Our Z Car Garage Big-Brakes and Z Car Garage CV Axles continue to win over Z-car enthusiasts locally and globally. Elmo P recently purchased a set of both for his 1972 Datsun 240Z and had them installed himself in SoCal. Before we go into the installation details let’s take a look at how Elmo got into Z cars…

 

ELMO: In 2005, I decided to sell my first 240z, a 1973 which I owned for almost 17 years, and the car on which I learned almost everything I know to this day about wrenching. I felt I had outgrown the Z and it no longer fit in my life. However, immediately after the sale, I felt sick to my stomach for weeks and never really got over its sale. Over the next 13 years, I would periodically search for a replacement 240z, only to find out prices had skyrocketed and I could no longer afford one. Fast forward to 2019, I was now ready to resume my search. I found a 1972 240z that had been meticulously cared for by its 2nd owner of almost 47 years. The car was mostly stock, minus the addition of an L-28, and Panasport wheels. 

 

My goal was to modify the car tastefully, with modern components where needed to increase driving pleasure, yet leave the classic body-line largely unmolested to not disturb or detract from the design’s natural beauty. Over the past 4 1/2 years, I’ve made modifications to every area of the car and I can finally say that I’m at about 95% of attaining my vision. As mentioned previously, Elmo wanted the body to remain mostly unchanged. The only additions have been a front grill and spoiler from Star Road in Japan, front bumper delete plates from Skillard, one-piece rear bumper, and Euro tail lights and front turn signals. Wheels are Volk TE37V, 16×8 +0, and 16×8.5 +10 with Toyo R888R tires in 245/45/16.

Interior

 

ELMO: The interior received many upgrades including Recaro seats, Speed Hut gauges, re-upholstered door panels, tranny tunnel, and rear shock towers, billet pedals, new dash cover and a Sparco steering wheel. However, one of my favorite modifications is that of cleaning up the rear shock towers by removing the old vinyl covering and plastic caps, and smoothing off and painting the tops of the towers, along with the addition of aluminum cover plates and new covering on the towers.

  

Drivetrain

 

ELMO: When I bought the car, I knew the drivetrain and suspension would be my main focus area and hence, the area where I would divert most of my modification funds. All suspension component upgrades are from Techno Toy Tuning., including adjustable coilovers, control arms and diff mustache bar. Gear shifts are handled via a rebuilt close-ratio 5-speed from a ZX which transmits power to a 3.9 OS Giken LSD. Although the L-28 that was in the car when I purchased it was recently rebuilt, my goal was to replace it with a larger displacement street/race engine to increase the fun-factor. After months of searching for a reputable L-Series builder, I came across a renowned Datsun engine builder by the name of Jeff Winter at Rallye Sport in Westminster, CO.

 

For my mostly street driving application, we decided on an L-28 bored .080 over, forged rods and flat top pistons, and one of his special cam grinds on my car’s original E88 head with a mild street port, all resulting in just under a 3.0L. Induction is handled by triple 44 PHH Mikuni carbs rebuilt by Taka from Kyusha House.

 

The exhaust is scavenged via a custom-made header from a small shop in Japan, fabricated bu Humble Engineering with a  2.5” straight pipe terminating into a 3-chamber Flowmaster. Below, also visible are T3 coil-overs, LCAs, diff brace and Z Car Garage CV Axles:

 

Z Car Garage Big-Brakes

  

ELMO: Although my new engine makes more power than the original L-24, and the stock brake system and half- shafts likely within their operating limits to support the increased power, I felt now was the time to make those upgrades to mitigate any future performance or drivability issues. Enter Z Car Garage. I had been following ZCG for a few years and knew that Rob was very well respected in the Datsun community, and offered many products to enhance the performance of the S30. I wanted to upgrade to rear disks, not just for better overall braking, but also for aesthetic reasons.

 

As fellow S30 owner/racer Glenn C mentioned in his review, on top of braking performance, pedal feel is extremely important and our Big-Brakes deliver. This is a direct result of working with Stoptech to create a totally bolt-in solution requiring no M/C change or additional proportioning valve/adjustments. All fitting behind a 15″ Watanabe or Panasport wheel and retaining factory emergency brake lever! A few details below:

Calipers: Stoptech ST42 4-piston front & rear race calipers (Alum 6061 mil-spec Type III anodized)

Rotors: 280mm x 20.6 with Alum 7075 hats

Pads: Stoptech 309 sport street pads

  

ELMO: In other words, the look of drum brakes sitting behind my new wheels just wasn’t cutting it, at least not in 2023. There is no shortage of aftermarket (AM) brake kits for the S30; however, after speaking with many owners who installed AM kits, they all shared one thing in common: No one seemed to be fully pleased with their performance. Most kits are sort of a “Frankenstein” collection of parts which often required different brake boosters, proportioning valves and other mods just to make them work somewhat effectively. In addition, most AM brake kits either did not come with a parking brake, and if they did,  functioned poorly.

