Reamed on rings: blew my gasket!

[Jason]

Mike scores again! Good stuff Mike. How'd you get rid of the truck, just call a scrap metal guy? I've got a cut up 510 wagon in my driveway I need to make go away now.

[datzenmike]

Hi Jason, man I'm stoked!! It's like buying a wallet at a yard sale and finding money in it lol. Yeah, the local yard won't give you much, if anything, for wrecks, and will pick them up for free. I just pulled the L20B and auto out, stripped anything else, and threw all my metal junk in the back. Gone. Saw it when I went to get my Z24 I mean my Z24i hee-hee.

 

If I lived near you I could borrow a chop saw, you know the thing that looks like a chain saw with a 16" metal cutting wheel on it. Literally, zip it into manageable sizes and throw in my truck. I used one last w/end to cut the front rad support and bumper off that 720. Like cutting butter.

 

My wife went shopping? in Victoria with a girlfriend for the w/end, another woo hoo (not as big) Toilet seat up for a few days. I need to fashion a tripod or some kind of beam I can put a chain hoist on to lift a motor. Best done while she's away. Last time I braced the plum tree limb, she shook her head. Now that I have a motor, I have to start digging in my parts nest for the Z 5spd from the old 200sx. The carb is missing from the Z24 so will an L20B one fit and run? I have a Z22 and a Z24 carb but they are unknowns. Will probably use my L20B flywheel like you said. Get her running and iron out any wrinkles before attempting EFI.

[Jason]

Hi Mike, thanks for the offer, but, it's been buzzed down into 8 pieces plus 4 doors and a hatch now, 2 guys can manage each hunk. In fact, I think the bondo and fiberglass on each piece weighs more than the actual metal now. I'm just too lazy to go down so I figured I'd call a scrap guy over and have him haul them in....

 

So you've a Z24i now eh? Should pull stumps eh?

[datzenmike]

Years ago I drove an '87 or '88 hard body. I know now that it was a Z24i, at the time I just knew it had 8 plugs. It pulled!!! Each gear pushed you in the seat like first.

 

If a throttle body will do that, a multi port injection EFI should too. And I still have the Z head I ported, I even cut the injector notches in it.

 

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0118.jpg[/img]"]

 

I got a second 200sx in the w/yard last fall, and stripped the EFI out of it too, and when I went for the fuel pump there was a brand new one in it! I also got to go through an '84 Maxima... same thing, a shinny new high pressure pump. That should take care of fuel delivery. Have you seen this...

 

http://datsun1200.com/modules/nsections/index.php?op=viewarticle&artid=99

 

If you make your own intake and plenum and add the 200sx EFI parts you could have an L20BE I guess.

 

Talk to you later, too much excitement to-day,

mike

[datzenmike]

http://i138.photobucket.com/albums/q251/datzenmike/00770024.jpg[/img]"]

Adding the EFI injector notches to the Z24 head. The Z24 never came with multi port injection. I used this carbide tip and my drill. Worked the aluminum very fast and did not need a high speed die grinder. I think they came out better than the factory ones and only took a minute each.

 

http://i138.photobucket.com/albums/q251/datzenmike/00770026.jpg[/img]"]

Z24 head with notches (top). Intake ports enlarged below valve seat, casting flash removed and polished with flex cable rotary grinder. The most metal was removed from the bottom or floor of the port as it approached the short turn radius. The short radius was extremely sharp edged and was smoothed. More on this, and the exhaust, on the last picture.

The 200sx EFI intake I'll use has round ports to match the Z20/Z22 head (bottom one) Have not port matched it yet as I didn't want to over-grind any thin areas. Maybe build up the head with JB weld and make a round entrance that matches the round intake.

 

 

http://i138.photobucket.com/albums/q251/datzenmike/00770009.jpg[/img]"]

This is how much is to be removed to port match the exhaust. I did the same with the cast iron manifold, it was much harder.

 

 

http://i138.photobucket.com/albums/q251/datzenmike/00770014.jpg[/img]"]

The left is just started the right has been extended all the way into the valve pocket. The majority of the metal removed came from the side walls and floor of the port. Again the short radius was smoothed away and blended into the valve seat. See last picture.

 

 

http://i138.photobucket.com/albums/q251/datzenmike/portmatchafterZ24.jpg[/img]"]

Two down two to go. For best repeatable results I would do a small area on one port then do all the others until they were the same, then move to another area, instead of finishing one port and trying to make the others match it.

