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Brickhouse VK56 240SX Build

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  • Brickhouse VK56 240SX Build

    Hey guys and gals! My name is Steve and my brother, Greg, and I are working on a 240SX VK56 swap kit starting with his S13 and later my S14. He's been doing all the actual work (I live in Japan) and is finally getting a build thread going on our local forum. I thought you guys might dig it and add some variety to the build section. He's a busy guy so I'm helping out getting it posted. Here's the copy and paste of the progress!

    My car Minty came into my possession less a motor. Since then it has had two engines in its bay: an SR20 - Failed, and the current KA-T - Awesome. Well as with all good things, they for some reason or another come to an end. This story is no different. Around this time last year my brother and I were discussing motor swaps, and Steve brought up doing a VK56 (for those unfamiliar with the engine code, it's the Nissan Titan V8 engine) with a z33 trans behind it. Initially we were thinking we would find an S13/14 shell and use it to perfect the swap, but current living arrangements and transport of the cars made it a silly venture. So what do you do, you use what you have. So for the third time in its brief history my car will go back under the knife for the sake of awesomeness! Cue 1980s jumping high fives!

    Some of you maybe wondering what will become of the KA-T, no fretting needed. A few months back Steve and I purchased a motorless S13 shell with the sole intent of it becoming "have fun/don't care/missile car". Lets face it, Steve and I need something we can care a bit less about in terms of body condition. We have both owned beaters which we quickly did body and paint work too. So to all you newb drifters, leave that wreck haggard, and have fun with it - my 2 cents. Anyway the turbine housing will be swapped for a faster spooling unit which will put it down in power, but should make it fun like the Matsuri car we both enjoyed to no end.

    Enough about that sweat heap, lets get on back to the reason I am even posting. Finding a motor and trans with ecu, a/c, p/s, intake, and all the rest of the necessary bits for a motor swap took about a month. Not to say you couldn't find one faster but I really didn't want to buy a good motor knowing I would be cutting, grinding, and welding around this motor. The motor we found came with low mileage and a knock. The gentlemen at the Joplin, MO, wrecking yard said he had seen the rods bend in roll overs and as time would tell he was right. No harm done though, this was the perfect price for what we wanted upon initial investment. This left me to start pulling out the old and trial fitting the new.

    As I began this endeavor, and endeavor is the correct word, I began to wonder why I do this to myself. I honestly do believe I just like to be busy, enjoy fabricating and furthering my abilities. On that note ---> Roll that beautiful bean footage:

    On the way back from Joplin, MO questioning if this is a smart move:


    Rolling home from last event Minty ran:


    Out with the old KAT in with the "new" VK56:


    Testing the adapter on the block:


    Then on the CD009 Transmission:


    Unsuspecting KAT about to get the boot:


    Dropping the new hotness:


    Touchdown!!!!


    No surprise, intake manifold will have to get redone later:


    H/I-beams ain't got nothing on the new "S" connecting rod:


    Where the knocking was coming from:
    IG: @brickhouse_products
    brickhouseproducts.com

  • #2
    I feel like this build has more work than my pictures show. Haha. I have over 200 pictures of this swap but a ton of them are for reference for when I reinstall, etc. So anyway it looks like I left off just before I started working on the motor mounts and cutting the oil pan.

    Motor mounts - these ended up taking some time as I had goals I wanted to accomplish. My initial goals were to mount the engine as low and far back as possible and have a good fore/aft angle; next was to try to clear the brake booster.

    I did end up mounting the motor low and back. It clears the radiator with G20/Altima fans. Unfortunately the brake booster had to be removed. I tried and tried to make it work with the stock unit but just couldn't get the clearance for it. If anyone knows of a 7" dual diaphragm Nissan unit I would be interested. The current plan is to ditch the booster and just run a Wilwood master cylinder in its place.

    Oil Pan - This things has been the biggest pain in the whole swap as you will see. I was very tentative in my cutting of the pan, never wanting to cut more than was absolutely needed. Ends up the whole bottom needs to go. I just wish I would have had a reciprocating saw sooner as it made my life easy. It was able to get some of the deeper areas cut. Instead I did most of it with my right angle grinder (RIP ol' buddy) and my hacksaw. FML. Got it done though.