 

Big-Brake Kits Available For DIY Install!

Z Car Garage is proud to offer our Big-Brake Kit to Z-Car owners that want to perform the installation themselves. We can ship worldwide and each kit contains everything needed with a comprehensive (40-page) installation guide. Blog posts documenting all of our customers running the ZCG Big-Brakes can be found HERE. Elmo’s beautiful S30 and his ZCG Big-Brake installation:

 

Our ZCG Big-Brake kit ships with everything needed to install and retains the factory parking brake function. Elmo successfully installed the BBK on his Z with and they look great behind the Volk TE37 wheels. Beyond ease of installation and quality components, our Big-Brakes perform by offering superb pedal feel…everyone that drives our demo Z confirms! This is a direct result of working with Stoptech to create a totally bolt-in solution requiring no M/C change or additional proportioning valve/adjustments. Elmo shares his feedback after replacing his existing brakes with the ZCG BBK:

  

ELMO: I contacted Rob to secure a set of his brakes but he advised me they were on backorder but that they’d be worth the wait, so I committed. Due to Covid supply chain issues, the wait was almost a year long, but as the saying goes, “some things are worth the wait”. I finally received my brakes and can confirm that aside from looking great, they meet or beat my performance expectations. Braking is effective, predictable, and confidence-inspiring. However, the best part is that there are no tricky performance issues that you have to figure out as they were designed from the ground-up for the S30, while still utilizing the stock brake booster and other components. All you simply have to do is install them as directed and you’re good to go. Oh, did I mention the parking brake works great!

Z Car Garage CV Axles

  

Our Z Car Garage CV Axles help transmit power to the ground and ensure smoother operation compared to your standard half shafts. We have over 200 CV axle kits on customer cars and we are stoked with all of the positive feedback.

ELMO: Now that the brake department was taken care of, all that was left to replace is the Achilles’ heel of any S30 with a much more powerful engine, the half-shafts. I had issues with them and their U-Joints on my first 240z which had a 3.0 and I felt that my current Z would benefit from an upgrade. Again, multiple AM options to choose from but given the research and quality of the ZCG brake kit, I felt the CV axles that Rob offered were the logical choice. The axles are beautifully machined and more than robust enough to handle my new engine’s power. I installed the axles myself and have noticed less clunking and vibration, and an overall smoother drive.

Elmo’s ZCG CV Axle set, #0446 installed:

 

What’s in store for Elmo’s Z?

ELMO: So, what’s left? Well, there’s a few odds and ends but nothing major, at least not until Rob introduces the next upgrade. I’m a firm believer that most of us never truly finish modifying our cars because they are like an ever-evolving canvas of ourselves.

 

Thanks for your support Elmo we love that you are Enjoying The Ride and Long Live The Z! More photos in the gallery below

The Last Stop in Braking for your Z

 

Z Car Garage Big Brakes are one of the best systems available for your S30 Z Car with over 200 kits sold worldwide and unanimous positive feedback. See our ZCG Big-Brakes on client cars HERE and enjoy the photos below:

   
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We met Ken W last summer when he stopped by Z Car Garage to meet Rob and have his S30 inspected. Our Z Car Garage Big-Brakes and Z Car Garage CV Axles along with upgraded suspension parts and a Rebello 3L engine transformed his 1971 240Z into a fantastic sports car.

 

The Right Z

Before we dive in to the upgrades let’s take a look at how Ken got into Z cars and finally found the right one…

“When I was a junior in High School, the cool kids were driving Mustangs, Camaros, and ‘Cudas. Always different, my imagination was captured by the ’71 Datsun 240z. Being a Kansas farm boy on the lower end of the economic scale, had to settle for a ’64 Ford Fairlane 500 4-door with the 269 V-8. Knew that someday I’d own a 240z. Spent 2018 researching the 240z market. In January 2019, bought a red ’72 240z with Wilwood brakes, QA1 coil-over suspension, 17” wheels. A little rough but convinced me that owning a 240z as a daily driver, was going to make me happy.”

 

We inspected Ken’s red ’72 240z and found many problems. Rob suggested finding a chassis in better shape to make his own. After our evaluation Ken consulted with fellow S30 owner/racer Glenn C to affirm that ZCG was the right place to be. Ken was convinced that the S30 is a great rally car and began searching again, finding this green ’71 on Craigslist, near Sacramento.

