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Jay Gadsby's Kouki Resto/Build Thread

6.5K views 21 replies 8 participants last post by  BoostinIX  
#1 ·
Hey guys/gals! My name is Jay Gadsby. I am an 11 year Army Staff Sergeant. Been deployed 4 times abroad, statoined in Germany, Texas, Kentucky and Maryland. Driven the Nurburgring with my Z and crushed the Autobahn as well. Owned quite a few cars to say the least. Well, I finally got my 240SX back in my possession. This is the 2nd Kouki I have owned. The first one died my first day at Fort Hood when a young guy in an SUV decided to park his vehicle in my lane, about 50 feet in front of me at 35mph. Sad days. Shortly after, I bought this Kouki. The paint was pretty terrible, but I Zaino waxed it up, clay barred, and polished to get this shine out of it.

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The car was BONE stock when I bought it. I pulled off all the parts from my other Kouki. (Wheels, exhaust, stereo, some interior stuff, everything except the suspension) Those photos were a few days after I lowered it (Megan Springs, KYB lower struts) It has since settled quite a bit. The reason I sold her was too many cars to juggle in a one car garage duplex (I was single at the time).

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I kept the Z and the Titan for a while. The Z I was building into a street/race application (twin GT3582 Turbos on a custom front mount turbo setup blah blah blah) but got rather...annoyed with the build. Things were taking to long that I had no control over, my engine builder (the first one) was a dipshit, the 2nd guy was legit though. Needless to say, I found my other passion. Boating. First here is the Z, no engine, tranny or fuel tank in this pic, barely any interior even.

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Well, I sold off all the parts, and decided to get back into boating. I grew up on the water, and missed it terribly. Here is what I am rocking now.

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This I am not selling off :) I run 75mph GPS in a 28 foot boat with a cabin, and all the goodies in her. But, I dont want to mess with perfection. Runs to smooth to tinker with the Mercury Racing 500EFI. :)


I pimped out the Titan a bit, ran it about 50 times at the local drag track and pulled consistent mid to low 14s in full street trim, even towed some people home after racing all night. Sold it after buying the boat since I needed a real truck to tow with. The Titan was just too little :)

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Now I have a deleted/tuned 6.7 Cummins Ram 2500 to pull the boat with.

Anyways, onto the 240... I sold her to my Mom actually who is actually a speed freak in disguise as my Mom. She loved it, but had way too much stuff going on for upkeep and such. She also has TERRIBLE luck with everything. The car has been hit, wheels bent, etc etc. She sold it back to me, and now I am in the process of restoring her to her original glory. Here is some crappy cell pics I took today in the garage as I was working.

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The clear coat is coming off every panel (Texas sun is a beast). I have some DA sanders and stuff I am going to start stripping the car with after I get the suspension right. Right now she needs some maintenance love.

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All the rubber items need replacing. The ball joints, tie rod ends, the tension rods, all need love. I have brand new adjustable tension rods from my Z32. Going to replace the others with OEM stuff. So, that is where I am starting. The interior needs some work as well. The radio bezel is fudged, the shift boot is torn, etc. I have some Z32 manual seats I want to recover in suede and put in eventually. Going to put a custom solobaric setup in the trunk with some quality components in the cabin. Should be a fun project. I do al my own work (even setting up a powdercoating oven and booth for some side work). I am excited to get her pimped out. Engine... she runs great right now. I am going to drive her for a while with the KA before I break it to my wife that I want more :) Not sure what I want yet. Only time will tell on that note. Anyhow. Thanks for reading. Sorry so much background story. Any feedback would be great thanks!
 
#4 ·
I think I am actually going to pull the engine and tranny out and clean, repair, replace everything the right way. I have a ton of Z32 parts still floating around, and I know a lot of them work on the S14 as well, so that is a plus. I am going to clean, and undercoat most of the front end, just for aesthetics sake mostly. My OCD gets pretty bad.