 

 

[/url]

Light metal removal below the intake seat to remove a very rough edge where the valve seat does not meet the port wall very well. Overall the intake ports are 'smoother' and better shaped than the exhaust. The valve seats are very slightly recessed into the head and leave a small ridge showing up as a dark ring around each valve and have to be polished out. No sharp edges, the head chamber must be polished smooth to prevent hot spots. There is slight shrouding in the 10 o'clock and 4 o'clock positions and it was opened slightly and polished. These areas are even worse on the Z20/Z22 head as they have a 4mm narrower bore. This shroud area is almost directly below the short radius problem areas.

 

 

[/url]

Here the exhaust pocket below the seat has been relieved and is ready for polishing. Note the shrouding caused by the spark plug above the intake valve. Arguably this plug would be cooled by the intake charge and indeed runs a hotter plug than the exhaust.

 

 

http://i138.photobucket.com/albums/q251/datzenmike/00770013.jpg[/img]"]

The short turn radius problem area is addressed by seesawing a strip of 80 grit belt sander belt through the port. With tension on the strip, only the high areas are removed and blended nicely into the port floor.

In order to improve this radius from sharp to a more rounded shape I tried something not mentioned in any porting info I could find, but none the less is probably done anyway. I ground away some of the valve seat and blended it into the port wall, without touching the valve contact area. This would be like driving over the curb to to go around a very sharp corner in a car. All this contributes to a more gentle radius and laminar air flow.

[Icehouse]

Saying "I do alright" is like saying that Jessica Alba is only "nice looking" or that Gong Li is just "a woman". You have a kack for understatement. lol

 

Thanks buddy :D I will take that as a compliment :D

 

We loaded it and I took it home and started pulling the tranny which I'll return as I don't want it. It

 

Now here's the best part. The truck was an '84 720 w/Z24 carb engine. When I removed the tranny, painted on the auto flywheel was...

 

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0175.jpg[/img]"]

 

Wooo Hoo!!!

I now have an '88 Z24i motor!!!!!!! Maybe this is why it had the high volume oil pump. The Z24i was a throttle body injection motor but the '84 carb and intake was put on it when it was swapped. There is even intake bolts missing! This motor is four years newer than I thought and was FI and automatic, so not too much wear 'n tear on it. Also no-one's going to swap a crappy motor into their truck, so it should run. (it was running when it was rolled)

 

Who is we?

 

Nice score to by the way :D I noticed the other day that there was a few more post but did have time to read them. Then I forgot until the newest post. Looking good! I've never read much about porting a head but it looks like fun. What are the rules? I saw a before and after of a SR20det head I forget who sells them but there are like 1500 bucks when they are done. The photo was crazy there was so much less metal!!!

[Cookapoop]

 

KA24E timing chain

 

 

KA18et timing chain!

[datzenmike]

Thanks buddy :D I will take that as a compliment :D

 

Who is we?

 

 

Nice score to by the way :D I noticed the other day that there was a few more post but did have time to read them. Then I forgot until the newest post. Looking good! I've never read much about porting a head but it looks like fun. What are the rules? I saw a before and after of a SR20det head I forget who sells them but there are like 1500 bucks when they are done. The photo was crazy there was so much less metal!!!

 

You should and it is... a compliment that is... and I like working those two fine ladies into the same sentence.

 

The we, is the lift truck. I disconnected the motor and tranny last w/end but waited till this Fri. I left work early and the wreckers had a lift truck to pull it up and out and load it in my truck. I slid the motor down a board ramp to unload at home.

 

Strangely it is fun. Done right you are making HP from nothing, or rather freeing up HP! And, it never wears out, or goes out of tune, is hidden out of sight and costs whatever your time is worth, to do it. Last year i ported, actually I removed the exhaust port liners from a W-58 P nut and removed the bumps that hold them in place. Some grinding, sanding and polishing that took at least 16-20 hrs all told. I sold it to Datslamd in Edmonton. I hope he gets it running.

 

Here's some light reading.

http://www.automotiverebuilder.com/ar/ar39924.htm

[datzenmike]

 

KA18et timing chain!

 

I found a Z18ET, KA24ET and a KA24DET but no KA18ET. Tell me more!

 

It has a double chain like a Z series. Looks like the lower rad hose comes out of the timing cover like an L series and not like the Z or KA. Sort of a KAZL18ET?

[Cookapoop]

Sorry for the delay of a reply. Its a z18et bottom end and a single cam ka head. This frankenstein engine has been done before a few times although i have yet to see a 1.8 turbo version. Its a fairly simple swap so far.

[datzenmike]

Tell me more. That can't be the KA timing cover as it would be about 4cm too tall, L18? Also is the double chain used with the single sprocket? If so that's an interesting idea! The Z18 turbo manifold will fit a KA head? If so this means a KA exhaust manifold will swap onto a Z24 then.

