will probably not work but I'll cross that bridge when I get there.
Quiet Saturday morning...
Perfect for some prototyping.
Starting to work out the shifter details on the TL70 conversion. I plan on using the original mounting points on the transmission as well as two additional points on one of the ribs. The plan is to mount it in rubber like the OEM. Right now the rectangular plate on the shifter sits level with the top of the tunnel and is towards the rear of the oval cutout. I’m trying to keep the shifter as high as I can so that the shift k**b height is close to stock. The problem is the angle of attack on the link between bottom of the shifter and the transmission looks to be a bit acute. This will allow me to actually shift through the gears to get a feel for it.
Ultimately this will most likely be a casting. Just because I can:)
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