    Initial modified stock vk56de motor mounts:


    Mocked mount Version 1:


    Mocked Mount Version 1:


    Mocked Trans Mount Version 1:


    Attempting to clear booster. Maybe I can mod the valve cover down the road, but plastic welding scares me:


    Clearing booster another angle:


    Fan to motor clearance:


    Motor to cross-member clearance:


    Rack to trans adapter clearance:


    Oil Pan to sway bar clearance:


    Oil Pan starting to get cut:


    Profile of cut oil pan:


    Off and running again...
    IG: @brickhouse_products
    brickhouseproducts.com

    Comment


    • #3
      So early on in the build and sometime before that I have been interested in CNC. Due to this build though I was forced to actually do something about it. I wanted to start basic and through some google searching I found Sketch-Up. It is easy to learn and for what I was needing it works great. Here are a few different parts for the build:

      Exhaust flange idea stage:


      Exhaust flange version 1:


      Exhaust flange version 2:


      Exhaust flange version 3:


      Exhaust flange version 4:


      Exhaust flange version 5:


      Exhaust flange in .dxf:


      Intake flange on paper:


      Attempting different ways to get accurate enough oil pan dimensions:


      Oil pan started:


      I am by no means a wiz at this but with a little practice it keeps getting easier.
      IG: @brickhouse_products
      brickhouseproducts.com

      Comment


      • #4
        Well, after cutting the oil pan and bit prior too, Steven and I had begun talks of getting a pretty crucial bit of welding equipment. A big thanks goes to Miller for making a cost effective TIG welder with a baller warranty. I will say it doesn't have any crazy extra controls, but it is inverter technology and allows it to run low amps (under 30) which is the same as most laundry dryers. Plus it can be unplugged and put in the back of the truck without the assistance of a crane! Great for a track-side setup later on or helping out a buddy at their house.

        On a personal level, this was a intimidating decision. I myself had never touched a TIG welder until this arrived. I had to learn a new way to weld. I will not accept good welds, I pride myself on my welding. So I knew I was in for a few nights of working out the movements and timing. Little did I know it would be about 3 weeks. I think I will finally know I can TIG when I am not ashamed to hashtag my welds on Instagram with #weldporn. All in due time, I am only a couple months in now and continually improving.

        Miller Welds:


        I love opening new stuff:


        Hello there:


        The front panel. Simple is great for the beginner:


        My first welds with the machine. I thought they looked like ****. Oh, wait, you need to run gas?! My first few welds were hindered because I hadn't set up gas flow on a machine in so long I forgot about the gas drop when you start welding. haha FAIL:


        My first try at aluminum and subsequent tries:


        Getting there. I got the gas running right, my cleaning action is much improved, heat is more consistent:


        This is a little later. I got the above positive, and I am starting to work on spacing of the rings:
        IG: @brickhouse_products
        brickhouseproducts.com

        Comment


        • #5
          Sometimes when you are building something, you have to depart from the actual project to build other "stuff" that will help you to better complete your task. Thankfully I had a pile of metal I had purchased for a failed project that could now get used.

          I now had a TIG welder and no good way to sharpen the tungsten electrodes. So, I did some quick research *cough, Google* and found a bench grinder with a drill is the preferred method. I already had a cordless drill so I picked up a bench grinder from the local big box store. The grinder looked pretty good out of the box but not so good on the floor. So surprise, surprise the bench grinder needed a small bench.

          Next, was to address how to mobilize the TIG welder. I drug that thing around the garage for about a month before I figured I would put together a cart. And why? I don't know, but when you have one new weld cart it makes you want another to match. So I built one for the MIG too.

          Finally, there was the issue of a small welding table. I had been tig welding in the most random places and couldn't concentrate of the feed, food, and heat that well. So I grabbed an old stool I had floating in the garage and figured the table height from that.

          I made all the items as light as possible. Most things are made from 1/2" or 3/8" round bar, and 1" x 1" square tube. The best part is the time involved was only a weekend, and the progress you will make from them will be strides better.

          These small projects helped to forward progress and quality so much. They put that little something extra in extraordinary! HAHA Name that movie!