Mike- You know the old adage "He who dies with the most toys, wins" :)
 
#6 ·
Awesome, thanks mike. I pulled off my front end today, down to the core support at least, found a lot of issues. It has been hit in the front, I know. The bolts and studs for the bumper support are all broken and missing lol. I cut out a lot of the crap and will be making brackets for replacements. I will get the front end lined up if it's the last thing I do. Pics to follow when I get home.
 
#7 ·
Ok, a little progress has been made. I got the front end as squared away as it is going to get without cutting everything off and welding on a new front end. Stripped out all the lights, spoiler, door handles, mirrors, and bumpers to prep for primer and body work. I have a nifty sanding setup that hooks to my shop vac and my air compressor and is virtually dustless :) Love it! For the most part I am sanding down to the original base coat, except on the bumpers and spoiler and such. Those are getting stripped 100%. I may decide to strip to the metal and proceed. We shall see. Here are some pics.

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And the biggest trouble spot. I am not sure how this happened, but it is obvious that the PO sucked at life and wanted a quick sale. There was no primer to speak of under the filler, so there is some surface rust on the roof skin. There is no way to get behind it to knock it out with a dolly since there is a support beam there. May have to cut the skin off and repair then weld back in, we shall see.

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i still need to mess with the windows and take em all out. Not looking forward to that :)

Thanks for looking. I am going to prime it as soon as I get it stripped, and then do the body work, then primer sealer and I think I will try out a single stage urethane. Texas sun is evil on clear coat, so maybe the SS will help out. Anyone have any ideas on the roof thing??
 
#8 ·
Just pull the windows or have someone come to pull them for you. It shouldn't be much to have them come out. By the pics it looks like just surface rust. I'd plan for a lot of sanding and shit but I don't think it has gone all the way thru.


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#10 ·
Oh I didnt realize it was crumbled in a little. I would just take it to some body shops and ask what they can do for you. If you can get off a lot of the filler and take it down to metal, the body shop should be able to make it smooth again with a slide hammer but just ask.

The roof skin is really thin that is why welding it would be really iffy. The metal will deform when you weld it so i would just see what they can do. 3M makes really good sandpaper and I'd just hack away at that filler.

Also when you sand and stuff, do not use any kind of media blasting or chemical strippers. Just do it by hand or with sanders and stuff. The short explanation is that there is no foolproof way to make sure you neutralized the chemicals and stuff so just do it by hand and spend the 20-40 hours that you need to on prepwork.

I do not look forward to sanding either but since that is the time tested way to do it, thats the way you should do it.
 
#12 ·
thanks sanddog. She is a work in progress.

I am sanding by hand, I have a 8" da, a 4" rotary, and a 9" orbital. All of them hook directly to my shop vac and suck all the dust up. Wonderful tools. I was debating the slide hammer, just need to find a welder to fill the holes correctly. I have a tig at work, might try that. My goal with this is to learn to do this all my self. I am a mechanic, just don't know a lot about auto body.
 
#13 ·
There is a wonderful tool called a stud gun . It is used to weld small studs to the crumpled panel and then a specific slide hammer is used to pull the dent out . The idea behind this is to not drill holes all in the body . I have done my fair share of body work , just something else to think about .
 
#15 ·
So I wanted to get my wheels stripped down and powdercoated before I had to go back to work, so I took this week to start on that. Here is what I Have so far.

I started off with bronze Gram Light 57C wheels. The paint had seen better day to say the least. I started sanding the wheel down a bit.
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The lip had a bit of curb rash on it, but I took care of that too.
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Finally after all the sanding and stripping was done, I ended up with this.
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And now I am here
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A freshly powder coated Satin Black Wheel. I am going to order the little Gram Lights stickers for it, and get new black center caps in black and red. I like it :) Its nice having your own powder coating facility for sure.

Oh, and I picked this up for the 240 as well :)

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Full GTO 5.7L Drivetrain, all accessories, T56 tranny, everything. I have a few parts I need to get her going, but for the most part it is all there. More to follow on that.
 
#22 ·
Don't mind D, he's on his what, 3rd or 4th SR swap? None of which drive.

Be nice to see this when it's done.