2007-2008 Small Steps

This is the basic condition of the suspension components. Lots of crust and mud.  This is the lower spring perch and shock mount.

Since I'm doing the entire car, I bought a basic blast cabinet to clean the parts.  The blast cabinet makes quick work for small parts.

To stop the rust and protect some of the parts I'm using POR-15.  

POR-15 is a very tough product when cured and paint doesn't stick well to its slick surface, but you can dust it with primer while slightly tacky and it creates a paintable surface.

Painted and complete (most undercarriage parts will get the same treatment).

Using a professional grade paint, but others choose to Powdercoat all of the suspension pieces. 

The brakes were of course locked up and the front brake cylinders were rusted solid.  The rust on the brake shoe retainers was the worst.

Really cleaned up nicely.

I plan on a red interior so a few splashes of red throughout the car will hopefully pull it all together.

The idler box was as bad as everything under the car.  Dean @ DatsunParts.com sells a rebuild kit for this and many other components.

Back together and has a nice firm feel with no slop.

Although my plan is to do everything myself, I did send the frame out for powder coat.  Savannah Powdercoat did a great job and the frame should stay protected for years to come.

The Roadster frame is stout. Time to chase some threads and start assembling some items.

Collecting up the front passenger side pieces for assembly.

Well, I have to deploy again, but I was going to see something on the car before I left.  I installed the Idler box using bolts I got in a full bolt kit from Pat Mahoney.  Notice the two bolts in the photo, those are the for the optional external oil cooler.  

Back at it.  This is the upper for the A Arm, there is a walnut size bumper for the bump stop that is completely hardened and rotted.

Blasted and bumper pad removed. 

The A arm pivots are threaded for solid screw in bushings that are tough to remove.

These are the swing arms that those bushings screw into.  Getting the same POR-15 treatment.

Ready for primer dusting and paint.

Last of the passenger side pieces getting their treatment.

Test fit to make sure all threads are good.

New seals available from DatsunParts.com.

Assembling the lower spring perch.

Solid bushings torqued in.  Need to add zerk fitting and grease assembly.

Final lower control arm assembled.

New lower ball joints. A Roadster list member worked to get these made.

Next step is to install the bump stop and its tower.  These are aftermarket energy suspension pieces.

Bolting down bump stop tower.

To complete the lower assembly I attached the spindle to the lower ball joint. 

Chasing threads on the upper ball joint.

Assembling the upper portion. Note the new rubber for that small walnut size bump stop.

Seals and bushings for the upper link.

To install the complete passenger side assembly, the whole unit is lifted and bolted to the crossmember.  To adjust angle there are various size shims with a lock tab.

To lift the bottom in place I need to install the springs. There is a rubber spring isolator installed in the upper plate.

Again, Energy Suspension generic items fit the bill   ( Original vs. New).

Bolted bottom up and installed shocks.

Brake hub carrier fit to spindle.

Final piece is the brake backing plate.

Got my son involved to bend the safety lock plates on the brake bolts.

Driving new bearing race in using the old bearing race as a drift.

Packed bearings and installed. 

Final step for hub is the bearing seal.

Bolted hub to new rotor.

Front wheel bearing in.

Shop helper bending the cotter pin around the castle nut.

To close it up and seal the grease I installed new dust caps.

Bolted on the brake hub.

Short of brake lines and pads the pass side is ready to go.