“Rob gave this car his approval as a basis for the rally car that I wanted to build. ZCG is so popular that we weren’t able to get it in for the chassis upgrades before the Mother Lode 400 rally in June 2019 . The car was fine, but only fine. Yes, the brakes and suspension worked and the motor was dependable, but with the enthusiastic style of rally driving, showed they really weren’t up to the task.”

 

ZCG Big-Brakes and CV Axles

The upgrade process began, giving Ken the ability to brake on a dime, perform well and daily drive. We handed him the keys to “Mrs. Butters”, our 1971 Series 1 240z shop demo car and he was sold on our Z Car Garage Big-Brakes (for small wheels) and Z Car Garage CV Axles! Butters has a way of doing this to our customers 🙂

    

As fellow S30 owner/racer Glenn C mentioned in his review, on top of braking performance, pedal feel is extremely important and our Big-Brakes deliver. This is a direct result of working with Stoptech to create a totally bolt-in solution requiring no M/C change or additional proportioning valve/adjustments. All fitting behind a 15″ Watanabe or Panasport wheel and retaining factory emergency brake lever! A few details below:

Calipers: Stoptech ST42 4-piston front & rear race calipers (Alum 6061 mil-spec Type III anodized)

Rotors: 280mm x 20.6 with Alum 7075 hats

Pads: Stoptech 309 sport street pads

Blog posts documenting all of our customers running the ZCG Big-Brakes can be found HERE.

A few closer detail shots of the calipers, rotors and hardware:

 

We removed Ken’s brakes and installed our ZCG Big-Brake kit. The Z also received Tokico 5-way struts with Eibach springs and suspension parts from Techno Toy Tuning. New parts included adjustable T/C rods, rear control arms, new bushings, rack bushings, steering coupler, factory Nissan ball joints, new wheel bearings and more.  We really appreciate Gabriel and his staff. They make some of the best suspension parts out there for Z cars.

 

ZCG Big-brakes up front:

 

T3 T/C rods and new brake master cylinder/booster:

 

Suspension Techniques sway bars installed front and rear:

 

At the rear, the factory drum brakes were replaced with our ZCG Big-Brakes. Factory handbrake functionality retained! Ken was pleased with the brakes:

“I really the brakes. Having experienced stock brakes and the Wilwood’s (Stage 4 front and rear), was really interested to discover if the ZCG Big Brake kit was all that I’d heard about. I’m here to say that the Big Brake kit exceeded all expectations. Under hard braking, feels like I’ve just driven into a huge pool of thick super glue or that someone immediately behind me has just switched on a huge electromagnet. Undeniably shorter braking distances. Huge confidence when diving deep into corners.”

 

Our Z Car Garage CV Axles help transmit power to the ground and ensure smoother operation compared to your standard half shafts. Ken’s Z received set #298. We have over 100 CV axle kits on customer cars and we are stoked with all of the positive feedback.

 

Stock half shafts and control arms (L):

   

Before/After suspension upgrades. Not shown is the ZCG exhaust system using 2.5″ piping to a stainless resonator and Magnaflow muffler with slash-cut tip:

 

Great feedback again from Ken regarding the suspension upgrades:

“In August 2019 it went into ZCG shop for the upgrades. Let’s talk about the suspension first. My red ’72 had QA1 coil-overs and it wasn’t particularly balanced or optimized. Too soft in front, too harsh in back, little squirrely under brake or gas. By comparison the ZCG components showed care in selection, thought in design and clear goals in creation of a balanced package. The car is impressive under braking, squatting uniformly and smoothly. Under hard acceleration, it tracks straight. The CV axles are works of art and well suited to handle the Rebello motor to come.”

 

More Power

 

With braking and suspension sorted all Ken needed was power to match. Without going too wild we opted for a Rebello 3L, retaining SU induction. The 3L still leaves room for aggressive cam/Mikuni induction upgrades should he feel the need. A few pictures of the fresh motor, more in the gallery below:

 

Ken enjoys tinkering with vintage motorcycles and rallying. While running the Snowball Rally the car did really well and he had a great time but unfortunately, it was hit by a motorist (not part of the rally). We called upon our man William from William’s Auto Body to fix everything and re-spray.

 

While the motor was out, we cleaned up the engine bay. Everything came out, the bay was painted, new seals around all hoses going through the firewall. The engine got an MSA 6 to 1 header, all intake/exhaust gaskets, MSD6Al box with tach adapter, Koyo race radiator, zinc’d hardware and new alternator/starter. We  ensured that he would be able to rally wherever and whenever.