[Cookapoop]

it is the z18 timing cover, mates right up to the ka head. the exhaust manifold is also from the z18 but the ports do not line up so it must be port-matched. I don't think it will fit in the 510 anyhow so i will be making a new one. I will try and get some pics of the manifold and the porting job i did on it so you can see exactly what i am talking about.

[datzenmike]

Before I get too wet, if you were selling it, what would you want for it? Was the head ported to match the manifold, or a bit of both? And yes pictures would be nice! Thank-you!

[Cookapoop]

well if I were to sell it i would have to get at least a lot for it in its current state (No turbo and what not). The block has been decked and o-ringed, HKS 2mm metal head gasket, ARP head studs and such. All the timing stuff is from the z18 as the KA Lower timing gear does not fit z crank. I only ported out the the exhaust mani kinda just for practice cause i knew that the z manifold was not going to be the final. I am going to see if it will fit on my ka in my blue 510 and turbo that as well:D

[Icehouse]

I forgot how much you did to that engine Cook :)

 

Why don't you build one mike?

[Cookapoop]

yeah theres a bit of work in it. but it should be worth it.

[datzenmike]

LOL, sorry Cook, I meant just the ex manifold.

[Cookapoop]

Oh I see now, haha.

 

Not too sure for just the mani. Icehouse has dibbs on it if i don't use it. If he doesn't want it i'm sure we can work something out

[datzenmike]

K

[datzenmike]

Well my truck is off the road not off road, lol. Made a scaffold and bought a small chain hoist. I borrowed one last time but why not have your own?

 

Here's a picture of my 280zx tranny along side of the 200sx that will be going in behind the Z24. OR I might just swap bells as the 200sx is an unknown and the 280zx is super good!

 

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0306.jpg[/img]"]

 

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0308.jpg[/img]"]

 

Here are the tranny ratios for the 280zx. Mine is probably one of the top two and the bottom is the one with the monster 5th gear Bleach talks about. The very top one is identical to the 200sx tranny I plan to use.

 

8/78-7/79 280zx Long Tail

3.321 2.077 1.308 1 0.864

 

8/79-6/80 280zx Long Tail

3.062 1.858 1.308 1 0.773

 

7/80-6/83 280zx Long Tail

3.062 1.858 1.308 1 0.745

[datzenmike]

Well just for kicks I put both trannys in 5th gear (o/d) and compared one input spline turn to the output spline at the tail stock. Here's what I got:

 

Both the 280zx and the 200sx output 1 1/8 turns or about .888 o/d. So the closest ratio to that is .864 (at the top of the list). Maybe I'm not accurate enough... the glove box booklet says .833 in 5th. A degree wheel would sure help or a plastic compass from a dollar store. I'll try again tomorrow.

[datzenmike]

Using a compass on the output I got 50 degrees+- on both trannys. This is 13.88% or 0.861 over drive. Again the closest ratio to this slightly more accurate measurement is the top one on the chart 0.864 or 13.6% (there is probably gear lash and wear losses)

 

Sure would help to have a splined shaft with degrees on it that would slip in the end of the tranny to direct read. Maybe I could invent something that would tell what ratios are on what trannys and eliminate some of the guess work.

[datzenmike]

L20B is out Clutch and f/w off.

 

p://i138.photobucket.com/albums/q251/datzenmike/removeL20BAug07.jpg[/img]"]

 

My 225mm (left) and a 200mm flywheel from a Z20E 200sx. The smaller one has the bolts and dowel pins closer to the center.

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0325.jpg[/img]"]

 

My 225mm flywheel (left) and a 720 4X4 240mm flywheel. You can see that the larger one has the bolt holes and dowel pins out closer to the rim.

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This is interesting. This is the engine side of the 240mm flywheel (left) and the 225mm from my 620. The 240mm has a ring of material removed and is much lighter that the 225mm one. The 225mm one is solid. The 240mm clutch would be bigger but not that much heavier! Will have to weigh them and compare.

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0330.jpg[/img]"]

[datzenmike]

Well I super accurately measured these flywheels on my neighbor's bathroom scales. Here's what I got:

 

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0348.jpg[/img]"]

 

The 200mm from a 200sx was just under 30 lbs.

 

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0349.jpg[/img]"]

 

The 240mm from an L20B 720 4X4 was 23 lbs.

 

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0345.jpg[/img]"]

 

I have two 225mm like this one from an L20B at 29 lbs AND:

 

http://i138.photobucket.com/albums/q251/datzenmike/IMG_0350.jpg[/img]"]

 

This one, a 225mm weighing only 23 lbs! As you can see the engine side is hollowed out just like the 240mm one that weighs the same. I thought it was from an L20B but it might by off a 280 z/zx? That's 6 lbs lighter, over 20% lighter!

[]2eDeYe]

Nice, my lightened flywheel was pared down to 17 lbs. Just for reference ;)