          The start of new bits of awesome:


          The grinder on its new digs:


          The reason you want the grinder in the first place:


          The TIG cart:


          The MIG cart:


          Finally the TIG Table:
          IG: @brickhouse_products
          brickhouseproducts.com

          Comment


          • #6
            I have been wanting to get another post up, but I have been torn with how I wanted to present things: Objectively or Chronologically. It seems most people post chronologically but the way my build has gone it is very scattered. Example being: I started the oil pan, but don't have the sheet material to complete it, so I moved to the power-steering setup, but then hit a road block on it, so then bumped over to headers and so on. So my thought was to progress the build objectively. Also, I think it will work out good to for those that want to reference a picture or post.

            First up, is the power-steering setup. Why is this first? Honestly it was between this and the headers as I have both of them to a point I can make a jig off them and make the final part.

            Oh yeah, I never mentioned that! I really don't like having my parts look like the "trial and error" pieces that come from a project such as this. So all parts made currently are actually just to be used to test fit, initial start up, and will then be used to make jigs so that I can replicate the trial piece. This way the finished product has fewer cuts, cleaner welds, and overall more factory looking.

            Back to the power-steering. It may seem unrelated but I have wanted A/C in my fun car for sometime. So a VK56 power-steering relocation to the a/c location wasn't going happen. Also I wasn't keen on going to the MR2 pump right now as it was pretty expensive and just seemed unnecessary now that I had the ability to weld aluminum. So I decided to work with what I had, a really oily power-steering/alternator bracket. The issue with the pumps currently location is the P/S pulley will hit the battery box and the front apron under the battery box, it does clear the lower "frame" box section though. The pump had room to move in and down towards the block and alternator, but would it be enough. It turns out it is, just barely. I will say if you are running a tube front end with the apron sheet metal removed forward of the strut tower you will be able to run an unmodified power-steering/alternator bracket. The other option would be to cut a relief in the front apron for the pulley sit in. This last option was strongly considered with the use of a formed piece of aluminum to keep road water/dirt from entering the belt drive. If my current set up fails, expect this to occur next.

            Also if anyone knows of a smaller pulley that will fit the VK P/S pumps splines, would you please post up what year, make, model it is from. I would like to try this route as well.

            Lets get to some picture as my work can then just be used for reference.

            Stock PS location. (huge pulley on the far left)


            Stock PS location clearance - front.


            Stock PS location clearnance - overhead.


            About where I want it to be.


            Taking it slow, removing parts of the brackets as the pump contacts it.


            Realized the front needs a new piece altogether.


            Front of bracket removed.


            Getting artsy around the bolt hole.


            Rear bolt hole getting relocated to new home.


            New clearance to front apron. Kind of bad angle more room that it shows.


            All lined up.
            IG: @brickhouse_products
            brickhouseproducts.com

            Comment


            • #7
              awesome

              Comment


              • #8
                in for moreeeeeee.

                Comment


                • #9
                  yes
                  Volvo Build Thread
                  Bmw Build Thread
                  Toyota Build Thread
                  zanebonk instagram
                  Tumblrrrr

                  Comment


                  • #10

                    Comment


                    • #11
                      OH, for shizzle!!
                      "Dont let the opinions of the average man sway you.
                      Dream, and he thinks your crazy.
                      Succeed, and he thinks you're lucky.
                      Aquire wealth, and he thinks your greedy.
                      Pay no attention. He simply does'nt understand"

                      Comment


                      • #12
                        VK56 FTW! I love the attention to detail and how legit this is coming out. I'll gladly take your KA-T setup
                        The only thing lower than my standards is my truck.

                        Build thread!!!

                        Comment


                        • #13
                          This thread is already excellent.

                          Comment


                          • #14
                            u are good at manufacturing, in for update!
                            subbbbed

                            Comment


                            • #15
                              Thanks for all the support and kind words! It's great to see people dig the project!

                              Originally posted by Isuzupickup View Post
                              VK56 FTW! I love the attention to detail and how legit this is coming out. I'll gladly take your KA-T setup
                              The KA-T rips for sure. I got a bit carried away when building it the first time but really happy with how well it's ran. Can't wait to get it in the beater car next year with the smaller turbine housing. It should be like instant torque.
                              IG: @brickhouse_products
                              brickhouseproducts.com

                              Comment

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