Honey Badger the Y60

[BrazilianY60]

Looking good mate. Your not going to want to drive it when it's done.

Quite the opposite mate! It isn't done and I am already eager to drive it!
Once the seats are ready, he will install just the driver's one and I'll bring it home for a weekend. I will then proceed with the floor sound deadening and return it to him on a monday for him to continue with the carpet.

[BrazilianY60]

Roof lining installed! With all blue handles in place!
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I hadn't washed the pinch welds because I am still looking for navy blue ones to replace them all. No luck so far. I'll give it some more time and if I can't find anything decent, I may need to use black ones.

[mudski]

Is the plastic paint a special type of paint? How does it go with the usual wear a tear of daily use?

[BrazilianY60]

Automotive paint, just the prep is different with the use of an adhesion promoter. Then, after the paint some heavy coats of clear coat to be the sacrificial surface. With use things will eventually need touch ups.

[PeeBee]

You can use a product avail here called BIN22 which etches the surface of just about everything and then you apply paint over it - have paint a pile of stuff with it at home.

[BrazilianY60]

Started to work on the floor sound deadening and noticed this hole that I either didn't notice before or never understood how someone could have done such damage to a firewall. Front collision could have sent the engine against the firewall? Maybe.
But then after years working on the car and learning from here and also from my own sweat replacing the TB45 on my GU, I now know that the bell housing top bolts are a pain in the but to reach. Looking closer at it, I believe someone at some point got really pissed with it and punched a hole through the firewall. The (AUS) driver side bolt does not have a corresponding hole but has a nice dent/crack on its direction, so I suppose that one is now reachable from the engine bay. Thought about fixing it but then, fark it... I would never do something like this but since it is already done, I will benefit from it in the future when I need to replace a clutch or something. I have only bent the sharp edges back in and sealed it with the butyl material used on the sound deadening. On the engine side I sealed it with a more heat resistant material.

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[mudnut]

In 1985, a Nissan engineer was designing the upcoming Y60 series. He realises the difficulty that mechanics will have accessing that bolt in the future. He draws that particular hole in the plans, with a rubber plug to be installed. A day later, a tight-fisted Bean counter scrutinises the plans and spots the hole. He does a quick calculation and deduces it will cost Nissan 2 cents to punch the hole and 3 cents to obtain and fit the plug. He multiplies it by the expected run of GQs and screws every poor bastard over by removing that well thought out addition. You are lucky to have that hole

[BrazilianY60]

I have sound deadening almost finished now. I have covered the whole floor pan covered with 3 layers of different products, except for the trunk, where different products (yet to be acquired) will be tried. On the higher part of the firewall I will also try something different.

Passenger side (AUS driver) start, then using the rear A/C piping cover to find the plastic bushes that I forgot to take a "before" picture and that side complete with the A/C piping in place.

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Then driver side (AUS passenger) start, some work over the transmission tunnel and that side complete.

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Final result of the 1st layer (butyl).

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[BrazilianY60]

Second layer was (I think) open cell foam.

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Nothing of the 1st layer was left exposed, I am missing a picture here.


Then, to cover it all, the 3rd layer was (this I am pretty sure) closed cell foam. This time I covered even the A/C piping covers. I was contemplating "what if" I need to take this pipes off and then, well, there is nothing there to damage, places where people step over it are covered with a steel plate so I did it. I am missing a picture of the 3rd layer also, it was very late on a Sunday, tired, I totally forgot.

On the firewall I remember when taking the old stuff out that it was a very thick vinyl panel with a very thick layer of that bitumen impregnated wool. Always remembered that when watching Car Builders videos and they showing their mass loaded vinyl product. So, for the firewall, in the absence of a similar product of the shelf, I plan make it myself from the basic components as I can buy those here. Plan is to glue them together, template the shape, cuts and wholes and transfer those.

For the trunk I am going to use butyl on the wheel wells (wheel arches?) as this would probably benefit the region from gravel expelled by the tires, but I will wait for the time I tackle the rear fridge installation to make sure it will fit. The trunk floor I am not much keen of glueing anything as I see it as a zone more susceptible to getting dirty and requiring some cleaning or washing, even though with a lot of care. So for the trunk I am considering something similar to what I have in plan for the firewall but thinner.