 

Backing the 3L is a 5-speed with JWT aluminum flywheel and Exedy clutch:

 

Rob dyno-tuned the Z with the stock L24 (109hp/128tq) and the 3L, now making 199hp/209tq to the wheels:

 

Enjoy the L-Series music!

 

Panasport Wheels

 

What is the perfect companion for Ken’s Z, now that it has full suspension and wicked brakes and fresh paint? Panasport wheels! We replaced the old-school slotted wheels with 16×7 Panasports and Bridgestone’s killer S-007a tire in 225/50/16.

“The Wilwood Stage 4 front brakes required a spacer to move the generic Japanese front wheels out far enough to avoid fouling the calipers. This meant running 215/45/17 tires. A drawback to the 17” wheels is that the space-saving spare can’t exceed 16” in the spare tire well.  I totally love the beautiful Panasport wheels! When I take the car to Z car meet-ups, everyone says “this car has been to ZCG, right?” The wheel and brake combo means I gained 10mm tire width and no spacers. We agreed that for rally purposes, I’d change the tires every 3 years, so Rob picked out some nice sticky ones.”

 

Rallye On!

 

Ken was smiling ear to ear and told us we built him a Z car he really enjoyed:

“The results are fabulous! My car is such a hoot to drive. Quick off the line, easy to spin the tires. Now I understand why Rob recommended the CV shafts. The car was awesome on the 2019 California Melee. Had so much fun driving the rally with my brother who flew in from Kansas. He drove it much slower than I did, so when I took my first shift, diving it deeper and deeper into the corners, accelerating harder and harder out of the corners, that I proposed establishing a safe word if he wanted me to ease off the fun.”

 

 

We have been checking in with Ken and he’s happily Enjoying The Ride. We even spotted his Z cars while cruising through the neighborhood.

 

“I’m so happy to have met Rob and provided him with a car that has ‘good bones’. Enjoyed working with ZCG. A key for me is that ZCG has been able to provide all the upgrades, in an integrated package. Didn’t want to use multiple shops and fight through finger pointing. Trust Rob and his crew, they’ve done these upgrades 100 times or more. They know what works and what doesn’t. Personally, I care more about the quality of work performed and the result, rather than shopping for the lowest price.”

 

Thank you Ken for allowing us to help you achieve your vision of the ultimate Z car. We loved working with you. Long Live The Z!

More pictures in the gallery below:
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***This Z is up for auction on Bring a Trailer right now, link HERE***

 

Our client Brian P’s 1973 Datsun 240z is up for auction on Bring a Trailer. This S30 features our ZCG Big-Brake kit, Z Car Garage CV Axles, dyno tuning and more. Read our full blog report HERE and happy bidding!

 

We had the pleasure of working with Daisy to help get her 1972 Datsun 240z back on the road. Our Z Car Garage Big-Brakes and Z Car Garage CV Axles along with upgraded suspension parts transform this Z into a fantastic sports car.

 

Before we dive in to the upgrades let’s take a look at Daisy’s story:

“My Z history actually started with a 370Z–it was my first car, bought even before I knew how to drive a stick. When I was ready for my next automotive chapter, I tried to think of another beautiful, fun, sporty coupe that wasn’t going to cost 60k, and realized it was my car’s great-great-great-etc-grandmother–the 240Z. So I was on the lookout through Craigslist for almost a year, in search of an S30 that hadn’t had a ton of performance work done to it already, but was still in overall good shape…

 

Daisy was looking for a shop to take care of her 1972 Datsun 240z  and heard about ZCG from a few different sources–the Z Car FB group and from following Courtney Frisk (Cutchen) the automotive photographer, who’s also worked with us:

“I knew that it was time for some more significant work, so I got in touch with Rob. Ultimately, the goal was to make this a capable daily driver (though I only really use it on the weekends)–not super powerful, just safe(r), reliable, capable, reasonable to drive on contemporary streets–a joy to drive.” 

Daisy brought the Z in late last year and we performed a full inspection.

The inspection revealed many items to be addressed from brakes, suspension to carburation which was really off. Initially we spent a few hours getting it driveable while we put together a plan to add some ZCG touches to her S30.

 

Photographer Larry Chen visited Z Car Garage back in February to bring his very own S30 in for our ZCG Big-Brakes. While he was at the shop he featured our customer James Stephens’ turbocharged 1972 Datsun 240z for an episode of Hoonigan Autofocus. In this video Larry chats with Rob Fuller about the build and also gets to dyno/test drive it. We had a blast hanging out with Larry and his crew. More Hoonigan Autofocus spotlights from our shop and high-res pics are coming soon. Enjoy the video!