Beginning Stage 1 of the Build

Before getting too deep into modding the car I wanted to make sure it was all running properly and put together nicely so I wouldn't have any unpleasant surprises later on. The main parts of this were:

1.Engine/Transmission:
- Unable to use First or Reverse.
- If I somehow got the car in reverse, the car would move with the clutch pushed in all the way.
- Oil pan and valve cover were leaking

2. Exhaust:
- The stock exhaust was completely rusted through
- The header on the car when I bought it was meant for an S13 so the EGR didn't line up, and the poor welding job to plug the EGR blew through which made the car excessively loud.

3. Interior:
- Completely stripped, missing almost all the parts
- Minor rust started on the floor boards under the factory soundproofing

4. Suspension:
- Subframe bushings worn out
- Tie rods were worn out
- Strut mounts worn out
- Rear brakes completely worn out

I found most of the stuff I needed for the interior on son240sx.org, as well as a spare engine, transmission, and a fairly new SS exhaust system, including a header and 2.5" catback.  I also decided to go with a stock replacement clutch made by Exedy

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So to start, since so much needed to be done to the engine and transmission I decided it would be much easier just to pull the engine and do the work outside the car.

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 In the meantime I got the tie rods installed, started to piece together the interior and resealed the engine and transmission.

Before

Dry Ice

After

Complete

After 14 hours straight in the garage overnight I installed the new clutch, put the engine and transmission back together and got it all installed into the car.  After the car wouldn't start despite trying everything and double-checking everything over again I found that i put in the distributor 180 degrees off so the messed up timing wouldn't let me start it and just led to lots of backfire while cranking.  After getting that sorted out and the car started I noticed the oil pan was leaking even more than before, so out of frustration I called up the tow truck and had the car towed to the shop I used to work at and had them replace the oil pan gasket.

Once the leak was fixed I got the safety done but couldn't pass the e-test because my EGR wouldn't line up with the header.